TW201306326A - 具有小型光學之高功率發光器包裝 - Google Patents
具有小型光學之高功率發光器包裝 Download PDFInfo
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Abstract
本發明提供一種發光器,其包含一平坦支撐表面、一安置於散熱器(spreader)區域上的光源及一安置於該散熱器區域上以圍繞該光源的密封物。除了受到對該平坦支撐表面之黏著力約束的部分之外,該密封物能夠回應溫度變化而膨脹及收縮,以使得由不同組份之間的熱膨脹係數差異導致的力最小化。可將一個或多個反射元件安置在光源附近以提高發光器之發光效率。該等反射元件可包含散熱器區域上的反射層及/或密封物之一部分上的反射層。
Description
本發明係關於發光器,且更明確地說,係關於具有配置成可經受熱應力之組件的發光器包裝。
本申請案主張2003年4月30日申請之美國臨時專利案第60/467,193號之權利。
發光器係一種重要的將電能轉換成光的固態裝置。一種此發光器為發光二極體(LED),其通常包含夾於兩個反向摻雜的區域之間的半導電材料主動區域。當將一偏壓施加於摻雜區域上時,電子洞及電子被注入主動區域中並於此處重新結合而產生光。光可自該主動區域發射並穿過LED表面。
LED通常視其功率額定值(power rating)而分成若干等級。儘管對於不同等級沒有標準範圍,但是低功率LED通常具有0.1瓦特至0.3瓦特(或更低)範圍內的功率額定值,而高功率LED通常具有0.5瓦特至1.0瓦特(或更高)範圍內的額定值。
低功率LED之習知包裝通常包含一反射杯,其中LED安裝於該反射杯底部。將陰極及陽極引線電耦接至該LED以提供功率。陰極引線可延伸穿過該反射杯而陽極引線可經導線結合(wire bonded)。反射杯的主要功能在於將所發射的光重新定向為特定方向,從而控制LED之遠場強度場型(far-field intensity pattern)。該反射杯可包含一高反射表
面光潔度並可受平板衝壓或以諸如鋁(Al)或銀(Ag)的金屬電鍍。
整個結構可包裝於一透明、堅硬的密封物(諸如塑膠或環氧樹脂)中。該密封物具有衆多功能。其一功能在於為LED晶片提供真空密封(hermetic seal)。其另一功能在於:光於密封物/空氣介面處折射,以使得密封物之外形可充當一透鏡以進一步控制LED之強度場型。
然而,此包裝配置之一缺點在於:LED晶片、反射杯及密封物各自通常具有不同的熱膨脹係數(CTE)。因此,在運作之加熱循環期間其以不同比率膨脹及收縮,此將對裝置造成高機械應力。詳言之,通常用於密封物的環氧樹脂及聚矽氧具有與金屬或陶瓷之CTE完全不同的CTE。CTE失配亦可由製造流程(諸如環氧樹脂固化過程)所強加之約束加劇。另外,此等包裝由於缺少良好的熱性能而不能有效地自LED晶片耗散熱。然而,由於該LED以低功率運作,所以其生成之熱的量相對較低,以使得CTE的差異不會導致不能接受的失效率(failure rate)。
然而,高功率LED通常更大、使用更大的包裝組件並產生更高熱量。因此,CTE失配對可靠性具有更大的影響,且若使用低功率LED類型之包裝,則該等包裝組件之CTE差異可導致不能接受的失效率。最普遍的失效之一為密封物的斷裂或破裂。
高功率LED包裝已被介紹為具有一充當剩餘組件之堅硬平臺的散熱器(heat spreader),且係由具有高導熱性
(thermal conductivity)之材料(諸如金屬或陶瓷)製成,此材料有助於將LED晶片中的熱量輻射出去。一反射杯安裝於該平臺上,而LED晶片安置於杯的底部。LED晶片與堅硬平臺上的導線結合接觸。反射杯、LED晶片及導線結合包裝於一提供環境保護的光學透明材料中。為了補償包裝組件之熱膨脹係數(CTE)差異,該光學透明材料可包含如聚矽氧的軟凝膠。隨著不同組件在熱循環過程中膨脹及收縮,軟凝膠易變形並補償不同的CTE。
