Source: https://patents.google.com/patent/WO2009119038A2/en
Timestamp: 2019-09-17 01:18:34
Document Index: 634722215

Matched Legal Cases: ['art\n19', 'art 19', 'art 19', 'art 19', 'art 19', 'arts 64', 'art 76']

WO2009119038A2 - Molded resin product, semiconductor light-emitting source, lighting device, and method for manufacturing molded resin product - Google Patents
WO2009119038A2
WO2009119038A2 PCT/JP2009/001175 JP2009001175W WO2009119038A2 WO 2009119038 A2 WO2009119038 A2 WO 2009119038A2 JP 2009001175 W JP2009001175 W JP 2009001175W WO 2009119038 A2 WO2009119038 A2 WO 2009119038A2
PCT/JP2009/001175
WO2009119038A4 (en
WO2009119038A3 (en
2008-03-28 Priority to JP2008087734 priority Critical
2008-03-28 Priority to JP2008-087734 priority
2009-03-17 Application filed by Panasonic Corporation filed Critical Panasonic Corporation
2009-10-01 Publication of WO2009119038A2 publication Critical patent/WO2009119038A2/en
2009-12-10 Publication of WO2009119038A3 publication Critical patent/WO2009119038A3/en
2010-02-18 Publication of WO2009119038A4 publication Critical patent/WO2009119038A4/en
A light-emitting source 101, as shown in Fig. 13, is provided with an LED element 105 implemented, as the light source, on a main surface of a substrate 103. The LED element 105 is sealed with resin that includes a phosphor material in the state where the LED element 105 is disposed in a reflection hole of a reflection plate 107. Note that the resin used to seal the LED element 105 is called a sealing resin member 109. A circumferential surface constituting a reflection surface 107a reflects the light coming from the LED element 105 so that it travels in a predetermined direction (see Patent Document 1 identified below).
With the above-described structure, the light emitted from the LED element 105 is converted into a desired color by the phosphor material contained in the sealing resin member 109 as the light passes through the sealing resin member 109, and then either directly emitted from the light-emitting source 101 or reflected by the reflection surface 107a to travel in a predetermined direction and then emitted from the light-emitting source 101.
A typical trend in solving the above-described problem in recent years is that, as shown in Fig. 14 or 15, a resin that does not include a phosphor material is used as the resin for sealing the LED element 105 (this resin is also sealing resin member and is represented by reference numbers 113 and 123), and that a resin including a phosphor material (this resin is called phosphor layer and is represented by reference numbers 115 and 125) is also used independently of the sealing resin members 113 and 123, where a gel-like or rubber-like resin such as a silicon resin is used as the phosphor layers 115 and 125 (see Patent Document 2 identified below).
Japanese Patent Application Publication No. 2005-311170 Japanese Patent Application Publication No. 2005-166733
In the above-stated molded resin product, the translucent resin may include at least one of a silicon resin and a fluorine resin. Also, in the above-stated molded resin product, the resin member may include, either inside or in an outer surface thereof, at least one of a pigment and a light diffusion material. Further, in the above-stated molded resin product, the convex part may contain a light diffusion material inside thereof, and contain a phosphor material outside thereof.
Fig. 1 is a perspective view of a light-emitting source in Mode for the Invention 1, where a phosphor layer is partially cut away to show its inside. Fig. 2 is a plan view of the light-emitting source. Fig. 3 is a sectional view taken along the line A-A of Fig. 2, looking in the direction of the arrows. Fig. 4 is a plan view of the light-emitting source in the state where the phosphor layer has been removed. Fig. 5 shows a method for forming the phosphor layer and interim states thereof during formation. Fig. 6 shows a lighting device in Mode for the Invention 2. Fig. 7 is a plan view of a light-emitting source in Modification 1. Fig. 8 is a sectional view taken along the line B-B of Fig. 7, looking in the direction of the arrows. Fig. 9A is a longitudinal sectional view of a molded resin product in Modification 2-1. Fig. 9B is a longitudinal sectional view of a molded resin product in Modification 2-2. Fig. 10 shows a method for manufacturing the molded resin product in Modification 3. Fig. 11A shows one example of the structures of the shape maintaining member in a modification. Fig. 11B shows one example of the structures of the shape maintaining member in a modification. Fig. 11C shows one example of the structures of the shape maintaining member in a modification. Fig. 11D shows one example of the structures of the shape maintaining member in a modification. Fig. 11E shows one example of the structures of the shape maintaining member in a modification. Fig. 11F shows one example of the structures of the shape maintaining member in a modification. Fig. 12 shows a lighting device in Mode for the Invention 2. Fig. 13 is a front sectional view of a conventional lighting device. Fig. 14 is a front sectional view of a conventional lighting device. Fig. 15 is a front sectional view of a conventional lighting device.
