LIGHT EMITTING DEVICE, LIGHT EMITTING MODULE, METHOD OF MANUFACTURING LIGHT EMITTING DEVICE, AND METHOD OF MANUFACTURING LIGHT EMITTING MODULE

• US 20200135999A1
• Filed: 10/31/2019
• Published: 04/30/2020
• Est. Priority Date: 10/31/2018
• Status: Active Grant

• Current Assignee: Nichia Corporation
• Original Assignee: Nichia Corporation
• Inventors: DAIKOKU, Shinichi, HASHIMOTO, Toru
• Granted Patent: US 11,489,098 B2
• Time in Patent Office: Days
• CPC Class Codes: G02B 6/0068 Arrangements of plural sources, e.g. multi-colour light sources
• CPC Class Codes: G02B 6/0073 Light emitting diode [LED]
• CPC Class Codes: H01L 2224/18 High density interconnect [HDI] connectors; Manufacturing methods related thereto
• CPC Class Codes: H01L 2933/0033 relating to semiconductor body packages
• CPC Class Codes: H01L 2933/005 relating to encapsulations
• CPC Class Codes: H01L 2933/0058 relating to optical field-shaping elements
• CPC Class Codes: H01L 2933/0066 relating to arrangements for conducting electric current to or from the semiconductor body
• CPC Class Codes: H01L 33/486 adapted for surface mounting
• CPC Class Codes: H01L 33/54 having a particular shape
• CPC Class Codes: H01L 33/60 Reflective elements
• 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

The light emitting device includes a light emitting element having an electrode-formed surface on which electrode posts are formed; a covering member covering the electrode-formed surface and lateral surfaces of the light emitting element while forming an exposure portion of each of the electrode posts which are exposed from the covering member; a pair of electrode layers provided on a surface of the covering member and electrically connected to the exposed portions of the electrode posts; and a pair of electrode terminals which are respectively electrically connected to the electrode layers, having a surface area larger than a surface area of the electrode posts, and having an outer edge positioned at an end portion of the covering member; and an insulating member provided between the pair of the electrode terminals while being in contact with lateral surfaces of the pair of electrode terminals.

Claims

1. A light emitting device comprising:

a light emitting element having an electrode-formed surface on which a pair of electrode posts are formed;

a covering member covering the electrode-formed surface and lateral surfaces of the light emitting element while forming an exposure portion for each of the pair of electrode posts exposed from the covering member;

a pair of electrode layers provided on a surface of the covering member and electrically connected to the exposed portions of the pair of electrode posts; and

a pair of electrode terminals which are respectively electrically connected to the pair of electrode layers, having a surface area larger than a surface area of a pair of the electrode posts, and having an outer edge positioned at an end portion of the covering member; and

an insulating member provided between the pair of electrode terminals while being in contact with lateral surfaces of the pair of electrode terminals.

2. The light emitting device according to claim 1, wherein the insulating member entirely covers surfaces of the pair of electrode layers exposed from the pair of electrode terminals and a surface of the covering member.

3. The light emitting device according to claim 1, wherein a surface of the insulating member and surfaces of the pair of electrode terminals are flush with each other.

4. The light emitting device according to claim 1, wherein

the insulating member has light-transmissivity, and

the pair of electrode posts are disposed inward of the insulating member.

5. The light emitting device according to claim 1, wherein a thickness of one of the pair of electrode terminals is greater than a thickness of one of the pair of electrode layers.

6. The light emitting device according to claim 5, wherein the thickness of one of the pair of electrode terminals is not less than 10 times the thickness of one of the pair of electrode layers.

7. The light emitting device according to claim 1, wherein

the electrode-formed surface of the light emitting element has a quadlangular shape, and

the pair of the electrode terminals are disposed at symmetric positions on the outer edge of the electrode-formed surface.

8. A light emitting module comprising:

the light emitting device according to claim 1; and

a light-transmissive light guiding plate in which a recessed portion is formed on a second principal surface opposite to a first principal surface serving as a light emitting surface from which light exits,

the light emitting device being disposed in the recessed portion of the light guiding plate.

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

providing an intermediate body in which a light emitting element including a pair of electrode posts formed on an electrode-formed surface is covered with a covering member, and the covering member forms exposure portions for the pair of electrode posts in which the pair of electrode posts are exposed from the covering member;

forming a pair of electrode layers on a surface of the covering member, the pair of electrode layers being electrically connected to the exposed portions of the pair of electrode posts in the intermediate body;

providing a pair of electrode terminals, which is respectively electrically connected to the pair of the electrode layers and having a surface area larger than a surface area of the pair of electrode posts, such that an outer edge of each of the pair of electrode terminals is respectively positioned at one of end portions of the covering member; and

forming an insulating member between a pair of the electrode terminals while being in contact with lateral surfaces of the pair of electrode terminals.

10. The method of manufacturing a light emitting device according to claim 9, wherein,

covering the light emitting element and at least one additional light emitting element with the covering member in the step of providing the intermediate body,

forming the pair of electrode layers and the pair of electrode terminals in a state of being connected to the pair of electrode posts of the light emitting element in the step of forming the pair of electrode layers and the step of forming the pair of electrode terminals, and

after the forming the insulating member, cutting the covering member between the light emitting element and at least one additional light emitting element, the pair of electrode layers and the pair of electrode terminals to separate the intermediate body into individual light emitting devices.

11. The method of manufacturing a light emitting device according to claim 9, wherein the insulating member is entirely formed over the covering member and portions of surfaces of the pair of electrode layers exposed from the pair of electrode terminals.

12. The method of manufacturing a light emitting device according to claim 11, wherein a surface of the insulating member is flush with surfaces of the pair of electrode terminals.

13. The method of manufacturing a light emitting device according to claim 12, wherein the insulating member is provided in a state where the pair of electrode terminals is embedded in the insulating member, and

the surface of the insulating member is polished or ground to make the surface of the insulating member flush with the surfaces of the pair of electrode terminals.

14. The method of manufacturing a light emitting device according to claim 10, wherein the insulating member is in contact with the covering member at the surfaces of the light emitting element and at least one additional light emitting element, the pair of electrode layers and the pair of electrode terminals.

15. The method of manufacturing a light emitting device according to claim 10, wherein a light-transmissive material is prepared as the insulating member, and

the pair of electrode posts are disposed inward of the insulating member while being in contact with the insulating member in a state where the pair of electrode posts are embedded in the insulating member.

16. The method of manufacturing a light emitting device according to claim 10, wherein a thickness of one of the pair of electrode terminals is greater than a thickness of one of the pair of electrode layers.

17. The method of manufacturing a light emitting device according to claim 10, wherein the pair of electrode layers are configured by a metal thin film, and the pair of electrode terminals are provided by applying a metal paste to the surfaces of the pair of electrode layers.

18. A method of manufacturing a light emitting module, comprising:

providing the light emitting device manufactured by the method according to claim 10, and

a light guiding plate having a first principal surface serving as a light emitting surface, and a second principal surface positioned opposite to the first principal surface, the second principal surface is provided with a recessed portion;

bonding the light emitting device to the recessed portion;

providing a light-reflective member on the second principal surface of the light guiding plate to embed the light emitting device; and

polishing the light-reflective member to expose the pair of electrode terminals, and forming an electrically conductive film on surfaces of the exposed pair of electrode terminals.