CN203644815U - 一种led封装结构 - Google Patents

一种led封装结构 Download PDF

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CN203644815U
CN203644815U CN201320835533.2U CN201320835533U CN203644815U CN 203644815 U CN203644815 U CN 203644815U CN 201320835533 U CN201320835533 U CN 201320835533U CN 203644815 U CN203644815 U CN 203644815U
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metal
metal level
led chip
led
insulating barrier
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张黎
赖志明
陈栋
陈锦辉
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Jiangyin Changdian Advanced Packaging Co Ltd
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Abstract

本实用新型涉及一种LED封装结构,属于半导体封装技术领域。其包括硅基本体(110)和LED芯片(200),硅基本体(110)的正面设置不连续的金属反光层(410、420),硅通孔(111)内设置不连续的金属层Ⅰ(810)、金属层Ⅱ(820),LED芯片电极(210)、金属块/柱(321)、金属反光层(410)、金属层Ⅰ(810)实现电气连接,LED芯片电极(220)、金属块/柱(322)、金属反光层(420)、金属层Ⅱ(820)实现电气连接;金属层Ⅲ(830)位于硅基本体(110)的背面的绝缘层Ⅱ(520)的表面且位于金属层Ⅰ(810)、金属层Ⅱ(820)之间。本实用新型封装结构依靠圆片级封装技术获得全角度出光的LED封装结构,能够降低热阻、提高可靠性、使出光角度不受限、且能降低设计和制造成本。