19a Lattice-shaped part
19b, 68a Outer circumferential frame
19c, 68b Frame pad
20, 66a Line-like members
Also, as shown in Fig. 3, the substrate 3 has a two-layer structure composed of an insulating layer 3a and a metal base 3b, and the wiring pattern 13 is formed on the main surface of the insulating layer 3a.
The shape maintaining member 19, as shown in Fig. 2, includes a lattice-shaped part 19a, an outer circumferential frame 19b, and a plurality of (in this example, two) frame pads 19c. The lattice-shaped part 19a is in the shape of a lattice in a plan view. The outer circumferential frame 19b is in the shape of a circle in a plan view. The frame pads 19c are used to fix the phosphor layer 7 to the substrate 3.
The frame pads 19c are disposed at predetermined positions (positions that are symmetric about the center of the phosphor layer 7 in a plan view) of the outer circumferential frame 19b. Ends of line-like members 20 constituting the lattice-shaped part 19a are attached to the outer circumferential frame 19b. Through holes 23 for inserting attachment screws 21 which are to fix the phosphor layer 7 to the substrate 3 are formed in the frame pads 19c, and screw holes 25 are formed in the substrate 3, respectively (see Fig. 3).
The lattice-shaped part 19a is structured with a plurality of line-like members 20. In this example, eight line-like members 20 are used in total. The line-like members 20 are formed as follows: first, two sets of four line-like members 20 are prepared; line-like members of each set are arranged in parallel with each other with a predetermined interval (equal interval) therebetween; the two sets of line-like members 20 are assembled to be perpendicular to each other; and they are fixed at the intersections.
The flat-plate-like shape maintaining member 31 (State a) can be transformed into the dome-shaped shape maintaining member 33 (State b) by, for example, a compression molding method (namely, the Method A shown in Fig. 5) by using a pair of molds 39 and 41. That is to say, the pair of molds 39 and 41 are respectively a male mold 39 and a female mode 41, where the male mold 39 has a convex 39a that corresponds to the curving surface of the dome-shaped shape maintaining member 33, and the female mode 41 has a concave 41a. The dome-shaped shape maintaining member 33 can be obtained by putting together the molds 39 and 41 with the flat-plate-like shape maintaining member 31 disposed therebetween.
One example of Method B for forming the resin member 34 based on the dome-shaped shape maintaining member 33 (State b) is an injection molding method (Method B shown in Fig. 5). In this method, a space 43a (whose shape corresponds to the phosphor layer) that has been formed preliminarily in a mold 43 is filled with a translucent resin in the state where the dome-shaped shape maintaining member 33 is disposed inside the mold 43. This forms the phosphor layer 35 which includes the resin member 34 in which the dome-shaped shape maintaining member 33 has been formed as a bony framework.
In the substrate 3, a ceramic substrate, such as an insulating alumina, is used as the insulating layer 3a, and an aluminum plate is used as the metal base 3b. The substrate 3 is in a square shape, with each side being 30 mm in length. Note that the insulating layer 3a is 0.2 mm thick, and the metal base 3b is 1.0 mm thick.
The wiring pattern 13 is formed on the main surface of the insulating layer 3a by, for example, etching an approximately 10 micrometer thick copper foil in the predetermined pattern.
The sealing member 5 is made of resin such as silicon resin, and is approximately 1.2 mm thick. Also, in a plan view, the sealing member 5 is in the shape of a circle which is 20 mm in diameter. Note that even if silicon resin is used as the material of the sealing member 5, the shape of the sealing member 5 is maintained since the shape the sealing member 5 itself is close to flat. Also, color unevenness does not occur even if the sealing member 5 is deformed since the sealing member 5 does not include a phosphor material.
In the phosphor layer 7, the line-like members 20 in the shape maintaining member 19 are made of a stainless material, and the resin member 17 is made of a silicon resin. The phosphor layer 7 is in a dome shape which is 25 mm in diameter and 11 mm in height.
