TW201501364A - 發光組件及製作方法 - Google Patents

發光組件及製作方法 Download PDF

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Publication number
TW201501364A
TW201501364A TW103111887A TW103111887A TW201501364A TW 201501364 A TW201501364 A TW 201501364A TW 103111887 A TW103111887 A TW 103111887A TW 103111887 A TW103111887 A TW 103111887A TW 201501364 A TW201501364 A TW 201501364A
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TW
Taiwan
Prior art keywords
led
transparent
light
adhesive layer
assembly
Prior art date
Application number
TW103111887A
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English (en)
Other versions
TWI651871B (zh
Inventor
hong-zhi Liu
Yi-Ting Kuo
Tzu-Chi Cheng
Original Assignee
Huga Optotech Inc
Interlight Optotech Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Huga Optotech Inc, Interlight Optotech Corp filed Critical Huga Optotech Inc
Priority to TW103111887A priority Critical patent/TWI651871B/zh
Priority to US14/309,828 priority patent/US20150003038A1/en
Priority to JP2014129754A priority patent/JP2015012292A/ja
Priority to CN202010156075.4A priority patent/CN111457260B/zh
Priority to CN201410298192.9A priority patent/CN104253200B/zh
Publication of TW201501364A publication Critical patent/TW201501364A/zh
Application granted granted Critical
Publication of TWI651871B publication Critical patent/TWI651871B/zh
Priority to US17/091,938 priority patent/US11543081B2/en
Priority to US18/091,922 priority patent/US20230142465A1/en

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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21KNON-ELECTRIC LIGHT SOURCES USING LUMINESCENCE; LIGHT SOURCES USING ELECTROCHEMILUMINESCENCE; LIGHT SOURCES USING CHARGES OF COMBUSTIBLE MATERIAL; LIGHT SOURCES USING SEMICONDUCTOR DEVICES AS LIGHT-GENERATING ELEMENTS; LIGHT SOURCES NOT OTHERWISE PROVIDED FOR
    • F21K9/00Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
    • HELECTRICITY
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    • H01L24/28Structure, shape, material or disposition of the layer connectors prior to the connecting process