然而,軟凝膠不如塑膠、環氧樹脂及玻璃堅固,且在沒有塗層或覆蓋層作為真空密封的情況下不能用於某些惡劣環境中,而此會增加LED製造過程的複雜性。軟凝膠傾向於吸收水,此可縮短LED使用受命。亦更難於設計軟凝膠之形狀以控制LED包裝之發射場型。
已介紹利用堅硬環氧樹脂密封物的其他高功率LED包裝,而此種裝置未於密封物內利用一反射杯。相反,於散熱器上包含一第二區域,該第二區域之一區經衝壓、模塑或蝕刻以形成一可塗覆有反射材料的凹陷(depression)。LED晶片隨後置放於凹陷底部並與其接觸。堅硬的環氧樹脂或聚矽氧填充該凹陷,從而覆蓋LED及所有導線結合。此配置會減少(但不能消除)環氧樹脂或聚矽氧密封物的斷裂及破裂。此配置亦可遇到另一問題,即環氧樹脂或聚矽氧密封物於LED熱循環過程中分層並自凹陷表面剝落。
Carey等人的第6,274,924號美國專利揭示另一高功率LED包裝,其包含***一***式模塑引線框中的散熱棒
(heat sinking slug)。散熱棒可包含一反射杯,而LED晶片及熱傳導基座架(submount)配置於該杯底部。金屬引線與散熱棒電絕緣及熱隔離。藉由安裝一熱塑性透鏡至該散熱棒上來添加一光學透鏡。該透鏡可模塑成在LED與該透鏡內表面之間為軟密封物留出空間。本發明主張在高功率條件下可靠地運作,但是其製造複雜、困難並且昂貴。熱塑性透鏡亦不能經受通常用於將LED焊接至一印刷電路板之處理中的高溫。
本發明試圖提供如下之LED包裝,其尤其適用於使用高功率LED且被配置成可減少由包裝組件之CTE差異所導致的LED包裝失效。該等LED包裝亦係簡單、可撓且堅固的。
根據本發明之發光器之一實施例包括一實質上平坦的支撐表面(substantially planar supporting surface)、一安置於該支撐表面上的光源及一安置於該支撐表面上的密封物。密封物圍繞著光源並能回應溫度變化而膨脹及收縮,而僅受到對該平坦支撐表面之黏著力的約束。
根據本發明之發光器之另一實施例包括一散熱器及一光源,該光源熱接觸於該散熱器之一實質上平坦表面。散熱器為該光源提供支撐且圍繞該光源安置一密封物,該密封物能回應溫度變化而膨脹及/或收縮,而僅受到對該平坦表面之黏著力的約束。將一第一反射元件安置成反射來自光源的光,該反射元件與散熱器及密封物中之至少一個整
合。
根據本發明之光學顯示器(optical display)之一實施例包括一具有一實質上平坦表面的散熱器。複數個發光器安置於該平坦表面上,每一發光器包括一熱接觸於散熱器的光源。一密封物安置於散熱器上以圍繞光源,該密封物能回應溫度變化而膨脹及收縮,此僅受到對該平坦表面之黏著力的約束。每一發光器包括至少一個反射元件,其安置於散熱器及/或密封物上以提高顯示器的發光效率。
製造發光器的方法之一實施例包含:提供一實質上平坦的支撐表面並提供一安置於該實質上平坦的支撐表面上的光源。提供一安置於該支撐表面上及該光源上的密封物,以使得該密封物可隨溫度變化而膨脹及收縮,而僅受到對該平坦表面之黏著力的約束。
由以下詳細描述及附圖,熟習此項技術者應瞭解本發明之此等及其他特徴及優點。
圖1說明根據本發明之一實施例之發光器10。發光器10包含散熱器12,且光源14被安置且熱接觸於該散熱器區域12上。散熱器區域12提供一用於固持光源14之支撐結構且至少部分由高導熱性材料製成以促進熱量自光源14流走。較佳散熱器由高導熱性材料製成,諸如銅(Cu)、鋁(Al)、氮化鋁(AlN)、氧化鋁(AlO)、矽(Si)、碳化矽(SiC)或其組合。
光源14包括一LED,但是其亦可包含其他發光器,尤其諸如固態雷射器、雷射二極體或有機發光二極體。由第一
