LIGHT EMITTING DEVICE, RESIN-ATTACHED LEAD FRAME, AND METHODS OF MANUFACTURING THE SAME

• US 20190326492A1
• Filed: 04/23/2019
• Published: 10/24/2019
• Est. Priority Date: 04/23/2018
• Status: Active Grant

• Current Assignee: Nichia Corporation
• Original Assignee: Nichia Corporation
• Inventors: MARUTANI, Yukitoshi
• Granted Patent: US 10,910,537 B2
• Time in Patent Office: Days
• CPC Class Codes: H01L 21/4821 Flat leads, e.g. lead frames with or without insulating supports
• CPC Class Codes: H01L 2224/48091 Arched
• CPC Class Codes: H01L 2224/48247 connecting the wire to a bond pad of the item
• CPC Class Codes: H01L 2224/48465 the other connecting portion not on the bonding area being a wedge bond, i.e. ball-to-wedge, regular stitch
• CPC Class Codes: H01L 23/49541 Geometry of the lead-frame
• CPC Class Codes: H01L 23/49586 Insulating layers on lead frames
• CPC Class Codes: H01L 2924/00014 the subject-matter covered by the group, the symbol of which is combined with the symbol of this group, being disclosed without further technical details
• CPC Class Codes: H01L 2933/0033 relating to semiconductor body packages
• CPC Class Codes: H01L 2933/0066 relating to arrangements for conducting electric current to or from the semiconductor body
• CPC Class Codes: H01L 33/483 Containers
• CPC Class Codes: H01L 33/486 adapted for surface mounting
• CPC Class Codes: H01L 33/52 Encapsulations
• CPC Class Codes: H01L 33/62 Arrangements for conducting electric current to or from the semiconductor body, e.g. lead-frames, wire-bonds or solder balls

Abstract

A light emitting device includes: a base body including two conductive members, a resin body, and a fiber member placed inside the resin body, and a light-emitting element. The resin body includes an isolation section located between the two conductive members, and includes a pair of sandwiching portions sandwiching the isolation section. The fiber member has a length which is greater than a distance between the two conductive members, and is located at least in an adjoining region of at least one of the pair of sandwiching portions, the adjoining region adjoining the isolation section. In the adjoining region, the fiber member extends in a direction which is non-orthogonal to a direction in which that the pair of sandwiching portions extend.

Claims

1. A light emitting device comprising:

a base body including two conductive members each having an upper face and a lower face, a resin body covering a part of each conductive member, and a fiber member placed inside the resin body, a part of the upper face of each conductive member being exposed from the resin body at an upper side of the base body, and a part of the lower face of each conductive member being exposed from the resin body at a lower side of the base body; and

a light-emitting element electrically connected to the two conductive members, wherein,

the resin body includes an isolation section located between the two conductive members, and includes a pair of sandwiching portions sandwiching the isolation section;

the fiber member has a length which is greater than a distance between the two conductive members, and is located at least in an adjoining region of at least one of the pair of sandwiching portions, the adjoining region adjoining the isolation section; and

,

in the adjoining region, the fiber member extends in a direction which is non-orthogonal to a direction in which the pair of sandwiching portions extend.

2. The light emitting device of claim 1, wherein,

each sandwiching portion has an outer lateral face;

at least one of the two conductive members includes an extending portion, the extending portion extending toward the outer lateral face of one of the pair of sandwiching portions and having an end face which is exposed at said outer lateral face; and

the fiber member is located downward of the extending portion.

3. The light emitting device of claim 1, wherein,

each sandwiching portion has an outer lateral face;

at least one of the two conductive members includes an extending portion, the extending portion extending toward the outer lateral face of one of the pair of sandwiching portions and having an end face which is exposed at said outer lateral face; and

the fiber member is located upward of the extending portion.

4. The light emitting device of claim 1, wherein,

each sandwiching portion has an outer lateral face;

the two conductive members each include an extending portion, the extending portion extending toward the outer lateral face of one of the pair of sandwiching portions and having an end face which is exposed at said outer lateral face;

the fiber member includes a first fiber portion located downward of the extending portion and a second fiber portion located upward of the extending portion; and

the first fiber portion and the second fiber portion come in contact with each other in between the extending portions of the two conductive members.