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21KNON-ELECTRIC LIGHT SOURCES USING LUMINESCENCE; LIGHT SOURCES USING ELECTROCHEMILUMINESCENCE; LIGHT SOURCES USING CHARGES OF COMBUSTIBLE MATERIAL; LIGHT SOURCES USING SEMICONDUCTOR DEVICES AS LIGHT-GENERATING ELEMENTS; LIGHT SOURCES NOT OTHERWISE PROVIDED FOR
    • F21K9/00Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
    • F21K9/20Light sources comprising attachment means
    • F21K9/23Retrofit light sources for lighting devices with a single fitting for each light source, e.g. for substitution of incandescent lamps with bayonet or threaded fittings
    • F21K9/232Retrofit light sources for lighting devices with a single fitting for each light source, e.g. for substitution of incandescent lamps with bayonet or threaded fittings specially adapted for generating an essentially omnidirectional light distribution, e.g. with a glass bulb
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21KNON-ELECTRIC LIGHT SOURCES USING LUMINESCENCE; LIGHT SOURCES USING ELECTROCHEMILUMINESCENCE; LIGHT SOURCES USING CHARGES OF COMBUSTIBLE MATERIAL; LIGHT SOURCES USING SEMICONDUCTOR DEVICES AS LIGHT-GENERATING ELEMENTS; LIGHT SOURCES NOT OTHERWISE PROVIDED FOR
    • F21K9/00Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
    • F21K9/90Methods of manufacture
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    • F21LIGHTING
    • F21VFUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V19/00Fastening of light sources or lamp holders
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    • F21Y2103/00Elongate light sources, e.g. fluorescent tubes
    • F21Y2103/10Elongate light sources, e.g. fluorescent tubes comprising a linear array of point-like light-generating elements
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    • F21Y2115/10Light-emitting diodes [LED]
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Abstract

本發明之一實施例揭露有一發光二極體組件,其包含有一透明基板、數個發光二極體晶片、一線路、一透明封裝體、以及二電極板。該透明基板具有面對相反方向的一第一表面以及一第二表面。該等發光二極體晶片,固定於該第一表面上。該線路電性連接該等發光二極體晶片。該透明封裝體設於該第一表面上,大致包裹該等發光二極體晶片與該線路。該等電極板設置於該第一表面或該第二表面,透過該線路電連接至該等發光二極體晶片,作為該發光二極體組件之二電源輸入端。

Description

發光組件及製作方法
發明之實施例係關於一發光二極體(light emitting diode,LED)組件與製作方法,尤其關於可提供全周光光場之LED組件以及相關之製作方法。
目前生活上已經可以看到各式各樣LED商品的應用,例如交通號誌機車尾燈、汽車頭燈、路燈、電腦指示燈、手電筒、LED背光源等。這些商品除前端之晶片製程外,幾乎都必須經過後端之封裝程序。