及第二導線結合16、18為光源14提供功率同時於光源14上施加一偏壓,且在所展示的實施例中,該等導線結合將一偏壓施加於LED光源之反向摻雜層上從而導致光源發光。在根據本發明之其他實施例中,可使用僅一個導線結合,而光源14亦經由散熱器區域12接觸。在另外的實施例中,光源14僅經由散熱器區域12接觸。
在設計成作為單一光源或在顯示器中發光的系統中,可包含根據本發明之發光器。根據本發明之發光器亦可包含單一光源或發射相同或不同波長之光的光源之陣列。為簡單及易於論述起見,發光器10及下列圖中的發光器均展示為具有一個光源。然而,應瞭解,根據本發明之發光器可以許多不同方式配置。
透明密封物20安置成圍繞光源14,且其用於封裝及真空密封光源14及導線結合16、18。密封物20通常安置於散熱器區域12之頂表面上。密封物20可由許多不同的堅硬且光學透明的材料(諸如環氧樹脂、聚矽氧、玻璃或塑膠)製成,且其可係預模塑透鏡或直接形成於光源14上。可使用諸如噴射模塑之技術來製造預模塑密封物或透鏡,然後將其結合至散熱器12。
散熱器區域12亦可包含在與光源14相同表面上的反射層22,該反射層22至少實質上覆蓋所有未受光源14覆蓋的表面。在所展示的實施例中,反射層22覆蓋整個表面,以使得該反射層之部分夾置於光源14與散熱器區域12之間。光源14全向發光,以光路徑1、2、3、4及5代表來自光源的
少數可能存在的光路徑。光路徑1、2及3自光源14延伸並穿過密封物20。光亦可沿自光源14延伸至反射層22並穿過密封物20的光路徑4及5流動。反射層22可反射來自光源14的光以提高發光器10之光學效率。反射層22可包括許多以吾人感興趣的波長反射的反射材料,諸如鋁(Al)、銀(Ag)或其組合。
發光器10具有許多優點,其中一個在於其較不複雜,且因而其成本低於習知裝置。降低複雜性的一種方式係藉由將反射層22與散熱器區域12組合以消除對與密封物20及散熱器12分離之反射器結構的需要,此導致一簡化的製造過程。
由於反射器功能與發光器10中包含的其他組件相整合,所以熱應力亦降低了。因此,以不同的比率相對於彼此膨脹及收縮的組件較少。因此,光源14可更可靠地以較高功率運作,並且因此較高溫度使得發光器10失效的風險變小。另一失效原因可為與所使用之不同材料之間的CTE失配相關聯的密封物20斷裂或破裂。然而,發光器10之配置可降低此事件發生的可能性。密封物20與散熱器區域12之間的表面係平坦的,以使得密封物20僅在一個表面受到約束。此對導線結合16及/或18造成的應力較小,而此種應力可導致該等導線結合斷開或鬆動並減少發光器10的使用壽命。
密封物20可包含堅硬且熔點高的材料(諸如玻璃)以提供受真空密封的包裝,因為與此等材料相關聯的固化處理及
溫度循環已不再是問題。發光器10亦在材料的選擇上提供更大靈主動,該等材料由於可匹配以獲得黏著力所以可用於密封物20及散熱器區域12。因此,密封物20在發光器熱循環過程中分層並自散熱器區域12剝落的可能性降低了。
另一優點在於:發光器10具有較小的佔用面積,以使得一包裝陣列可相互靠攏地安置在一起。此特徴在光顯示器中是有用的,其中通常需要將該等包裝相互靠攏地安置成一陣列從而提高解析度及顯示品質。
圖2至8說明根據本發明之額外實施例之發光器。應注意的是,本揭示案之剩餘部分說明的發光器包含與圖1中說明的組件類似的組件且使用類似的編號,應瞭解以上與發光器10相結合的論述同樣適用於圖2至8中論述的發光器。
圖2說明根據本發明之另一實施例之發光器30。發光器30包含散熱器區域12並可包含反射層22。將光源14安置於反射層22上且安置一密封物40以封裝並密封光源14。密封物40於其底部成形以提供一成角度的表面42,該表面42藉由全內反射(total internal reflection)旁向反射自光源14發射的定向光。