5. The light emitting device of claim 1, wherein,

the resin body includes a pair of interconnecting portions interconnecting the sandwiching portions;

and

each of the pair of interconnecting portions has an outer lateral face, an end face of the fiber member being exposed at the outer lateral face of one of the pair of interconnecting portions.

6. The light emitting device of claim 1, wherein an end face of the fiber member is located inside the resin body.

7. A resin-attached lead frame, comprising:

a lead frame;

a resin member; and

plurality of fiber members,

wherein the lead frame includes;

a plurality of conductive portions arrayed along a first direction and a second direction which intersects the first direction, each conductive portion having an upper face and a lower face in relation to a third direction which is perpendicular to the first direction and the second direction, and each conductive portion including first and second conductive subportions in a plane containing the first direction and the second direction, the first and second conductive subportions being arranged along the first direction and spaced apart from each other by a gap; and

a plurality of connecting portions connecting between the plurality of conductive portions along the first direction and along the second direction,

wherein the resin member includes;

a plurality of isolation portions each placed in the gap between the first and second conductive subportions; and

a latticework portion placed between the plurality of conductive portions so as to surround each conductive portion while leaving a part of the upper face and a part of the lower face of the conductive portion exposed, the latticework portion including a plurality of first portions extending along the first direction and a plurality of second portions extending along the second direction,

wherein the plurality of fiber members each has a length which is greater than a distance between the first and second conductive subportions, and

wherein, in the resin member, one end of each isolation portion is connected to a corresponding one of the plurality of first portions; and

wherein one of the plurality of fiber members is located at least in an adjoining region of the first portion to which each isolation portion is connected, the adjoining region adjoining the isolation portion, the one fiber member extending within the adjoining region in a direction which is non-orthogonal to the first direction.

8. The resin-attached lead frame of claim 7, wherein,

in the resin member, another end of each isolation portion is connected to another one of the plurality of first portions;

and

another one of the plurality of fiber members is located at least in an adjoining region of the other first portion to which each isolation portion is connected, the adjoining region adjoining the isolation portion, the other fiber member extending within the adjoining region in a direction which is non-orthogonal to the first direction.

9. The resin-attached lead frame of claim 7, further comprising a plurality of additional fiber members, wherein,

the latticework portion of the resin member includes a plurality of second portions extending along the second direction;

the additional fiber members are embedded in the plurality of second portions; and

the fiber members and the additional fiber members constitute a knotless net.

10. The resin-attached lead frame of claim 7, further comprising a plurality of additional fiber members, wherein,

the latticework portion of the resin member includes a plurality of second portions extending along the second direction;

in the resin member, another end of each isolation portion is connected to the second portion; and

one of the plurality of additional fiber members is located at least in an adjoining region of the second portion to which each isolation portion is connected, the adjoining region adjoining the isolation portion, the one additional fiber member extending within the adjoining region in a direction which is non-orthogonal to the second direction.

11. The resin-attached lead frame of claim 7, wherein,

the lead frame includes an outer frame portion surrounding the plurality of conductive portions arrayed along the first and second directions, and a plurality of hooks located inside the outer frame portion;

and

the plurality of fiber members are engaged on and supported by the plurality of hooks.

12. The resin-attached lead frame of claim 7, wherein the plurality of fiber members are impregnated with a resin, and the resin has been cured.

13. The resin-attached lead frame of claim 7, wherein,

the plurality of connecting portions of the lead frame include

first connecting portions each connecting the first conductive subportion of a conductive portion to the second conductive subportion of an adjacent conductive portion along the first direction, and

second connecting portions each connecting the first and second conductive subportions of a conductive portion to the first and second conductive subportions of an adjacent conductive portion along the second direction;

each fiber member includes a first fiber portion that is located above the corresponding second connecting portion and a second fiber portion located below the corresponding second connecting portion; and

in between second connecting portions, the first fiber portion and the second fiber portion are engaged with each other.