LED封裝的主要功能在於提供LED晶片電、光、熱上的必要支援。LED晶片這樣的半導體產品,如果長期暴露在大氣中,會受到水汽或是環境中的化學物質影響而老化,造成特性上的衰退。LED封裝中,常用環氧樹酯來包覆LED晶片以有效隔絕大氣。此外,為了達到更亮更省電的目標,LED封裝還需要有良好的散熱性以及光萃取效率。如果LED晶片發光時所產生的熱沒有及時散出,累積在LED晶片中的熱對元件的特性、壽命以及可靠度都會產生不良的影響。光學設計也是LED封裝製程中重要的一環,如何更有效的把光導出,發光角度以及方向都是設計上的重點。
白光LED的封裝技術,除了要考慮熱的問題之外,還需要考 量色溫(color temperature)、演色係數(color rendering index)、螢光粉等問題。而且,若白光LED是採用藍光LED晶片搭配黃綠螢光粉時,因藍光的波長越短,對人眼的傷害越大,因此需要將藍光有效阻絕於封裝結構之中,避免藍光外漏。
為了LED商品能在市場上具有競爭力,如何讓LED封裝的製程穩固、低成本、高良率,也是LED封裝所追求的目標。
本發明之實施例揭露一發光二極體組件,其包含一透明基板、數個發光二極體晶片、一線路、一透明封裝體、二電極板。該透明基板具有面對相反方向的一第一表面以及一第二表面。該等發光二極體晶片,固定於該第一表面上。該線路電性連接該等發光二極體晶片。該透明封裝體(capsule),設於該第一表面上,大致包裹該等發光二極體晶片與該線路。該等電極板貼附於該第一表面或該第二表面,透過該線路電連接至該等發光二極體晶片,作為該發光二極體封裝結構之二電源輸入端。
100、100a、100b、100c‧‧‧LED組件
102‧‧‧上表面
104‧‧‧下表面
106‧‧‧透明基板
107、107A、107B‧‧‧導通孔
108、108a、108b‧‧‧藍光LED晶片
110‧‧‧焊線
112‧‧‧透明膠體
114、116‧‧‧終端
118‧‧‧導電電極板
119‧‧‧導電電極板
120‧‧‧導電電極板
122‧‧‧導電電極板
130‧‧‧垂直導通元件
131‧‧‧螢光層
132、133‧‧‧透明黏著層
148、150、151、152、154、154a、155、155a、156、157、158‧‧‧步驟
160‧‧‧次基板
180‧‧‧燈罩
182‧‧‧散熱機構
183‧‧‧電連接機構
190‧‧‧焊錫
192‧‧‧電路板
194‧‧‧金屬夾片
196、198‧‧‧導電電極板
200、200a、200b、200c‧‧‧LED組件
300、300a、300b‧‧‧LED組件
400、400a、400b‧‧‧LED組件
402‧‧‧導電條
500a、500b‧‧‧LED燈泡
502‧‧‧夾具
600、600a、600b、700‧‧‧LED組件
第1圖為依據本發明的一實施例之LED組件的立體示意圖。
第2A圖顯示LED組件100a的上視圖。
第2B圖顯示LED組件100a的下視圖。
第3A與3B圖分別顯示第2A圖中AA與BB剖面示意圖。
第4圖顯示LED組件100設置於一燈泡。
第5A圖顯示用焊錫固定LED組件100。
第5B圖顯示用金屬夾片固定LED組件100。
第6圖顯示形成第3A與3B圖中之LED組件的製程方法。
第7A圖與第7B圖分別顯示LED組件100b的上視圖與下視圖。
第8A與8B圖顯示第7A圖中AA與BB剖面示意圖。
第8C圖與第8D圖顯示LED組件100c之二剖面圖。
第9圖顯示LED組件100b的製程方法。
第10圖為依據本發明的一實施例之發光二極體組件400的立體示意圖。
第11A圖與第11B圖顯示LED組件400a的上視圖與下視圖。
第12A圖與第12B圖分別顯示第11A圖中LED組件400a的AA與BB剖面示意圖。
第12C圖顯示另一LED組件400b。
第13圖顯示LED組件200的立體示意圖。
第14與15圖分別為LED組件200a的一上視圖與一側面圖。
第16圖與第17圖顯示另一LED組件200b。第18圖顯示另一LED組件200c。
第19圖顯示LED組件200c的一種製程方法。
第20圖顯示依據本發明的另一實施例之LED組件300的立體示意圖。
第21A與21B圖顯示一LED組件300a的上視圖與下視圖。
第22圖顯示LED組件300a的一剖面圖。
第23圖顯示LED組件300b的一側面圖。
第24圖顯示LED組件600的立體示意圖。
第25A圖與第25B圖顯示LED組件600a與600b之上視圖。
第26A圖顯示依據本發明的另一實施例之LED組件700的立體示意圖。
第26B圖及第26C圖分別顯示LED組件700的上視圖及剖面圖。
第27A與27B圖顯示分別以LED組件300與600作為燈蕊的二LED燈泡。
第1圖為依據本發明的一實施例之發光二極體(light-emitting diode,LED)組件100的立體示意圖。LED組件100包含有一透明基板106,在一實施例中,為不導電的一玻璃基板。透明基板106具有面對相反方向的上表面102以及下表面104。如第1圖所示,透明基板106大致為一長條狀,具有兩終端114與116。在此說明書中,透明僅僅用來表示可以透過光線,其可能是完全透明(transparent)或是半透明(translucent,or semitransparent)。在另一實施例中,透明基板106的材料可以是藍寶石、碳化矽、或類鑽碳。
