Source: http://www.google.com/patents/US7800124?ie=ISO-8859-1&dq=5311516
Timestamp: 2014-03-17 21:39:21
Document Index: 679503983

Matched Legal Cases: ['art 72', 'art 72', 'art 72', 'arts 73', 'art 150', 'art 150', 'art 150', 'Application No. 2006', 'Application No. 2006']

Patent US7800124 - Light-emitting device - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inAdvanced Patent SearchPatentsA light-emitting device of the present invention includes: a LED chip 10; a chip mounting member 70 having a conductive plate (heat transfer plate) 71 one surface side of which the LED chip 10 is mounted on and a conductor patterns 73, 73 which is formed on the one surface side of the conductive plate...http://www.google.com/patents/US7800124?utm_source=gb-gplus-sharePatent US7800124 - Light-emitting deviceAdvanced Patent SearchPublication numberUS7800124 B2Publication typeGrantApplication numberUS 11/993,956Publication dateSep 21, 2010Filing dateJun 30, 2006Priority dateJun 30, 2005Also published asCN100565948C, CN101213675A, EP1909336A1, EP1909336A4, US8044424, US20090026485, US20100301373, WO2007004572A1Publication number11993956, 993956, US 7800124 B2, US 7800124B2, US-B2-7800124, US7800124 B2, US7800124B2InventorsYouji Urano, Takuya Nakatani, Yasuhiro HidakaOriginal AssigneePanasonic Electric Works Co., Ltd.Export CitationBiBTeX, EndNote, RefManPatent Citations (21), Non-Patent Citations (3), Referenced by (23), Classifications (21), Legal Events (3) External Links: USPTO, USPTO Assignment, EspacenetLight-emitting deviceUS 7800124 B2Abstract A light-emitting device of the present invention includes: a LED chip 10; a chip mounting member 70 having a conductive plate (heat transfer plate) 71 one surface side of which the LED chip 10 is mounted on and a conductor patterns 73, 73 which is formed on the one surface side of the conductive plate 71 through an insulating part 72 and electrically connected to the LED chip 10; and a sheet-shaped connecting member 80 disposed on the other surface side of the conductive plate 71 to connect the conductive plate 71 to a body of the luminaire 90 which is a metal member for holding the chip mounting member 70. The connecting member 80 is made of a resin sheet which includes a filler and whose viscosity is reduced by heating, and the connecting member 80 has an electrical insulating property and thermally connects the conductive plate 71 and the body 90 of the luminaire to each other.
a LED chip;
a chip mounting member having a heat transfer plate and a conductor pattern: said heat transfer plate being made of a heat conductive material and one surface side of which said LED chip is mounted on, said conductor pattern being formed on the one surface side of said heat transfer plate through an insulating part and electrically connected to said LED chip;
a sheet-shaped connecting member disposed on the other surface side of said heat transfer plate to connect said heat transfer plate to a metal member for holding said chip mounting member, said connecting member having an electrical insulating property and connecting said heat transfer plate and said metal member thermally to each other;
a dome-shaped color converting member which is a molding made of a translucent material and a phosphor, the phosphor emitting a light having a color different from an emission color of the LED chip when excited by the light emitted from the LED chip, the color converting member covering the optical member from the light output surface side of the optical member, the color converting member being arranged so that an air layer is formed between the light output surface and the color converting member,
wherein said connecting member is made of an epoxy resin sheet which includes a filler and whose viscosity is reduced by heating, and
wherein said epoxy resin sheet has a high flowability in heating.
2. The light-emitting device as set forth in claim 1, wherein
said LED chip has a light-emitting part made of a GaN-based compound semiconductor material on a main surface side of a conductive substrate formed from a SiC substrate or a GaN substrate.
3. The light-emitting device as set forth in claim 1, further comprises
a sub-mount member which is larger in chip size than said LED chip and is disposed between said LED chip and said heat transfer plate to relieve a stress applied to said LED chip due to a difference in linear expansion coefficient between said LED chip and said heat transfer plate.
4. The light-emitting device as set forth in claim 1, wherein said connecting member has a plane size larger than that of said heat transfer plate. Description
Also, conventionally, in the light-emitting device having an LED chip and a circuit board on which the LED chip is mounted, a structure for effectively dissipating heat generated in a light-emitting part of the LED chip to the outside has been proposed so as to increase the power of the light output by constraining a rise of a junction temperature of the LED chip and increasing the input power (for example, see Japanese Patent Application Laid-Open No. 2003-168829 (hereinafter, referred to as Patent Document 2), Paragraph [0030] and FIG. 6).
In this case, it is possible to set a lattice constant of a substrate for crystal growth of the LED chip close to that of the GaN-based compound semiconductor material, and, because the substrate for crystal growth has conductivity, it is possible to form an electrode on the substrate for crystal growth, In addition, as compared with a case where the substrate for crystal growth is a sapphire substrate, the heat transfer property of the substrate for crystal growth is superior, so it is possible to reduce the heat resistance of the substrate for crystal growth. Therefore, it is possible to improve the heat radiation property.
