CN105070813A - 一种大功率led支架及其封装方法 - Google Patents
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Abstract
本发明公开了一种大功率LED支架及其封装方法,该支架包括铜板、基板,基板置于铜板上,两者压合连接在一起,在基板两侧设置有导孔,所述铜板和基板的电路通过导孔连接,所述LED芯片安装在铜板上,其电极通过金线与基板上的电极连接,所述LED芯片、金线通过硅树脂封装,所述硅树脂呈半圆,起到光学透镜的作用,所述硅树脂外部设置有玻璃透镜。该支架具有高导热,具有反射被且体积小,封装时有点胶和模压两种封装方式,能够实现轻薄小尺寸功率型封装。
Description
技术领域
本发明涉及LED灯技术领域,具体的说是涉及一种大功率LED支架及其封装方法。
背景技术
LED封装行业朝着可实现大规模生产,降低成本,设计灵活,尺寸更小,符合LED产品轻薄化、高集成、小体积的应用趋势发展。
随着LED芯片功率的增大,特别是固态照明技术的发展需求,对LED封装的光学、热学、电学和机械结构等提出了新的、更高的要求。为了有效的降低封装热阻,提高出光效率,必须采用全新的技术思路来进行封装设计。
如图1所示的现有技术中的LED封装结构,常规大功率LED主要由支架17、LED芯片14、金线16、封装胶13、透镜11等组成;支架17由铜柱15、反射碗杯12、支架引脚、支架碗杯等组成;封装时芯片安装在反射杯内,金线需跨过反射杯来连接芯片和支架引脚,再通过封装胶保护整个支架碗杯内芯片金线。封装体尺寸大,不易实现大规模生产。
发明内容
针对现有技术中的不足,本发明要解决的技术问题在于提供了一种大功率LED支架及其封装方法,该支架具有高导热,具有反射被且体积小,封装时有点胶和模压两种封装方式,能够实现轻薄小尺寸功率型封装。
为解决上述技术问题,本发明通过以下方案来实现:一种大功率LED支架,该支架包括铜板、基板,基板置于铜板上,两者压合连接在一起,在基板两侧设置有导孔,所述铜板和基板的电路通过导孔连接,所述LED芯片安装在铜板上,其电极通过金线与基板上的电极连接,所述LED芯片、金线通过硅树脂封装,所述硅树脂呈半圆,起到光学透镜的作用,所述硅树脂外部设置有玻璃透镜。
进一步的,所述基板为BT树脂基覆板。
进一步的,所述基板可以使用FR4覆铜板替代。
进一步的,所述铜板厚度为0.2mm,基板厚度为0.3mm,支架整体厚度为0.5mm。
进一步的,所述支架为350~450W/(m·K)导热系数的支架。
一种大功率LED支架的封装方法,该方法包括以下步骤:
1)、将铜板进行捞槽,形成一条条的槽沟,捞槽的目的是为了实现铜板的正负极,捞槽后使用有机树脂对槽沟进行填满,目的是将正负极实现电气绝缘且粘合牢固;
2)、对基板捞出反射杯,并钻出基板和铜板连接的导孔;
3)、将基板和铜板贴合,贴合后对导孔进行沉铜电镀以实现电路连接;对铜板表面进行电镀银,以防止封装时铜的氧化和增加反射提高封装体的出光;
4)、封装时先将LED芯片安装在反射杯中心的铜板上,通过金线)实现LED芯片和基板上电极的电路连接;
5)、将步骤4)中的LED芯片上封装出玻璃透镜;
6)、封装完成后再对整块支架进行切割,切割成单颗材料。
进一步的,所述金线的焊盘在基板上表面,基板焊盘位置再捞出两个焊线位置,基板上不再需要设计焊盘电路和与铜板连接的导孔,金线直接与铜板键合。
相对于现有技术,本发明的有益效果如下:
1、实现轻薄小尺寸功率型封装,铜板厚度0.2mm,基板厚度0.3mm,支架整体厚度0.5mm。
2、支架可使用点胶和模压两种封装方法。
3、支架具有高导热率,导热系数在350~400W/(m·K)。
4、实现中大功率LED较小尺寸封装,低成本。
5、本发明封装体在应用时需要采用反贴,电路板需要开孔,才能使LED光散出去。
6、金线的焊盘在BT基板上表面,封装时焊线需要金线的跨度较大,存在金线用量较大和线弧不够稳定的问题,故在基板焊盘位置再捞出两个焊线位置,基板上不再需要设计焊盘等电路和与铜板连接的导孔,金线直接与铜板键合,线弧较低可以得到稳定的线弧。
7.本发支架具有高导热,具有反射被且体积小,封装时点胶和模压两种封装方式;可实现轻薄小尺寸功率型封装。
附图说明
为了更清楚地说明本发明实施例或现有技术中的技术方案,下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍,显而易见地,下面描述中的附图仅仅是本发明的一些实施例,对于本领域普通技术人员来讲,在不付出创造性劳动的前提下,还可以根据这些附图获得其他的附图。
图1为传统的LED灯封装结构示意图。
图2为本发明大功率LED支架结构示意图。
图3为本发明大功率LED封装结构示意图。
图4为本发明铜板捞槽结构示意图。
图5为本发明BT基板捞出反射杯结构示意图。
图6为本发明BT基板和铜板贴合结构示意图。