第2A圖顯示LED組件100a的上視圖。請同時參考第1圖。在上表面102上,固著有數個藍光LED晶片108,彼此透過焊線(bonding wire)110所形成線路來電性連接。每一藍光LED晶片108可係為單一LED,其順向電壓約為2~3V(下稱「低電壓晶片」),或是具有數個發光二極體串聯在一起且順向電壓係大於低電壓晶片,例如12V、24V、48V等(下稱「高電壓晶片」)。具體言之,有別於打線方式,高電壓晶片係藉由半導體製程在一共同基板上形成數個彼此電連結之發光二極體單元(即至少具有發光層之發光二極體結構),此共同基板可以為長晶基板或非長晶基板。在第1圖與第2A圖中,藍光LED晶片108沿著連接透明基板106的兩終端114與116之一縱軸的兩側,排成兩列,彼此以焊線110串聯在一起,電性上,等效的成為 一個高順向電壓的發光二極體。但是本發明並不侷限於此,在其他實施例中,上表面102上的藍光LED晶片108可以排列成任意的圖案,且彼此的電性連接可以具有、串聯、並聯、同時有串聯並聯混合、或是橋式結構的連接方式。
如同第2A圖所示,在靠近終端114附近,透明基板106具有一導通孔107。導通孔107具有一通孔,其貫穿透明基板106直達上表面102以及下表面104,且其中形成有導電物填滿通孔或僅覆蓋通孔之內壁,以形成導通孔107。通孔中的導電物係可提供導通孔107兩端電性連接。在靠近終端114的上表面102,設置有一導電電極板118。導電電極板118並沒有直接接觸到導通孔107,亦即未直接接觸通孔內之導電物。靠近終端114的藍光LED晶片108其中之一(標示為108a)以一焊線110電連接到導電電極板118。靠近終端114的藍光LED晶片108其中之一(標示為108b),以另一焊線110電連接到導通孔107。
位於上表面102上的所有焊線110與藍光LED晶片108都被透明膠體112所覆蓋,用來預防大氣中的濕氣或是化學物質對焊線110與藍光LED晶片108所可能造成的老化與損害。透明膠體112的主要構成物可以是環氧樹酯或是矽膠(silicone)。透明膠體112包含有至少一種螢光粉,可以受藍光LED晶片108所發出的部分藍光(譬如說其波峰值為430nm-480nm)所激發,而產生黃光(譬如說其波峰值為570nm-590nm)或黃綠光(譬如說其波峰值為540nm-570nm)。而黃光或黃綠光與剩餘之藍光適當地混成時,人眼會視為白光。在一實施例中,透明膠體112包含兩種螢光粉。其中之一螢光粉可受藍光LED晶片108所發出的部分藍光(譬如說其波峰值為 430nm-480nm)所激發,而產生黃光或黃綠光或綠光(譬如說其波峰值為520nm-590nm);另一螢光粉可受藍光LED晶片108所發出的部分藍光(譬如說其波峰值為430nm-480nm)所激發,而產生紅光(譬如說其波峰值為610nm-680nm)。第1圖只是一個示意圖。在一例子中,如前所述,透明僅僅用來表示可以透過光線,其可能是完全透明(transparent)或是半透明(translucent,or semitransparent),因此透明膠體112可為完全透明或半透明,可清晰或隱約見到透明膠體112下之焊線110與藍光LED晶片108。在另一例子中,第1圖中的LED組件100,因為透明膠體112中之螢光粉,可能無法如同第1圖所示的看到透明膠體112下的焊線110與藍光LED晶片108且使透明膠體112呈現螢光粉之顏色。
第2B圖顯示LED組件100a的下視圖。如同第2B圖所示,下表面104上,無設置任何LED晶片。在靠近終端114的下表面104上,設置有另一導電電極板120,其一部分與導通孔107相重疊,並直接接觸通孔中的導電物而與其相互電連接。惟,於另一實施例中,導電電極板120可以不直接與導通孔107相連,而透過另一導體,如焊線110,與導通孔107形成電連接。在靠近終端116的下表面104上,可以選擇性地設置有另一導電電極板122。這樣的設計,可以使導電電極板122與導電電極板120共平面,藉此,LED組件100a放置上可以比較穩固,能避免運送或處理過程中翻落而造成的損害。在此實施例中,導電電極板122可以為電路上的浮接,沒有電性連接到LED組件100a中任何的電子元件、電路、或是其他電極板,因為其主要目的是使LED組件100a可以放置平穩。
如同第2A與2B圖之實施例所示,導電電極板120與118的邊 界位於下表面104與上表面102之內,也就是大致不超過下表面104與上表面102之邊界。導電電極板120、118與122的形狀不需約為長方形,大小也不需大致相同。在另一個實施例中,導電電極板120與118其中之一大致是長方形,另一大致是圓形,以方便識別出LED組件100a的正負極。