Description

一种LED封装结构
技术领域
本实用新型涉及一种LED封装结构,属于半导体封装技术领域。
背景技术
一般的,发光二极管(Light-Emitting Diode,简称LED,下同)的封装有多种封装形式。早期的,采用引线框为基板进行封装,将LED芯片通过导热膏(或导电胶)贴装至引线框上,通过引线键合的方式实现电流加载从而使其发光;随着技术进步,一些新的、高性能的基板材料出现,在大功率LED的应用中起到了引领作用,如陶瓷基板、AlN基板等。但作为商用化的产品而言,现有的LED封装技术还存在如下问题:①热阻高。由于LED芯片发光是通过电子复合过程所激发,因而在产生光的同时产生大量的热。众所周知,热的产生反过来影响着电转化为光的效率,降低了LED本身的发光性能。②LED芯片通过贴装工艺与金属反光层连接,由于LED芯片的自身重量越来越轻,其电极与焊锡的润湿力常存在不平衡,在回流时就可能发生的漂移、立碑或旋转等不良连接方式,影响LED封装的可靠性;                                                
Figure 79626DEST_PATH_IMAGE001
出光角度受限。现有的LED灯珠,其LED芯片坐落于下凹的反光杯罩内, 出光角度最大不超过150度,受限的出光角度导致LED灯珠使用范围受限,在某些需要超大角度甚至全角度的场合,必须辅以二次光学设计结构;由于出光角度大小不一致,二次光学设计结构需要考虑具体的出光角度有针对性地进行设计,不仅增加了二次光学设计难度,而且增加了LED结构的复杂性,同时,设计和制造成本也相应增加。
发明内容
本实用新型的目的在于克服上述不足,提供一种能够降低热阻、提高可靠性、使出光角度不受限、并且能降低设计和制造成本的LED封装结构。
本实用新型的目的是这样实现的:
本实用新型一种LED封装结构,包括背面开设若干个硅通孔的硅基本体和带有LED芯片电极的LED芯片,所述硅基本体的正面设置绝缘层Ⅰ,所述硅通孔的内壁设置绝缘层Ⅱ,
所述绝缘层Ⅰ的表面设置不连续的金属反光层,所述硅通孔的顶部设置贯穿绝缘层Ⅰ和绝缘层Ⅱ的绝缘层开口,所述绝缘层Ⅱ的表面设置不连续的金属层Ⅰ、金属层Ⅱ,所述金属层Ⅰ、金属层Ⅱ一端分别通过绝缘层开口与金属反光层连接,另一端沿硅通孔向外延展至硅基本体的背面并向相反方向延展,所述LED芯片通过金属块/柱倒装至金属反光层,所述LED芯片电极、金属块/柱、金属反光层、金属层Ⅰ实现电气连接,所述LED芯片电极、金属块/柱、金属反光层、金属层Ⅱ实现电气连接;
本实用新型一种LED封装结构,还包括金属层Ⅲ,所述金属层Ⅲ位于硅基本体的背面的绝缘层Ⅱ的表面且位于金属层Ⅰ、金属层Ⅱ之间,所述金属层Ⅲ与金属层Ⅰ、金属层Ⅱ均不连接。
可选地,所述金属块/柱材质为铜,其高度为5-15um。
可选地,所述金属块/柱和/或金属块/柱的个数至少两个以上。
可选地,所述金属块/柱与LED芯片电极之间分别设置金属连接层。
可选地,所述金属连接层材质为锡或锡合金,高度在8-20um。
可选地,所述金属层Ⅲ通过若干个金属柱与金属反光层连接,所述金属柱贯穿绝缘层Ⅱ,部分或全部进入硅基本体。
可选地,还包括透光层,所述透光层通过粘合剂设置于LED芯片的上方。
可选地,所述粘合剂填充透光层与硅基本体之间的空间。
可选地,所述LED芯片与金属反光层的间隙填充填充剂。
可选地,所述LED芯片的***涂覆荧光粉胶层。
本实用新型结构旨在通过圆片级封装方式提升LED灯珠的出光性能、散热性能,降低设计和封装成本。LED芯片落座于平展的反射层上,四周无遮挡,LED光线能够全角度出射;针对实际使用需要的LED出光角度,后续的二次光学设计结构均可在LED光线全角度出射的基础上加以优化;LED芯片通过铜/锡栅结构与金属反光层实现倒装连接,提升了倒装工艺的稳定性和可操作性;特意设置于硅基本体背面的大比例的金属反光层Ⅱ快速地传导LED芯片工作时产生的热,有效地降低LED封装结构的热阻,有助于提升LED性能。
本实用新型有益效果是: 
1、LED芯片落座于平展的反射层上,四周无遮挡,LED光线能够全角度出射;
2、针对实际使用需要的LED出光角度,后续的二次光学设计结构均可在LED光线全角度出射的基础上加以优化;
3、LED芯片通过金属栅结构与金属反光层实现倒装连接,提升了倒装工艺的稳定性和可操作性;
4、特意设置于硅基本体背面的大比例的金属反光层快速地传导LED芯片工作时产生的热,有效地降低LED封装结构的热阻,有助于提升LED性能。
附图说明
图1为本实用新型一种LED封装结构的实施例的示意图;
图2为图1的实施例的LED芯片与金属反光层Ⅱ的位置关系示意图;
图3为图1的实施例的LED芯片与金属反光层Ⅱ的位置关系示意图;
图4为图1的变形实施例一的示意图;
图5和图6为图1的变形实施例二的示意图;
图7为图1的变形实施例三的示意图;
图中:
硅基本体110
硅通孔111
LED芯片200
LED芯片电极210、220
金属连接层311、312