The phosphor material to be included in the silicon resin of the resin member 17 is, for example, a phosphor material that emits yellow light. With this structure, the blue light emitted from the LED element Dnm is converted in color by the phosphor material, so that white light is output from the light-emitting source 1. In the case of, for example, neutral white light, the silicon resin of the resin member 17 should contain from 8 wt% to 10 wt% (preferably, 9.1 wt%) of phosphor material. This is because the content percentage makes it possible to reduce the change over time in a desired color temperature.
The translucent silicon resin used in the resin member 17 is a methyl-based rubber-like silicon that has refraction index 1.42 and light transmission efficiency 85% in the visible light region. The resin member 17 is 1.0 mm thick, and is A20 in shore hardness (conforming to JISK6253).
The lighting circuit 57 is fixed in a manner where a substrate 64c is attached to the holder 55 by using locking means, fixing means or the like, in the state where a plurality of electronic parts 64a, 64b and so on have been implemented on the substrate 64c.
The globe 62 is, for example, the A type. A light diffusion film 62a for diffusing the light emitted from the light-emitting source 1 is formed on an inner surface of the globe 62. The globe 62 also has an opening-side end 62b that is fixed by a fixing agent 58 in the state where the opening-side end 62b is inserted in a space between the circumferential wall of the holder 55 and an end of a case 59 surrounding the circumferential wall on an opening side (an end placed opposite to the base). Note that a flange 55a is formed on the entire outer circumference of the holder 55 to prevent the fixing agent 58 from flowing down.
1. Light-Emitting Source
The n and m in the sealing members Rnm respectively corresponds to the n and m in the LED elements Dnm. The sealing members Rnm are made of silicon resin or the like, as in Mode for the Invention 1.
The phosphor layer 65, as in Mode for the Invention 1, includes a shape maintaining member 66 and a resin member 67, where the shape maintaining member 66 is embedded in the resin member 67 as a bony framework thereof. Also, the shape maintaining member 66 includes line-like members 66a made of a stainless material, and the resin member 67 is made of a silicon resin.
The shape maintaining member 66, as shown in Fig. 7, includes a lattice-shaped part, an outer circumferential frame 68a, and frame pads 68b. The lattice-shaped part is in the shape of a lattice in a plan view. The outer circumferential frame 68a is in the shape of a square in a plan view. The frame pads 68b are used to fix the phosphor layer 65 to the substrate 63.
The phosphor layer 65 is fixed to the substrate 63 in a manner where the frame pads 68b is fixed to the substrate 63 by fixing screws 69. Note that the line-like members 66a which actually exists is hidden by the line B-B in Fig. 7.
A molded resin product 70, as in Mode for the Invention 1, includes a shape maintaining member 71, a resin member 72a, and a resin member 72b, where the resin member 72a is made of a translucent resin including a phosphor material, and the resin member 72b includes a light diffusion material. For example, the resin member 72a including a phosphor material is formed inside the shape maintaining member 71 (on the LED element side), and the resin member 72b including a light diffusion material is formed outside the shape maintaining member 71 such that the shapes of the resin member 72a and the resin member 72b are maintained by the shape maintaining member 71.
In the present Modification 2-1, a resin member (72b) including a light diffusion material (for example, silica) is explained. However, not limited to this, the resin member may include other materials.
A molded resin product 76, as shown in Fig. 9B, includes a concave part 76a which is curved in correspondence with the light emission directions of the light emitted from an LED element 105. Note that a light-emitting source 74 in Modification 2-2 includes an LED element 105, a sealing member 75, and a molded resin product 76.
In Mode for the Invention 1 and so on, silicon resin is used. However, not limited to this, other resins may be used. For example, fluorine resin may be used instead, or both silicon resin and fluorine resin may be used.
A molded resin product 84 is made through a first forming step, a second forming step, a deforming step, and an attaching step. The first forming step forms a flat-plate-like shape maintaining member 77 (which corresponds to State d in Fig. 10) that is composed of an outer circumferential frame 77b and a lattice-shaped part, where the lattice-shaped part has been formed by arranging and connecting with each other a plurality of line-like members 77a. The second forming step forms a resin member 78 (which corresponds to State e in Fig. 10) by a translucent resin with use of the shape maintaining member 71, which is flat-plate-like, as the bony framework. The deforming step deforms the resin member 78 into a dome shape (which corresponds to State f in Fig. 10). The attaching step attaches a frame pad to the outer circumferential frame 77b after the deforming step.