從電性上來看,藍光LED晶片108以及導通孔107串接於導電電極板120與118之間。導電電極板120與118可以做為LED組件100a的兩個電源輸入端。一驅動電源(未顯示)的正電源端與負電源端可以分別電連接到導電電極板120與118,以驅動藍光LED晶片108,使其發光。
第3A圖顯示第2A圖中LED組件100a的AA剖面示意圖;而第3B圖為第2A圖中LED組件100a的BB剖面示意圖。
與先前所述類似的,在第3A圖中,藍光LED晶片108b透過一焊線110電性連接到導通孔107,其連接到下表面104的導電電極板120;在第3B圖中,藍光LED晶片108a透過另一焊線110電性連接到上表面102上的導電電極板118。第4圖顯示LED組件100設置於一燈泡中,燈泡包含一燈罩180、LED組件100、電路板192、散熱機構182、及電連接機構183(例如:愛迪生燈座)。LED組件100的終端114固定在電路板192上;電路板192與散熱機構182相連接,用以將LED組件100所產生的熱帶離燈泡;電連接機構183與散熱機構182相連接。因為用來驅動藍光LED晶片108a之導電電極板120與118分別位於透明基板106之同一終端114側的上表面102與下表面104,所以可以用焊錫之類的導電體,將導電電極板120與118同時焊接於一電路板上,如同第5A圖所示。焊錫190不但可以提供驅動電源之電性連接使LED組件100發光,也同時提供機械性支撐給終端114,使LED組件100垂直 站立於電路板192上向四周圍發光,可提供全周光的光場。在第5A圖中,LED組件100僅僅靠焊錫190的機構支撐,即可大致垂直的站立於電路板192上,電路板192同時透過焊錫190對LED組件100供電。第5B圖是用金屬夾片194所構成的夾子,把LED組件100夾住而大約垂直地固定於電路板192上。金屬夾片194同時提供供電電源以及機構固定兩個功能,也可以達到降低製作流程複雜度與成本的效果。惟,LED組件100亦可以非垂直方式斜插於電路板192上。
在第3A圖之實施例中,上表面102之導通孔107所在位置上,可設置有一垂直導通元件130,作為導通孔107與一焊線110之間的電連接。舉例來說,垂直導通元件130為一pn接面二極體(例如:垂直型發光二極體、蕭基二極體或稽納二極體)、電阻、或是一金屬塊,以導電銀膠黏著於導通孔107上。在另一實施例中,垂直導通元件130與導電銀膠可以省略,而一焊線110可以直接接觸導通孔107,產生電性連接。
在第3A與3B圖中,每個藍光LED晶片108下有一透明黏著層132,用以將藍光LED晶片108固著於透明基板106之上表面102上。在第3A與3B圖中,每個藍光LED晶片108下有相對應之一透明黏著層132,彼此為一對一的關係,但本發明不限於此。在一實施例中,上表面102上有數個透明黏著層132,且每個透明黏著層132上黏著有數個藍光LED晶片108;在另一個實施例中,上表面102上只有單一一個透明黏著層132,其上承載了所有的藍光LED晶片108。透明黏著層132面積越大,對其上的藍光LED晶片108散熱效果越好,但是卻可能產生因為熱膨脹係數差異所造成之應力(shear)越大之缺點。因此,透明黏著層132的面積大小,以及承載藍光LED晶片108 的數量,可視實際應用而定。在一實施例中,透明黏著層132中混合有一些高導熱係數之導熱顆粒,譬如說氧化鋁粉、類鑽碳(diamond-like carbon)、或碳化矽(SiC),其導熱係數大於20W/mK,除了可以提高散熱效果外,也可以有光散射的效應。
第3A與3B圖中,透明黏著層132的材料,舉例來說,可以是環氧樹酯(epoxy resin)或是矽膠(silicone),並混合有跟透明膠體112中相同、類似或相異的螢光粉。舉例來說,螢光粉可以是YAG或是TAG螢光粉。如同先前所述的,具有螢光粉之透明膠體112覆蓋住焊線110與藍光LED晶片108的四周與上方,而透明黏著層132位於藍光LED晶片108的下方。換句話說,每個藍光LED晶片108不只是被透明膠體112以及透明黏著層132所包夾,也大致上完全被透明膠體112以及透明黏著層132所形成的一透明封裝體(capsule)所包裹。藍光LED晶片108所發出的藍光,不是被螢光粉轉換成黃綠光,就是跟黃綠光混合。因此,第3A與3B圖中的LED組件100a,可以防止藍光外漏的問題。
第6圖顯示形成第3A與3B圖中之LED組件100a的製程方法。首先,提供一透明基板106。透明基板106上預先形成有導通孔107(步驟148)。舉例來說,可以用雷射光從玻璃材質的透明基板106熔出一通孔,然後在通孔中填入導電物來形成導通孔107。步驟150預切透明基板106。在透明基板106上先形成一些溝槽,大略地預先定義了每個LED組件100在透明基板106上的位置,以方便之後的裁切。步驟152將導電電極板118與120分別貼附在透明基板106,靠近終端114之上表面102與下表面104的位置上。如果有導電電極板112的話,步驟152也將其形成在透明基板106上。在 另一實施例中,導電電極板是用印刷的方式形成於上表面102或下表面104上。步驟154於上表面102形成具有螢光粉的透明黏著層132,其位置係先設計好以放置藍光LED晶片108於其上。透明黏著層132的形成方法,舉例來說,可以用點膠、印刷或是噴塗的方式,將透明黏著層132形成在上表面102上。