金属块/柱321、322
金属反光层410、420
绝缘层Ⅰ510 
绝缘层Ⅱ520
绝缘层开口501、502
填充剂610
粘合剂620
荧光粉胶层630
透光层700
金属层Ⅰ810
金属层Ⅱ820
金属层Ⅲ830
金属柱831。
具体实施方式
参见图1,本实用新型一种LED封装结构,在硅基本体110的背面开设若干个硅通孔111,LED芯片200带有LED芯片电极210、220,硅基本体110的正面设置绝缘层Ⅰ510,硅通孔111的内壁设置绝缘层Ⅱ520。
绝缘层Ⅰ510的表面设置银、铝等材质的金属反光层410、420,金属反光层410和金属反光层420不连续,其之间的间隔小于LED芯片电极210与LED芯片电极220之间的间隔。利用银、铝等材质的高反射率性质,金属反光层410、420可以作为LED芯片200的反射层。由于LED芯片200坐落于平展的反射层上,可以实现了LED光线的全角度出射。LED芯片200与金属反光层410与金属反光层420之间可以无任何物质,也可以设置硅胶等填充剂610,提高其可靠性。
硅通孔111的顶部设置贯穿绝缘层Ⅰ510和绝缘层Ⅱ520的绝缘层开口501、502,所述绝缘层Ⅱ520的表面设置不连续的金属层Ⅰ810、金属层Ⅱ820,所述金属层Ⅰ810、金属层Ⅱ820一端分别通过绝缘层开口501、502与金属反光层410、420连接,另一端沿硅通孔111向外延展至硅基本体110的背面并向相反方向延展,金属层Ⅰ810、金属层Ⅱ820之间存在间隙。金属层Ⅰ810、金属层Ⅱ820在硅基本体110的背面可以延展呈矩形,如图2所示;也可以延展呈带有凸起801的矩形,凸起801的个数不少于硅通孔111的个数,一个凸起801至少对应一个硅通孔111,如图3所示。
LED芯片200通过金属块/柱321、322倒装至金属反光层410、420, LED芯片电极210、金属块/柱321、金属反光层410、金属层Ⅰ810实现电气连接,LED芯片电极220、金属块/柱322、金属反光层420、金属层Ⅱ820实现电气连接。在硅基本体110的背面绝缘层Ⅱ520的表面且位于金属层Ⅰ810、金属层Ⅱ820之间设置金属层Ⅲ830,所述金属层Ⅲ830与金属层Ⅰ810、金属层Ⅱ820均不连接。金属层Ⅲ830能够有效地将LED芯片200工作时传导至硅基本体110上的热量散出。
在LED芯片200的上方通过硅胶等粘合剂620固定玻璃、有机树脂等材质的透光层700,粘合剂620填充透光层700与硅基本体110之间的空间。其中,耐候性较好的玻璃材质的透光层700有助于延长LED灯珠在户外环境的寿命。
本实用新型一种LED封装结构,根据实际需要,也可以作如下结构变形。
变形实施例一,如图7所示
金属层Ⅰ810和金属层Ⅱ820之间的间隙可以大于LED芯片电极210、220之间的间距,以便最大限度地扩大金属层Ⅲ830的面积。在金属反光层410下方设置若干个金属柱831,金属柱831贯穿绝缘层Ⅱ520,与硅基本体110直接接触;也可以部分或全部进入硅基本体110,以增大接触面积。通过金属柱831可以将LED芯片200工作时产生的热快速地传导至硅基本体110背面的金属层Ⅲ830,实现LED芯片200温度节点到封装引脚的低热阻,有助于提升LED性能。
变形实施例二,如图5、图6和图7所示
金属块/柱321的个数至少两个以上,平行排列,形成金属栅结构,其材质为铜,其上设置锡或锡合金的金属连接层311。另一边的金属块/柱322的个数也可以至少两个以上,平行排列,也可以形成铜质金属栅结构,其上设置锡或锡合金的金属连接层312。LED芯片200通过金属栅与金属反光层410、420实现倒装连接,提升了倒装工艺的稳定性和可操作性,克服了LED芯片200在回流工艺中可能发生的漂移、立碑或旋转等不良连接方式,保证了圆片级工艺过程中LED芯片200连接的一致性与均匀性。其中金属块/柱321和金属块/柱322的厚度范围为5-15um,锡或锡合金的厚度范围为8-20um,能在实现可靠连接的同时,最大限度的降低热阻。金属栅也可以应用于传统的设置有LED反射杯的LED灯珠,或其他微小金属部件与金属面/块的连接。
变形实施例三,如图4、图5和图7所示
单色的LED芯片200一般只能激发R(红)、G(绿)、B(蓝)三色光。而在人们的实际生活中,更需要地是使用白光,为了得到白光LED灯珠,可以选择蓝色LED芯片200激发分布于其周围的荧光粉,该荧光粉制成的荧光粉胶层630可以涂覆于蓝色LED芯片200的发光面,荧光粉也可以与硅胶等粘合剂620混合,填充于透光层700与硅基本体110之间的空间。
本实用新型一种LED封装结构,变形结构的实施例一、实施例二、实施例三可以根据实际需要自由组合,以提高LED封装结构的各项性能。
本实用新型的LED封装结构不限于上述实施例,任何本领域技术人员在不脱离本实用新型的精神和范围内,依据本实用新型的技术实质对以上实施例所作的任何修改、等同变化及修饰,均落入本实用新型权利要求所界定的保护范围内。