光路徑6、7展示來自光源14的兩個可能的光路徑,此二者皆入射至表面42。表面42可藉由全內反射(TIR)將光路徑6及7分別沿光路徑8及9朝密封物40之頂部反射。此減少了自密封物40側面發射的光並增加了自其頂部發射的光。結果,發光器30可產生更多具有更佳發光效率的聚焦光。應注意的是,自光源14發射的光亦可由反射層22反射並穿
過密封物40(直接或間接地遠離表面42)以進一步提高發光效率。發光器30包含上述發光器10之所有特徴,且具有附加的優點,即更聚焦的光、更佳的光學效率。
圖3說明根據本發明之另一實施例之發光器50,其類似於圖2中的發光器30。發光器50包含散熱器區域12,且散熱器區域12上具有一反射層22。光源14安置於反射層22上且安置一密封物60以圍繞光源14並提供真空密封。密封物60亦包括一成角度的表面42,且於成角度的表面42上施加一反射層64。鄰近第二反射層64及散熱器區域22安置支撐區域49。
第二反射層64反射大多數或所有入射於成角度的表面42上的光,包含未經受TIR並且否則將穿過成角度的表面42的光。此使得來自光源14的光進一步朝向密封物60頂部聚焦並藉由增加發光量來提高光學效率。第二反射層64可由具有不同反射率之不同材料製成,諸如銀(Ag)、鋁(Al)、氧化鈦(TiO)、白樹脂或其組合。可使用許多不同方法(諸如塗布(painting)、電鍍或沈積)來施加第二反射層64,且亦可於密封物60安置於光源14上之前或之後施加第二反射層64。對光不透明的層64之一額外優點在於:其允許包含可提供機械支撐及環境保護而不降級發光器50之光效率的可選用障壁區域49。應選擇用於區域49之材料,使得其在熱循環中不會約束密封物60。
圖4說明根據本發明之另一實施例之發光器70,其類似於圖1之發光器10。發光器70包含散熱器區域12、光源14
及反射層22。發光器70亦包括密封物80,其係於底部具有一空腔81的預成型透鏡。與上述密封物類似,透鏡80可由環氧樹脂、聚矽氧、玻璃或塑膠製成並可使用諸如噴射模塑的方法來製造。密封物80安裝至散熱器12之頂表面上位於光源14上方,而光源14及導線結合16、18配置於空腔81中。結合材料(bonding material)82填充空腔81中的空間並將透鏡80固定至散熱器12。可使用不同類型的密封物,只要其具有配合散熱器12的尺寸同時為光源14、導線結合16與18及結合材料82提供一空腔。
結合材料82可包含不同的材料,諸如環氧樹脂、膠(glue)或聚矽氧凝膠。結合材料82之折射率較佳與密封物80相同以最小化兩種材料間的反射並可被選擇以以得到所要的發光效率。可在將密封物80安置於光源14上方之前,將材料82安置於空腔81中,或者可將密封物80安置於適當位置且經由密封物80或經由散熱器12中的一個孔(未圖示)注入材料82。該孔隨後可用由樹脂或類似材料製成的插塞加以密封。
此配置具有發光器10的優點,且可安裝於光源14及散熱器12上方的密封物在類型及形狀上具有更大靈活性。可使用不同類型的透鏡,只要其具有配合散熱器12的尺寸同時為光源14、導線結合16與18及結合材料82提供一空腔。若聚矽氧凝膠用於材料82,則其可補償不同材料之CTE差異。
圖5說明根據本發明之另一實施例之發光器90。發光器
90包含散熱器區域12、光源14及反射層22。發光器90亦包含一"子彈形"密封物100,其可為預成型透鏡或安置於於光源14上方並成形的環氧樹脂。密封物100之形狀選定成:當光於表面121處穿過密封物100時,可將沿光路徑1、3、4及5的光折射朝向發光器90之頂部。光折射有助於聚焦來自光源14的光。正好以90°角(即,沿光路徑2)撞擊密封物100之表面的光將不會受到折射。
圖6說明根據本發明之另一實施例之發光器110,其同樣包含散熱器區域12、光源14及反射層22。發光器110亦包含一"凹"形密封物120,其更為有效地在內部朝向發光器110之頂部反射光,並可更為有效地將穿過密封物120的光折射朝向發光器110之頂部。密封物120包含一成角度的表面122,其以提高密封物120的聚焦能力及發光器110的發光效率的方式成形。可選擇表面122之角度及形狀,以在光聚焦中獲得所要的增益並減少任何由TIR導致的損耗。