步驟155將藍光LED晶片108固著於透明黏著層132上。舉例來說,可用真空吸嘴將藍光LED晶片108自藍膜(blue tape)上吸起,放置於透明黏著層132上。藍光LED晶片108的放置位置最好是完全被一透明黏著層132之周邊所圍繞,亦即,透明黏著層132的面積係大於藍光LED晶片108之面積,以避免藍光外漏的問題。垂直導通元件130可在此時,用導電銀膠黏著於上表面102之導通孔107上。步驟156形成焊線110,來電性連接一藍光LED晶片108到另一藍光LED晶片108、藍光LED晶片108a到導電電極板118、以及藍光LED晶片108b到垂直導通元件130。步驟157可以用點膠(dispense)或是印刷方式,將具有螢光粉之透明膠體112形成在上表面102上,覆蓋住焊線110與藍光LED晶片108。步驟158可以用人工扳裂或是機器切割的方式沿著先前預形成之溝槽,將一個個LED組件100獨立出來。
從第6圖之製程方法可知,在LED組件的形成過程中,除了形成導電電極板120或122於下表面104之外,其他的步驟大致都是針對上表面102進行處理。因為下表面104僅有導電電極板這樣大面積,且不容易被刮傷的圖案,所以製程載具可以用吸附或是持守住下表面104的方式,來搬運或是固定透明基板106,以避免位於上表面102上的細膩結構受到摩擦、刮傷等機械應力所產生之傷害。製程良率可以相當地提升。
在第3A、3B與6圖中的實施例中,藍光LED晶片108的發光方向並沒有受到任何的限制。對下方而言,藍光LED晶片108可以透過透明黏著層132以及透明基板106,而提供混成的光線;對四周以及上方而言,透過透明膠體112,藍光LED晶片108也可以提供混成的光線。因此,LED組件100a可視為一種可以提供六面發光的發光元件,而第4圖中有LED組件100的燈泡,則可視為一種全周光(Omnidirectional)照明裝置。
在第2A、2B、3A與3B圖中,藍光LED晶片108是直接用透明黏著層132黏著於透明基板106上,但本發明並不限於此。第7A圖與第7B圖分別顯示,在另一個實施例中,LED組件100b的上視圖與下視圖。LED組件100b之二剖面圖則顯示於第8A圖與第8B圖。第9圖顯示LED組件100b的製程方法。第7A、7B、8A、8B與9圖分別類似與對應第2A、2B、3A、3B與6圖,其中相同的符號或是記號所對應的元件、裝置或步驟,為具有類似或是相同的元件、裝置或步驟。為簡潔故,其解釋可能在此說明書中省略。
不同於第2A圖,第7A圖多了一個次基板(submount)160,其放置於透明黏著層132之周邊以內,被夾於藍光LED晶片108與透明黏著層132之間。次基板160的材料可以是透明玻璃、藍寶石、碳化矽、或類鑽碳。跟第3A與3B圖不同的,第8A與8B圖中的藍光LED晶片108中之部分或全部是固著於次基板160上,而次基板160以透明黏著層132固著於透明基板106上。
第9圖中,步驟154a以及步驟155a分別取代了第6圖中的步驟154以及步驟155。步驟154a以具有螢光粉之透明黏著層132將次基板160固接於透明基板106上。在一實施例中,透明黏著層132先形成於次基板160的 背面,然後次基板160才貼附於透明基板106上;在另一個實施例中,透明黏著層132先塗佈形成於透明基板106的上表面102上,然後次基板160才貼附於透明黏著層132上。步驟155a則接著將藍光LED晶片108固著於次基板160上。
第7A、7B、8A、8B與9圖中的實施例中,藍光LED晶片108可以用跟透明黏著層132一樣或是類似的材料,固著於次基板160上。但是本發明並不限於此,在一實施例中,藍光LED晶片108可以用不含螢光粉之透明膠或是共晶金屬,固著於次基板160上。在另一個實施例中,次基板160上印刷有導電條,而藍光LED晶片108以覆晶(flip chip)方式固著於其上,因此第9圖中的步驟156可能可以省略,然,藍光LED晶片108b仍需透過焊線100以和導通孔107電性連接;及藍光LED晶片108a亦需透過焊線100以和導電電極板118電性連接。在另一個實施例中,藍光LED晶片108是以異方性導電高分子或異方導電膜(anisotropic conductive Polymer,ACP;anisotropic conductive film,ACF)固著於次基板160上。
第7A、7B、8A、8B與9圖中的LED組件100b,享有跟第2A、2B、3A、3B與6圖中的LED組件100a一樣的好處。舉例來說,LED組件100b的終端114可以單單用焊錫固定立在一電路板上並同時地提供驅動電源之電性連接;LED組件100b的下表面104比較不怕刮傷,製程良率能有效提升;LED組件100b可以適用於是一全周光照明裝置;LED組件100b可以減輕或消弭藍光漏光的問題。
