LIGHT-EMITTING DEVICE AND METHOD FOR MANUFACTURING THE SAME

Abstract

The invention provides a light-emitting device 10 including an light-emitting element 12 and a substrate 11 where the light-emitting element 12 is arranged, characterized in that a housing part 28 housing the light-emitting element 12 and having a shape that is tapered upward from the substrate 11 and a metal frame 15 surrounding the light-emitting element 12 and including the side face 28A of the housing part 28 made into an almost mirror-polished surface are provided on the substrate 11.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of a related art light-emitting device.

FIG. 2 is a cross-sectional view of a light-emitting device according to the first embodiment of the invention.

FIG. 3 is a plan view of the metal frame shown in FIG. 2.

FIG. 4 is a plan view of another metal frame applicable to a light-emitting device of this embodiment.

FIG. 5A shows a step of manufacturing a light-emitting device according to the first embodiment of the invention.

FIG. 5B shows a step of manufacturing a light-emitting device according to the first embodiment of the invention.

FIG. 5C shows a step of manufacturing a light-emitting device according to the first embodiment of the invention.

FIG. 5D shows a step of manufacturing a light-emitting device according to the first embodiment of the invention.

FIG. 5E shows a step of manufacturing a light-emitting device according to the first embodiment of the invention.

FIG. 5F shows a step of manufacturing a light-emitting device according to the first embodiment of the invention.

FIG. 5G shows a step of manufacturing a light-emitting device according to the first embodiment of the invention.

FIG. 5H shows a step of manufacturing a light-emitting device according to the first embodiment of the invention.

FIG. 5I shows a step of manufacturing a light-emitting device according to the first embodiment of the invention.

FIG. 6A is a plan view of the metal plate shown in FIG. 5D.

FIG. 6B is a plan view of the metal plate shown in FIG. 5E including a plurality of recessed parts formed thereon.

FIG. 6C is a plan view of the metal plate shown in FIG. 5F including a plurality of housing parts formed thereon.

FIG. 7 is a cross-sectional view of a light-emitting device according to the second embodiment of the invention.

FIG. 8 shows a step of manufacturing the light-emitting device according to the second embodiment of the invention.

FIG. 9 is a cross-sectional view of a light-emitting device according to the third embodiment of the invention.

FIG. 10 is a plan view of the light-emitting device according to the third embodiment of the invention.

FIG. 11 is a plan view of a metal frame.

FIG. 12 is a cross-sectional view of a light-emitting device according to a variation of the third embodiment.

FIG. 13 is a plan view of another metal frame including a cutting part.

FIG. 14 shows a step of manufacturing the light-emitting device according to the third embodiment of the invention.

FIG. 15 is a plan view of the metal plate shown in FIG. 14.

FIG. 16 is a cross-sectional view of a light-emitting device according to the fourth embodiment of the invention.

FIG. 17 is a plan view of the light-emitting device according to the fourth embodiment of the invention.

FIG. 18 is a plan view of a metal cover.

FIG. 19A shows a step of manufacturing a light-emitting device according to the fourth embodiment of the invention.

FIG. 19B shows a step of manufacturing a light-emitting device according to the fourth embodiment of the invention.

FIG. 19C shows a step of manufacturing a light-emitting device according to the fourth embodiment of the invention.

FIG. 19D shows a step of manufacturing a light-emitting device according to the fourth embodiment of the invention.

FIG. 19E shows a step of manufacturing a light-emitting device according to the fourth embodiment of the invention.

FIG. 19F shows a step of manufacturing a light-emitting device according to the fourth embodiment of the invention.

FIG. 20A is a plan view of the metal plate shown in FIG. 19A.

FIG. 20B is a plan view of the metal plate shown in FIG. 19B.

FIG. 20C is a plan view of the metal plate shown in FIG. 19C.

Claims

1. A light-emitting device comprising: a light-emitting element,a substrate where the light-emitting element is arranged, anda metal frame provided on the substrate including a housing part for housing the light-emitting element, the housing part having a shape that is tapered upward from the substrate.

2. The light-emitting device according to claim 1, wherein the substrate includes a metal frame inserting part where at least part of the metal frame is inserted, anda cutting part for allowing the external shape of the metal frame to be deformable is provided on the metal frame.

3. The light-emitting device according to claim 1, further comprising: a reflecting member for reflecting light emitted from the light-emitting element, provided on the face of the housing part surrounding the light-emitting element.

4. A light-emitting device comprising: a light-emitting element, anda substrate where the light-emitting element is arranged, whereina metal cover including a housing part for housing the light-emitting element and a through hole for transmitting light emitted from the light-emitting element, is provided on the substrate.

5. The light-emitting device according to claim 4, further comprising: a reflecting member for reflecting light emitted from the light-emitting element, provided on the face of the metal cover surrounding the light-emitting element.

6. A method for manufacturing a light-emitting device including a light-emitting element, a substrate where the light-emitting element is arranged and a metal frame including a housing part for housing the light-emitting element, the housing part provided on the substrate and having a shape that is tapered upward from the substrate, the method comprising:a metal plate preparation step of preparing a metal plate including a plurality of metal frame forming areas where the metal frame is formed, anda housing part forming step of forming, by way of press working, the housing part on the metal plate corresponding to the metal frame forming areas.

7. The method for manufacturing a light-emitting device according to claim 6, further comprising: a metal plate cutting step of cutting the metal plate along the external shape positions of the metal frame forming areas by way of press working after the housing part forming step.

8. The method for manufacturing a light-emitting device according to claim 7, further comprising: a reflecting member forming step of forming a reflecting member for reflecting light emitted from the light-emitting element on the face of the housing part surrounding the light-emitting element between the housing part forming step and the metal plate cutting step.

9. A method for manufacturing a light-emitting device including a light-emitting element, a substrate where the light-emitting element is arranged and a metal frame including a housing part for housing the light-emitting element, the housing part having a shape that is tapered upward from the substrate, the substrate including a metal frame inserting part where at least part of the metal frame is inserted, the method comprising:a metal plate preparation step of preparing a metal plate including a plurality of metal frame forming areas where the metal frame is formed,a housing part forming step of forming, by way of press working, the housing part on the metal plate corresponding to the metal frame forming areas, anda cutting part forming step of forming on the metal plate a cutting part to allow the external shape of the metal frame to be deformable.

10. A method for manufacturing a light-emitting device including a light-emitting element, a substrate where the light-emitting element is arranged, a housing part arranged on the substrate for housing the light-emitting element and a metal cover including through holes for transmitting light emitted from the light-emitting element, wherein the method comprising:a metal plate preparation step of preparing a metal plate including a plurality of metal cover forming areas where the metal cover is formed,a housing part forming step of forming, by way of press working, the housing part on the metal plate corresponding to the metal cover forming areas, anda through hole forming step of forming, by way of press working, the through holes in the metal plate corresponding to a position where the housing part is formed.

11. The method for manufacturing a light-emitting device according to claim 9, further comprising: a metal plate cutting step of cutting the metal plate along the external shape positions of the metal frame forming areas by way of press working after the housing part forming step.

12. The method for manufacturing a light-emitting device according to claim 10, further comprising: a metal plate cutting step of cutting the metal plate along the external shape positions of the metal cover forming areas by way of press working after the housing part forming step.