圖7說明根據本發明之另一實施例之發光器130,其包括散熱器區域12、光源14、導線結合16與18及反射層22。發光器130亦包括一蘑菇形密封物140,其具有圓頂142及成角度的莖幹(stem)146。莖幹146可由一第二反射層64覆蓋,從而將來自光源14並沿光路徑6及7撞擊莖幹146的光分別沿光路徑8及9反射朝向圓頂142。由於損耗於TIR的光較少,所以此配置亦可提供聚焦光且更為有效。
圖8說明根據本發明之另一實施例之發光器150,其包含散熱器區域12、光源14及反射層22。發光器150亦包含一
球形密封物160,該球形密封物160亦可於其下半球上包含反射區域64以將沿光路徑6及7的光分別沿光路徑8及9反射朝向密封物160之頂部。由於密封物160及反射區域64,所以此配置同樣提供聚焦光並具有較少的TIR損耗。同樣應瞭解,該密封物可為根據本發明之許多其他具體形狀。
圖9說明一種用於製造根據本發明之發光器的方法之一實施例的流程圖200。該方法包含:步驟201,其提供一具有至少一個平坦表面的散熱器區域,該表面上具有一反射層;及步驟202,其提供安置於至少一個平坦表面上的一光源。步驟203包含提供一安置於散熱器區域之平坦表面上且位於光源上之密封物。由於是平坦的,所以該密封物隨溫度變化的膨脹及收縮僅於該平坦表面受到約束。
可安置密封物以使得其真空密封光源,且該真空密封隨溫度變化保持完好。可安置密封物以使得其與光源之相對位置隨溫度變化保持不變。當溫度變化時,若沒有東西(即一3D反射器結構)可供該密封物推壓,則該相對位置將保持不變。
一可選用之步驟204包括:使密封物鄰近散熱器區域的表面成角度,以藉由將TIR光及折射光引導朝向發光器頂部來提高發光器之效率。
一可選用之步驟205包括提供一安置於成角度的表面上之第二反射元件以提高發光器之發光效率。該第二反射元件可藉由使用塗布、電鍍及沈積中之一種方法來形成。一可選用之步驟207可包括鄰近支撐表面及密封物之一底部
安置一障壁區。該障壁區可形成對光源更好的密封。應注意,可以不同次序執行流程圖200中說明的步驟,且不同的步驟可用於根據本發明之方法中。
儘管已參考本發明之某些較佳組態對其進行相當詳細的描述,但是其他版本也是可能的。上述透鏡可具有許多不同的形狀並可由許多不同材料製成。每一上述光源可進一步包括一基座架以提供靜電放電(ESD)保護。在上述每一實施例中,可蝕刻散熱器以提供一孔來容納光源,以使得光源不會延伸超出散熱器之頂表面。隨後密封物可具有一平坦底部以安裝至散熱器,並位於光源上方。
因此,本文描述的本發明之實施例是例示性的,且不難想象許多修改、變化及重新配置來達到實質上相等的結果,所有此等修改、變化及重新配置均應包含於附加申請專利範圍中所界定的本發明之精神及範疇之內。
1-9‧‧‧光路徑
10,30,50,70,90,110,150‧‧‧發光器
12‧‧‧散熱器/散熱器區域
14‧‧‧光源
16,18‧‧‧導線結合
20,40,60,80,100,120,140,160‧‧‧密封物
22‧‧‧反射層
42,122‧‧‧成角度的表面
49‧‧‧障壁區域/支撐區域
64‧‧‧第二反射層/反射區域
81‧‧‧空腔
82‧‧‧結合材料
121‧‧‧表面
142‧‧‧圓頂
146‧‧‧莖幹
圖1為根據本發明之一發光器的簡化剖視圖;圖2為根據本發明之另一實施例之發光器的簡化剖視圖;圖3為根據本發明之另一實施例之發光器的簡化剖視圖,其具有一成形透鏡(shaped lens);圖4為根據本發明之另一實施例之發光器的簡化剖視圖,其在成形透鏡上具有一反射表面;圖5為根據本發明之另一實施例之發光器的簡化剖視圖,其具有一子彈形透鏡;