第8C圖與第8D圖顯示LED組件100c之二剖面圖,分別為第8A圖與第8B圖的變形。LED組件100b(於第8A與8B圖中)中採用單一透明 黏著層132,將次基板160固著於透明基板106上。跟LED組件100b不同的,LED組件100c(於第8C與8D圖中)以兩個透明黏著層132與133,將次基板160固著於透明基板106上。至少透明黏著層132與133其中之一包含有螢光粉。在第8C與8D圖之實施例中,透明黏著層132具有螢光粉,而透明黏著層133沒有。透明黏著層133的材料,舉例來說,可以是環氧樹酯(epoxy resin)或是矽膠(silicone)。因為透明黏著層133沒有螢光粉,所以能夠提供比較好的黏著效果,附著於透明基板106上。透明黏著層132、133可為相同或不同的材料。在另一實施例中,次基板160與透明黏著層132之間也可形成另一透明黏著層133於其中,以增加相互之間的黏著性。
第1圖之發光二極體組件100中的藍光LED晶片108彼此是透過焊線110彼此電連接,但本發明不限於此。第10圖為依據本發明的一實施例之發光二極體組件400的立體示意圖,其中的藍光LED晶片108是以覆晶方式固著於上表面102上。第11A圖與第11B圖顯示LED組件400a的上視圖與下視圖。第12A圖顯示第11A圖中LED組件400a的AA剖面示意圖;而第12B圖為第11A圖中LED組件400a的BB剖面示意圖。第10、11A、11B、12A與12B圖分別類似與對應第1、2A、2B、3A與3B圖,其中相同的符號或是記號所對應的元件、裝置或步驟,為具有類似或是相同的元件、裝置或步驟。為簡潔故,其解釋可能在此說明書中省略。
第12A圖與第12B圖相異於第3A圖與3B圖,在於第12A圖與第12B圖中,透明基板106上印刷有導電條402,且藍光LED晶片108彼此是透過導電條402相電連接。所以第12A圖與第12B圖中的藍光LED晶片108對於四周以及上下方而言,都可以發出光線,因此LED組件400a可視為一種可 以提供六面發光的發光元件。第12C圖顯示另LED組件400b,其中的下表面104上塗佈有一螢光層131,螢光層131中具有螢光粉,可將藍光LED晶片108所發出的光線,轉換成另一種顏色之光線。如此,可以降低從下表面104洩漏藍光的機會。在另一實施例中,LED組件400a中的藍光LED晶片108可以用白光LED晶片取代,每個白光LED晶片基本上係為表面形成有一螢光層的一藍光LED晶片。如此,可以避免藍光外漏的問題。
儘管前面實施例中的LED組件100a與100b都具有導通孔107,作為一線路的一部分,使透明基板106之上下表面102與104上的導電電極板120與118可以作為LED組件100a與100b的二驅動電源輸入端,但本發明不限於一定要有導通孔。
第13圖顯示依據本發明的一實施例之LED組件200的立體示意圖。第14與15圖分別為LED組件200a的一上視圖與一側面圖。跟LED組件100a與100b不同的,第14與15圖中的LED組件200a在透明基板106之上表面102的兩終端114與116,分別形成有導電電極板118以及119。LED組件200a中,導電電極板118以及119有部分跨出或延伸超過透明基板106的二終端114、116。而且,LED組件200a並沒有導通孔107。第13、14與15圖中的LED組件200或200a之製造方法與步驟可以參考前述說明推知,故不再累述。
在LED組件200a中,每個藍光LED晶片108下有單一相對應的透明黏著層132,但本發明不限於此。如同先前所描述的,在其他的實施例中,許多個藍光LED晶片108可以共用一透明黏著層132,或是所有的藍光LED晶片108只透過一透明黏著層132黏著於透明基板106上。
第16圖與第17圖顯示另一LED組件200b,其與第14與15圖中 的LED組件200a類似,但第16圖與第17圖中的每個藍光LED晶片108是固著於一次基板160上,而次基板160是透過透明黏著層132固著於透明基板106上。LED組件200b中的細節,可以參考第8A圖以及第8B圖中的LED組件100b以及相關描述而推知,不再累述。
第18圖顯示另一LED組件200c之側視圖。第19圖則顯示LED組件200c的一種製程方法。第18圖與第17圖近似,第18圖之上視圖可與第16圖相似,第19圖與第9圖近似,其中相同之處不再累述。與第17圖不同的,在第18圖中,導電電極板118以及119是貼附於透明黏著層132上。第19圖中的製程方法,在步驟150與152之間插有步驟151,其塗佈透明黏著層132於透明基板106上。換言之,透明黏著層132的形成,可以在導電電極板118以及119貼附之前就進行。透明黏著層132可以是環氧樹酯(epoxy resin)或是矽膠(silicone),並混合有跟透明膠體112中相同或是類似的螢光粉。舉例來說,螢光粉可以是YAG或是TAG螢光粉。
第17圖與第18圖中的LED組件200b與200c是採用單一透明黏著層132,將次基板160固著於透明基板106上。但本發明並不限於此。在其他實施例中,LED組件200b與200c可以被改變,採用第8C與8D圖中的兩層透明黏著層132與133,將次基板160固著於透明基板106上。在另一實施例中,次基板160與透明黏著層132之間也可形成另一透明黏著層133於其中,以增加相互之間的黏著性。