Claims (10)

1.一种LED封装结构,包括背面开设若干个硅通孔(111)的硅基本体(110)和带有LED芯片电极(210、220)的LED芯片(200),所述硅基本体(110)的正面设置绝缘层Ⅰ(510),所述硅通孔(111)的内壁设置绝缘层Ⅱ(520 ),
其特征在于:所述绝缘层Ⅰ(510)的表面设置不连续的金属反光层(410、420),所述硅通孔(111)的顶部设置贯穿绝缘层Ⅰ(510)和绝缘层Ⅱ(520 )的绝缘层开口(501、502),所述绝缘层Ⅱ(520 )的表面设置不连续的金属层Ⅰ(810)、金属层Ⅱ(820),所述金属层Ⅰ(810)、金属层Ⅱ(820)一端分别通过绝缘层开口(501、502)与金属反光层(410、420)连接,另一端沿硅通孔(111)向外延展至硅基本体(110)的背面并向相反方向延展,所述LED芯片(200)通过金属块/柱(321、322)倒装至金属反光层(410、420),所述LED芯片电极(210)、金属块/柱(321)、金属反光层(410)、金属层Ⅰ(810)实现电气连接,所述LED芯片电极(220)、金属块/柱(322)、金属反光层(420)、金属层Ⅱ(820)实现电气连接;
还包括金属层Ⅲ(830),所述金属层Ⅲ(830)位于硅基本体(110)的背面的绝缘层Ⅱ(520 )的表面且位于金属层Ⅰ(810)、金属层Ⅱ(820)之间,所述金属层Ⅲ(830)与金属层Ⅰ(810)、金属层Ⅱ(820)均不连接。
2.根据权利要求1所述的一种LED封装结构,其特征在于:所述金属块/柱(321、322)材质为铜,其高度为5-15um。
3.根据权利要求2所述的一种LED封装结构,其特征在于:所述金属块/柱(321)和/或金属块/柱(322)的个数至少两个以上。
4.根据权利要求3所述的一种LED封装结构,其特征在于:所述金属块/柱(321、322)与LED芯片电极(210、220)之间分别设置金属连接层(311、312)。
5.根据权利要求4所述的一种LED封装结构,其特征在于:所述金属连接层(311、312)材质为锡或锡合金,高度在8-20um。
6.根据权利要求1所述的一种LED封装结构,其特征在于:所述金属层Ⅲ(830)通过若干个金属柱(831)与金属反光层(410)连接,所述金属柱(831)贯穿绝缘层Ⅱ(520 ),部分或全部进入硅基本体(110)。
7.根据权利要求1所述的一种LED封装结构,其特征在于:还包括透光层(700),所述透光层(700)通过粘合剂(620)设置于LED芯片(200)的上方。
8.根据权利要求7所述的一种LED封装结构,其特征在于:所述粘合剂(620)填充透光层(700)与硅基本体(110)之间的空间。
9.根据权利要求1所述的一种LED封装结构,其特征在于:所述LED芯片(200)与金属反光层(410、420)的间隙填充填充剂(610)。
10.根据权利要求1至9中任一项所述的LED封装结构,其特征在于:所述LED芯片(200)的***涂覆荧光粉胶层(630)。
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