In the chip mounting member 70, as a material of the conductive plate 71, a conductive material having a conductive property and a relatively high thermal conductivity, such as Cu and phosphor bronze, may be adopted, and as a material of the conductor patterns 73, 73, Cu may be adopted, for example. As a material of the insulating part 72 of the chip mounting member 70, a resin having an insulating property, such as glass epoxy resin such as FR-4, polyimide-based resin, and phenol resin may be adopted. In the present embodiment, the chip mounting member 70 is provided with window hole 75 at the center of the insulating part 72 for partially exposing a surface of the conductive plate 71, and the LED chip 10 is mounted to the conductive plate 71 through the sub-mount member 30 disposed inside the window hole 75. The conductive plate 71 only has to have about the same thickness as that of a lead frame. Therefore, as compared with the circuit boards of the light-emitting devices disclosed in the above Patent Documents 1 and 2, it is possible to reduce the thickness of the circuit board.
The material of the sub-mount member 30 is not limited to CuW, and for example as seen from Table 2 below, any material having a linear expansion coefficient which is relatively close to that of 6H-SiC, that is the material of the conductive substrate 11, and a relatively high thermal conductivity may be used, such as W, AIN, composite SiC, and Si. When the sub-mount member 30 is formed of an insulator such as AIN and composite SiC, for example, an electrode pattern may be conveniently provided on the surface of the sub-mount member 30 on LED chip 10 side to be connected with the cathode electrode, and the electrode pattern may be electrically connected with the other conductor pattern 73 via the bonding wire 14.
When the sub-mount member 30 is made of W and the sub-mount member 30 and the conductive plate 71 are connected to each other directly, as seen from Table 4 below, the thermal conductivity is increased and the heat resistance can be reduced therebetween, as compared with a case where the sub-mount member 30 and the conductive plate 71 are connected to each other using silver solder. When the conductive plate 71 is made of Cu and the sub-mount member 30 is made of AIN, composite SiC, or the like, the conductive plate 71 and the sub-mount member 30 may be connected to each other using a Pb-free solder such as AuSn and SnAgCu, but when AuSn is used for the connection, the surface of the conductive plate 71 for the connection should be subjected to a pretreatment for forming a metal layer of Au or Ag in advance.
In this embodiment, the sub-mount member 30 is made of AIN that has a relatively high thermal conductivity and an insulating property. The LED chip 10 has anode electrodes 13 a formed at two adjacent corners on one surface side thereof (see FIG. 7 and FIG. 8A), and has cathode electrodes 13 b formed at the other two corners thereof (see FIG. 7 and FIG. 8A). Each of the anode electrodes 13 a is electrically connected to one of the conductor patterns 73 via a bonding wire 14, and each of the cathode electrodes 13 b is electrically connected to the other of the conductor patterns 73 via another bonding wire 14. The resist layer 76 of the wiring board 74 is patterned so as to expose two portions of each of the conductor patterns 73 near the window hole 75 and also expose one part of each of the conductor patterns 73 at the peripheral part of the wiring board 74. In each of the conductor patterns 73, the two portions exposed near the window hole 75 form terminal parts 73 a to be connected to bonding wires 14, and the circular portions exposed at the peripheral parts of the resist layer 76 form electrode sections 73 b to be connected to the exterior. Out of the two electrode sections 73 b, the electrode section 73 b to which each anode electrode 13 a of the LED chip 10 is electrically connected (the right electrode section 73 b in FIG. 7) has a mark �+� thereon, and the electrode section 73 b to which each cathode electrode 13 b of the LED chip 10 is electrically connected (the left electrode section 73 b in FIG. 7) has a mark �−� thereon, which enables a visual recognition of the polar of the electrode sections 73 a, 73 b in the light-emitting device 1, whereby it is possible to prevent an error connection.
Furthermore, the optical member 160 is configured so that the light output surface 160 b has a convex surface which does not totally reflect the light entered therein from a light incident surface 160 a at the boundary between the light output surface 160 b and the air layer 180, and the optical member 160 is arranged so that the light axis thereof is aligned with that of the LED chip 10. Therefore, the light emitted from the LED chip 10 and entered in the light incident surface 160 a of the optical member 160 is not totally reflected at the boundary between the light output surface 160 b and the air layer 180, and it becomes easy for the light to reach the color converting member 170, whereby it is possible to increase the whole light flux. The light emitted from the sides of the LED chip 10 is propagated in the sealing part 150, the optical member 160, and the air layer 180, and reaches the color converting member 170, and the light excites the phosphor of the color converting member 170 or passes through the color converting member 170 without hitting the phosphor. The optical member 160 is formed to have a uniform thickness along the direction normal to the optical member 160 independently of the positions thereof.
In the light-emitting device 1 of the present embodiment, since the air layer 180 is formed between the color converting member 170 and the optical member 160, when an external force acts on the color converting member 170, a possibility that the color converting member 170 is deformed by the external force and makes contact with the optical member 160 is reduced, So, it can be prevented that the stress applied to the color converting member 170 by the external force is transmitted to the LED chip 10 and each bonding wire 14 via the optical member 160 and the sealing part 150. Therefore, variations in light emitting property of the LED chip 10 and disconnection of each bonding wire 14 due to the external force are less likely to occur, and the reliability can be increased. In addition, the air layer 180 formed between the color converting member 170 and the optical member 160 provides advantages that moisture in the ambient atmosphere does not easily reach the LED chip 10, and that the amount of light which is emitted by the LED chip 10 and passes through the sealing part 150 and the optical member 160 and enters the color converting member 170 and then is scattered by the powder of yellow phosphor in the color converting member 170 toward the optical member 160 and passes through the optical member 160 is reduced, and as a result, the light output efficiency of the light-emitting device 1 to the exterior can be increased as a whole.
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