One example of the method for forming the resin member 78 based on the flat-plate-like shape maintaining member 77 (State d) is an injection molding method (Method C shown in Fig. 10). In this method, a space 80a (whose shape corresponds to the three-dimensional shape of the molded resin product 84 which is flat-plate-like in State e) that has been formed preliminarily in the mold 80 is filled with a translucent resin in the state where the flat-plate-like shape maintaining member 77 is disposed inside the space 80a. This forms the flat-plate-like resin member 81 supported by the shape maintaining member 71.
The flat-plate-like resin member 81 (State e) can be transformed into the dome-shaped molded resin product 84 (State f) by, for example, a compression molding method (namely, the Method D shown in Fig. 10) by using a pair of molds 82 and 83. That is to say, the pair of molds 82 and 83 are respectively a male mold 82 and a female mode 83, where the male mold 82 has a convex 82a that corresponds to the curving surface of the molded resin product 84, and the female mode 83 has a concave 83a. The molded resin product 84 can be obtained by putting together the molds 82 and 83 with the flat-plate-like resin member 81 disposed therebetween.
A shape maintaining member 85 shown in Fig. 11A has a structure where a plurality of (in this example, three) line-like members 85a formed as concentric circles with different radii are disposed to have the same center. This structure gives the effect of increasing the force of a part whose shape, in particular, is desired to be maintained, by adjusting the circles in position, pitch or the like. For example, a larger number of circles may be disposed at the outer circumference.
A shape maintaining member 86 shown in Fig. 11B has a structure where a plurality of (in this example, four) line-like members 86a are disposed in a radial fashion at regular intervals in a circumferential direction. This structure gives the effect of improving the force for maintaining the shape against a stress (compression stress) applied from upward (in a direction perpendicular to the sheet plane).
A shape maintaining member 87 shown in Fig. 11C has a structure where a plurality of (in this example, seven) line-like members 87a and 87b are used, where three line-like members 87a formed as concentric circles with different radii are disposed to have the same center, and the remaining four line-like members 87b are disposed in a radial fashion at regular intervals in a circumferential direction. This structure gives the effect of improving the force for maintaining the shape against deforming stresses applied from every direction.
A shape maintaining member 88 shown in Fig. 11D has a structure where one line-like member 88a formed in a spiral shape is disposed such that one end thereof is disposed near the center, and the line-like member 88a
extends toward the circumference (namely, towards the other end of the line-like member) gradually, winding around the center. This structure gives the effect of forming the shape maintaining member by using one line-like member.
A shape maintaining member 89 shown in Fig. 11E has a structure where a plurality of (in this example, five) line-like members 89a are disposed in parallel with each other. This structure gives the effect of forming the shape maintaining member easily (implement easily) since it merely requires disposing the line-like members in parallel with each other.
A molded resin product, comprising:
a resin member made of a translucent resin including a phosphor material; and
a shape maintaining member that is made of a material having a higher elasticity modulus than the resin member, and that is provided either inside or on an outer surface of the resin member to maintain a shape of the resin member.
The molded resin product of Claim 1, wherein
the resin member has a convex part or a concave part.
The molded resin product of Claim 1 which is for use with a semiconductor light-emitting element as a light source, wherein
the resin member has a convex part whose inside is hollow, and
the convex part is in a shape of a circular arc in a longitudinal section, and radius of the circular arc is determined such that a center of light-emission is located in a vicinity of or at a center of the circular arc.
the shape maintaining member is composed of one or more line-like members.
The molded resin product of Claim 4, wherein
the shape maintaining member, in a plan view, is in one of a spiral shape, a lattice shape, a parallel-line shape, and a radiation shape, or in a shape which is a combination of two or more of the spiral shape, the lattice shape, the parallel-line shape, and the radiation shape.
the line-like members have been wound in a coil shape in a longitudinal direction of the line-like members.
the resin member has gel-like or rubber-like elasticity.
the translucent resin includes at least one of a silicon resin and a fluorine resin.
the resin member includes, either inside or in an outer surface thereof, at least one of a pigment and a light diffusion material.
The molded resin product of Claim 2, wherein
the convex part contains a light diffusion material inside thereof, and contains a phosphor material outside thereof.
the shape maintaining member is made of at least one material selected from the group consisting of metal, glass, ceramic, and resin.
the shape maintaining frame has an outer circumferential frame on a circumference thereof.
The molded resin product of Claim 13, wherein
the outer circumferential frame is provided with a frame pad.