14. The resin-attached lead frame of claim 7, wherein,

the latticework portion of the resin member includes a plurality of second portions extending along the second direction;

the plurality of connecting portions of the lead frame include

first connecting portions each connecting the first conductive subportion of a conductive portion to the second conductive subportion of an adjacent conductive portion along the first direction, and

second connecting portions each connecting the first and second conductive subportions of a conductive portion to the first and second conductive subportions of an adjacent conductive portion along the second direction;

each fiber member includes a first fiber portion that is located above the corresponding second connecting portion and a second fiber portion located below the corresponding second connecting portion;

in between second connecting portions, the first fiber portion and the second fiber portion are adhesively bonded to each other; and

each of the plurality of second portions of the latticework portion has the first fiber portion and the second fiber portion located therein, such that the first fiber portion and the second fiber portion are placed between a plurality of cut lines extending along the second direction but do not intersect the cut lines.

15. A method of manufacturing a resin-attached lead frame, comprising:

a step of providing a lead frame, the lead frame including

a plurality of conductive portions arrayed along a first direction and a second direction which intersects the first direction, each conductive portion having an upper face and a lower face regarding a third direction which is perpendicular to the first direction and the second direction, and each conductive portion including first and second conductive subportions in a plane containing the first direction and the second direction, the first and second conductive subportions being arranged along the first direction and spaced apart from each other by a gap, and

a plurality of connecting portions connecting between the plurality of conductive portions along the first direction and along the second direction;

a step of placing a plurality of fiber members adjacent to the first and second conductive subportions, each fiber member having a length which is greater than a distance between the first and second conductive subportions and extending along the first direction; and

an insert molding step of introducing a resin at least partially around the lead frame and at least partially around the plurality of fiber members for integration of the lead frame and the fiber members.

16. The method of manufacturing a resin-attached lead frame of claim 15, wherein,

the plurality of fiber members are impregnated with an uncured resin, the method further comprising:

between the step of placing the fiber members and the insert molding step, a step of curing the uncured resin.

17. The method of manufacturing a resin-attached lead frame of claim 15, wherein,

the fiber member is a part of a knotless net;

and

the step of placing the fiber members places the knotless net so that the plurality of connecting portions of the lead frame are supported by meshes of the knotless net.

18. The method of manufacturing a resin-attached lead frame of claim 15, wherein,

the lead frame includes an outer frame portion surrounding the plurality of conductive portions arrayed along the first and second directions, and a plurality of hooks located inside the outer frame portion;

and

the step of placing the fiber members comprises causing the fiber members to be engaged on and supported by the plurality of hooks.

19. The method of manufacturing a resin-attached lead frame of claim 17, wherein the plurality of fiber members are impregnated with an uncured resin, and the step of placing the fiber members comprises, after causing the plurality of fiber members to be engaged on a plurality of hooks, curing the uncured resin.

20. The method of manufacturing a resin-attached lead frame of claim 15, wherein,

the plurality of connecting portions of the lead frame include

first connecting portions each connecting the first conductive subportion of a conductive portion to the second conductive subportion of an adjacent conductive portion along the first direction, and

second connecting portions each connecting the first and second conductive subportions of a conductive portion to the first and second conductive subportions of an adjacent conductive portion along the second direction;

each fiber member includes a first fiber portion and a second fiber portion; and

the step of placing the fiber members comprises placing the first fiber portion and the second fiber portion of each fiber member above and below the corresponding second connecting portion, and allowing the first fiber portion and the second fiber portion to be engaged with each other in between second connecting portions.

21. The method of manufacturing a resin-attached lead frame of claim 15, wherein,

the plurality of connecting portions of the lead frame include

first connecting portions each connecting the first conductive subportion of a conductive portion to the second conductive subportion of an adjacent conductive portion along the first direction, and

second connecting portions each connecting the first and second conductive subportions of a conductive portion to the first and second conductive subportions of an adjacent conductive portion along the second direction;

each fiber member includes a first fiber portion and a second fiber portion; and

the step of placing the fiber members comprises placing each fiber member so that the corresponding second connecting portion is interposed between the first fiber portion and the second fiber portion of the fiber member, connecting the first fiber portion and the second fiber portion to the second connecting portion, and causing the first fiber portions and the second fiber portions to be connected to each other in between second connecting portions.

22. A method of manufacturing a light emitting device, comprising:

a step of producing a resin-attached lead frame by using the method of producing a resin-attached lead frame of claim 15;

a step of connecting a light-emitting element to each of the plurality of conductive portions;

a step of placing a sealing member covering the light-emitting elements; and

a step of singulating the resin-attached lead frame by cutting the resin-attached lead frame along cut lines.