Method for manufacturing a surface-mounted type optical semiconductor device
First Claim
1. A method for manufacturing a surface-mounted optical semiconductor device, comprising the steps of:
- mounting an optical semiconductor element on each of a plurality of insulating substrates;
adhering a sealing mold for transfer molding, having a through-gate structure and a dome-shaped portion, to a major surface of each of said insulating substrates;
continuously injecting a liquid epoxy resin having a melt viscosity of approximately 100 to 200 Pa·
s into the dome-shaped portion of said sealing mold;
hardening said liquid epoxy resin by thermal curing to form a projected, domed lens on said optical semiconductor element; and
removing said sealing mold, and separating said insulating substrates from one another, wherein each insulating substrate includes said optical semiconductor element.
1 Assignment
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Accused Products
Abstract
In manufacturing an optical semiconductor device, light-emitting elements are mounted on their respective printed boards of an insulating plate with a silver paste interposed therebetween. A sealing mold having a shape (a lens forming portion) necessary for forming a projected lens is adhered to the major surface of the insulating plate in accordance with each of the light-emitting elements of each of the printed boards. A liquid epoxy resin having a melt viscosity of 100 Pa·s to 200 Pa·s is continuously injected into the sealing mold with the lens forming portion of the sealing mold downward. The liquid epoxy resin is then hardened to form a projected, domed lens on each of the light-emitting elements. After that, the sealing mold is removed, and the insulating plate is separated for each of the light-emitting elements into surface-mounted optical semiconductor devices each having a projected, domed lens. Consequently, a lens having a large diameter can be formed in a short time, thereby increasing in luminance and improving in yield and quality, without increasing in manufacturing costs.
13 Citations
22 Claims
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1. A method for manufacturing a surface-mounted optical semiconductor device, comprising the steps of:
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mounting an optical semiconductor element on each of a plurality of insulating substrates; adhering a sealing mold for transfer molding, having a through-gate structure and a dome-shaped portion, to a major surface of each of said insulating substrates; continuously injecting a liquid epoxy resin having a melt viscosity of approximately 100 to 200 Pa·
s into the dome-shaped portion of said sealing mold;hardening said liquid epoxy resin by thermal curing to form a projected, domed lens on said optical semiconductor element; and removing said sealing mold, and separating said insulating substrates from one another, wherein each insulating substrate includes said optical semiconductor element. - View Dependent Claims (2, 3, 4, 5)
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6. A method for manufacturing a surface-mounted type optical semiconductor device, comprising the steps of:
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mounting a plurality of optical semiconductor elements on each of a plurality of insulating substrates; adhering a sealing mold for transfer molding, having a through-gate structure, to a major surface of each of said insulating substrates; continuously injecting a liquid epoxy resin having a melt viscosity of approximately 100 to 200 Pa·
s into said sealing mold; andhardening said liquid epoxy resin by thermal curing to form a projected, domed lens on said optical semiconductor element. - View Dependent Claims (7, 8, 9, 10, 11)
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12. A method for manufacturing a surface-mounted optical semiconductor device, comprising the steps of:
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mounting an optical semiconductor element on an insulating substrate; adhering a sealing mold for transfer molding, having a through-gate structure and a dome-shaped portion, to a major surface of said insulating substrate; continuously injecting a liquid epoxy resin having a melt viscosity of approximately 100 to 200 Pa·
s into the dome-shaped portion of said sealing mold;hardening said liquid epoxy resin by thermal curing to form a projected, domed lens on said optical semiconductor element; and removing said sealing mold. - View Dependent Claims (13, 14, 15, 16)
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17. A method for manufacturing a surface-mounted optical semiconductor device, comprising the steps of:
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mounting a plurality of optical semiconductor elements on an insulating substrate; adhering a sealing mold for transfer molding, having a through-gate structure, to a major surface of said insulating substrate; continuously injecting a liquid epoxy resin having a melt viscosity of approximately 100 to 200 Pa·
s into said sealing mold;hardening said liquid epoxy resin by thermal curing to form a projected, domed lens on said optical semiconductor element. - View Dependent Claims (18, 19, 20, 21, 22)
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Specification