A semiconductor light-emitting source, comprising:
a semiconductor light-emitting element that has been implemented on the substrate; and
The semiconductor light-emitting source of Claim 15, wherein
a phosphor layer that is different from the molded resin product is disposed in a vicinity of the semiconductor light-emitting element.
A lighting device characterized by comprising the semiconductor light-emitting source recited in Claim 15, as a light source.
A method for manufacturing a molded resin product which includes a translucent resin member and a shape maintaining member, the translucent resin member having a convex part or a concave part, at least one of the convex part and the concave part including a phosphor material, the shape maintaining member maintaining a shape of the translucent resin member,
a first step in which the translucent resin member is formed such that the shape maintaining member functions as a bony framework of the translucent resin member; and
a second step in which a part or all of the translucent resin member, which includes the shape maintaining member as a result of the first step, is compressed into a convex shape or a concave shape.
a first step in which the shape maintaining member is deformed into a convex shape or a concave shape; and
a second step in which the translucent resin member is formed such that the deformed shape maintaining member functions as a bony framework of the translucent resin member, wherein
the first step and the second step are performed in sequence in the stated order.
The manufacturing method of Claim 18 further comprising
a third step in which the translucent resin member is completely hardened by a heating process, wherein
the third step is performed following the second step.
PCT/JP2009/001175 2008-03-28 2009-03-17 Molded resin product, semiconductor light-emitting source, lighting device, and method for manufacturing molded resin product WO2009119038A2 (en)
EP20090725291 EP2263266B1 (en) 2008-03-28 2009-03-17 Molded resin product, semiconductor light-emitting source, lighting device, and method for manufacturing molded resin product
CN2009801054735A CN101946337B (en) 2008-03-28 2009-03-17 Molded resin product, semiconductor light-emitting source, lighting device, and method for manufacturing molded resin product
US12/867,728 US8890186B2 (en) 2008-03-28 2009-03-17 Molded resin product, semiconductor light-emitting source, lighting device, and method for manufacturing molded resin product
JP2010543753A JP5341915B2 (en) 2008-03-28 2009-03-17 Molded resin product, the semiconductor light emitting light source, a manufacturing method of a lighting apparatus and a resin molding
WO2009119038A2 true WO2009119038A2 (en) 2009-10-01
WO2009119038A3 WO2009119038A3 (en) 2009-12-10
WO2009119038A4 WO2009119038A4 (en) 2010-02-18
PCT/JP2009/001175 WO2009119038A2 (en) 2008-03-28 2009-03-17 Molded resin product, semiconductor light-emitting source, lighting device, and method for manufacturing molded resin product
TW (1) TW200950024A (en)
WO (1) WO2009119038A2 (en)
CN102694105A (en) * 2011-03-22 2012-09-26 台湾积体电路制造股份有限公司 Light-emitting diode (led) package systems and methods of making the same
EP2511603A1 (en) * 2009-12-07 2012-10-17 Sharp Kabushiki Kaisha Illumination device
JP2630075B2 (en) * 1991-01-22 1997-07-16 日本電気株式会社 Flying-body optical dome
TWM313317U (en) 2006-12-01 2007-06-01 E Pin Optical Industry Co Ltd LED assembly having molded glass lens
2009-03-17 WO PCT/JP2009/001175 patent/WO2009119038A2/en active Application Filing
2009-03-17 EP EP20090725291 patent/EP2263266B1/en active Active
2009-03-17 JP JP2010543753A patent/JP5341915B2/en active Active
2009-03-17 CN CN2009801054735A patent/CN101946337B/en active IP Right Grant
2009-03-17 US US12/867,728 patent/US8890186B2/en active Active
2009-03-23 TW TW098109345A patent/TW200950024A/en unknown
EP2511603B1 (en) * 2009-12-07 2015-12-16 Sharp Kabushiki Kaisha Lighting apparatus
US20110084297A1 (en) 2011-04-14
EP2263266A2 (en) 2010-12-22
CN101946337B (en) 2012-12-05
JP5341915B2 (en) 2013-11-13
JP2011512648A (en) 2011-04-21
CN101946337A (en) 2011-01-12
US8890186B2 (en) 2014-11-18
WO2009119038A4 (en) 2010-02-18
EP2263266B1 (en) 2015-05-06
WO2009119038A3 (en) 2009-12-10
TW200950024A (en) 2009-12-01
US20120300448A1 (en) 2012-11-29 Bulb-shaped lamp and lighting device
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