图7为本发明LED芯片电路连接示意图。
图8为本发明封装出玻璃透镜结构示意图。
图9为本发明封装完成后再对整块支架进行切割,切割成单颗材料示意图。
图10为本发明在基板焊盘位置再捞出两个焊线位置示意图。
图11为本发明采用模压方式模压出透镜胶体示意图。
附图中标记:铜板2、基板3、导孔4、LED芯片5、金线6、硅树脂7。
具体实施方式
下面结合附图对本发明的优选实施例进行详细阐述,以使本发明的优点和特征能更易于被本领域技术人员理解,从而对本发明的保护范围做出更为清楚明确的界定。
请参照附图2~3一种大功率LED支架,该支架包括铜板2、基板3,基板3置于铜板2上,两者压合连接在一起,在基板3两侧设置有导孔4,所述铜板2和基板3的电路通过导孔4连接,所述LED芯片5安装在铜板2上,其电极通过金线6与基板3上的电极连接,所述LED芯片5、金线6通过硅树脂7封装,所述硅树脂7呈半圆,起到光学透镜的作用,所述硅树脂7外部设置有玻璃透镜。所述基板3为BT树脂基覆板,所述基板3可以使用FR4覆铜板替代,所述铜板2厚度为0.2mm,基板3厚度为0.3mm,支架整体厚度为0.5mm,所述支架为350~450W/(m·K)导热系数的支架。
实施例1:
一种大功率LED支架的封装方法,该方法包括以下步骤:
1、如图4所示,将铜板2进行捞槽,形成一条条的槽沟2-1,捞槽的目的是为了实现铜板的正负极,捞槽后使用有机树脂对槽沟2-1进行填满,目的是将正负极实现电气绝缘且粘合牢固;
2、如图5所示,对基板3捞出反射杯3-1,并钻出基板3和铜板2连接的导孔4;
3、如图6所示,将基板3和铜板2贴合,贴合后对导孔4进行沉铜电镀以实现电路连接;对铜板2表面进行电镀银,以防止封装时铜的氧化和增加反射提高封装体的出光;
4、如图7所示,封装时先将LED芯片5安装在反射杯3-1中心的铜板上,通过金线6实现LED芯片5和基板3上电极的电路连接;
5、如图8所示,将步骤4中的LED芯片5上封装出玻璃透镜5-4;
6、如图9所示,封装完成后再对整块支架进行切割,切割成单颗材料。
如图10所示,所述金线6的焊盘在基板3上表面,基板3焊盘位置再捞出两个焊线位置,基板上不再需要设计焊盘电路和与铜板连接的导孔,金线6直接与铜板键合。
如图11所示,本发明采用模压方式模压出透镜胶体,可形成较好的出光效果,如使用点胶方式也可实现封装。
以上所述仅为本发明的优选实施方式,并非因此限制本发明的专利范围,凡是利用本发明说明书及附图内容所作的等效结构或等效流程变换,或直接或间接运用在其它相关的技术领域,均同理包括在本发明的专利保护范围内。
Claims (7)
1.一种大功率LED支架,其特征在于:该支架包括铜板(2)、基板(3),基板(3)置于铜板(2)上,两者压合连接在一起,在基板(3)两侧设置有导孔(4),所述铜板(2)和基板(3)的电路通过导孔(4)连接,所述LED芯片(5)安装在铜板(2)上,其电极通过金线(6)与基板(3)上的电极连接,所述LED芯片(5)、金线(6)通过硅树脂(7)封装,所述硅树脂(7)呈半圆,起到光学透镜的作用,所述硅树脂(7)外部设置有玻璃透镜。
2.根据权利要求1所述的一种大功率LED支架,其特征在于:所述基板(3)为BT树脂基覆板。
3.根据权利要求1所述的一种大功率LED支架,其特征在于:所述基板(3)可以使用FR4覆铜板替代。
4.根据权利要求1所述的一种大功率LED支架,其特征在于:所述铜板(2)厚度为0.2mm,基板(3)厚度为0.3mm,支架整体厚度为0.5mm。
5.根据权利要求1所述的一种大功率LED支架,其特征在于:所述支架为350~450W/(m·K)导热系数的支架。
6.一种以权利要求1所述的大功率LED支架的封装方法,其特征在于,该方法包括以下步骤:
1)、将铜板(2)进行捞槽,形成一条条的槽沟(2-1),捞槽的目的是为了实现铜板的正负极,捞槽后使用有机树脂对槽沟(2-1)进行填满,目的是将正负极实现电气绝缘且粘合牢固;
2)、对基板(3)捞出反射杯(3-1),并钻出基板(3)和铜板(2)连接的导孔(4);
3)、将基板(3)和铜板(2)贴合,贴合后对导孔(4)进行沉铜电镀以实现电路连接;对铜板(2)表面进行电镀银,以防止封装时铜的氧化和增加反射提高封装体的出光;
4)、封装时先将LED芯片(5)安装在反射杯(3-1)中心的铜板上,通过金线(6)实现LED芯片(5)和基板(3)上电极的电路连接;
5)、将步骤4)中的LED芯片(5)上封装出玻璃透镜(5-4);
6)、封装完成后再对整块支架进行切割,切割成单颗材料。
7.根据权利要求6所述的大功率LED支架的封装方法,其特征在于:所述金线(6)的焊盘在基板(3)上表面,基板(3)焊盘位置再捞出两个焊线位置,基板上不再需要设计焊盘电路和与铜板连接的导孔,金线(6)直接与铜板键合。
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