圖6為根據本發明之另一實施例之發光器的簡化剖視
圖,其具有一凹形透鏡;
圖7為根據本發明之另一實施例之發光器的簡化剖視
圖,其具有一蘑菇形透鏡;
圖8為根據本發明之另一實施例之發光器的簡化剖視
圖,其具有一圓球形透鏡;及
圖9為一簡化流程圖,其說明一種製造根據本發明之發
光器的方法。
1,2,3,6,7,8,9‧‧‧光路徑
12‧‧‧散熱器/散熱器區域
14‧‧‧光源
16‧‧‧導線結合
18‧‧‧導線結合
22‧‧‧反射層
30‧‧‧發光器
40‧‧‧密封物
42‧‧‧成角度的表面
Claims (2)
- 一種發光器,包括:一散熱器;一固態光源,其熱接觸於該散熱器的一實質上平坦的表面,而該散熱器為該光源提供支撐且吸取來自該光源的熱量;安置成圍繞該光源的一密封物,該密封物受到對該實質上平坦的表面及該光源之表面之黏著力而僅侷限在圍繞該光源的區域中,以使得該密封物能夠回應一溫度變化而膨脹及收縮;及安置成反射來自該光源之光的一第一反射元件,該反射元件係與該密封物整合且覆蓋該實質上平坦的表面,其中該光源係與該反射元件直接接觸。
- 一種發光器,包括:一實質上平坦的支撐表面;安置於該支撐表面上的一固態光源,該支撐表面提供圍繞該光源之一實質上平坦的表面;安置於圍繞該光源的該支撐表面上之一密封物,其中該密封物包括一向內成角度的較低部分,該密封物能夠回應一溫度變化而膨脹及收縮;與該支撐表面整合之一第一反射元件,其中該第一反射元件實質上覆蓋該平坦的支撐表面之全部;及與該向內成角度的較低部分整合之一第二反射元件。
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TWI583086B (zh) * | 2016-07-18 | 2017-05-11 | 華星光通科技股份有限公司 | 光發射器散熱結構及包含其的光發射器 |
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WO2004100279A2 (en) | 2004-11-18 |
CN100502062C (zh) | 2009-06-17 |
TW200501458A (en) | 2005-01-01 |
EP1620903B1 (en) | 2017-08-16 |
EP1620903A2 (en) | 2006-02-01 |
TWI484665B (zh) | 2015-05-11 |
JP2012064962A (ja) | 2012-03-29 |
CN101556985B (zh) | 2017-06-09 |
CA2523544A1 (en) | 2004-11-18 |
CN101556985A (zh) | 2009-10-14 |
KR20060015543A (ko) | 2006-02-17 |
WO2004100279A3 (en) | 2005-12-01 |
EP2264798B1 (en) | 2020-10-14 |
US9666772B2 (en) | 2017-05-30 |
CN1809934A (zh) | 2006-07-26 |
JP2006525682A (ja) | 2006-11-09 |
US20040227149A1 (en) | 2004-11-18 |
EP2270887A1 (en) | 2011-01-05 |
EP2270887B1 (en) | 2020-01-22 |
EP2264798A1 (en) | 2010-12-22 |
KR101148332B1 (ko) | 2012-05-25 |
TWI487149B (zh) | 2015-06-01 |
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