LED組件200a、200b與200c的下表面104完全沒有圖案,完全沒有下表面104刮傷的問題。LED組件200a、200b與200c一樣可以適用於全周光光場之應用,且較無藍光漏光問題。舉例來說,一燈泡可以用焊錫 或是導電夾具,來固定LED組件200a、200b或200c中,位於兩終端114與116之導電電極板118以及119,並同時透過此二電極板提供驅動電源之電性連接。
第20圖顯示本發明的另一實施例之LED組件300的立體示意圖。第21A與21B圖顯示一LED組件300a的上視圖與下視圖。第22圖顯示LED組件300a的一剖面圖。LED組件300a在透明基板106之下表面104的兩終端114與116,分別形成有導電電極板120以及122。在第21A、21B與22圖中,LED組件300a具有兩導通孔107A、107B分別形成在靠近終端114、116的位置。導電電極板120透過導通孔107A,而導電電極板122透過導通孔107B,電性連接到位於上表面102的藍光LED晶片108。藍光LED晶片108設置並電性地連接於導通孔107A與107B之間,也設置並電性連接於導電電極板120以及122之間。LED組件300a中的細節與可能之變化,可以參考此說明書中其他實施例之描述而推知,不再累述。
第23圖顯示LED組件300b的一側面圖。其中,次基板160夾於藍光LED晶片108與透明黏著層132之間。LED組件300b中的細節與可能之變化,可以參考此說明書中其他實施例之描述而推知,不再累述。
儘管在LED組件200與300中,位於兩終端之導電電極板有部分跨出或延伸超過透明基板106的二終端114、116,但本發明不限於此。第24圖顯示LED組件600的立體示意圖。第25A圖顯示LED組件600a,其為LED組件600的一種可能之上視圖。在第25A圖中,導電電極板118以及119都有一邊與透明基板106的邊緣切齊。第25B圖顯示LED組件600b,其為LED組件600的另一種可能之上視圖。在第25B圖中,導電電極板118以及119完全 坐落於透明基板106之內。
第26A圖顯示本發明的另一實施例之LED組件700的立體示意圖。第26B圖顯示LED組件700之上視圖。第26C圖顯示LED組件700之剖面圖。在第26A圖中之LED組件700具有兩導電電極板118及123,其位於靠近終端114之一側及上表面102之上,且透明基板106之下表面104並沒有其他LED元件。導電條198及196係分別從導電電極板118及123朝終端116之方向延伸。藍光LED晶片108固定於上表面102且位於導電條198及196之間。每一藍光LED晶片108之陽極及陰極係利用焊線110電連接至導電條198及196。因此,在第26A、26B與26C圖中之藍光LED晶片108係在導電條198及196間彼此並聯連接。導電條198及196可以做為LED組件700的兩個電源輸入端。在一實施例中,藍光LED晶片108可利用覆晶方式電連接至導電條198及196,即不需透過焊線110電連接至導電條198及196。如第26C圖所示,藍光LED晶片108實質上被透明黏著層132及透明膠體112所包裹。較佳地,藍光LED晶片108係被上下方之材料完全包覆,然焊線110仍可能有顯露於透明黏著層132及透明膠體112外之機會。透明黏著層132及透明膠體112皆包含至少一種螢光粉。在一實施例中,透明膠體112包含兩種螢光粉。其中之一螢光粉可受藍光LED晶片108所發出的部分藍光(譬如說其波峰值為430nm-480nm)所激發,而產生黃光或黃綠光或綠光(譬如說其波峰值為520nm-590nm);另一螢光粉可受藍光LED晶片108所發出的部分藍光(譬如說其波峰值為430nm-480nm)所激發,而產生紅光(譬如說其波峰值為610nm-680nm)。黃綠色螢光粉之成分係例如鋁氧化物(YAG或是TAG)、矽酸鹽、釩酸鹽、鹼土金屬硒化物、或金屬氮化物。紅色螢光粉之成分係例 如矽酸鹽、釩酸鹽、鹼土金屬硫化物、金屬氮氧化物、或鎢鉬酸鹽族混合物。第26A、26B與26C圖中的LED組件700之製造方法與步驟可以參考前述說明推知,故不再累述。
LED組件700可根據本發明所述之實施例而作變化。例如,藍光LED晶片108可固定於一次載體上。次載體可藉由至少一透明黏著層132黏結至透明基板106,其中,透明黏著層132可包含或者不包含螢光粉。
第27A圖顯示以LED組件300作為一燈蕊的LED燈泡500a。LED燈泡500a有兩個夾具502。夾具502可為V型或Y型。在一實施例中,夾具502可為長方形且具有一凹槽,用以固定LED組件300。每個夾具502係皆以導電物所構成,用夾具502的兩個尖端,箝制固定LED組件300兩終端的導電電極板,並使LED組件300的上表面102朝上(Z的方向)。夾具502也使LED組件300兩端的導電電極板電連接到LED燈泡500a之愛迪生燈座,以提供LED組件300發光需要的電能。第27B圖類似第27A圖,但以LED組件600作為一燈蕊的LED燈泡500b。與LED燈泡500a不同的,LED燈泡500b中LED組件600的上表面102朝向Y的方向,大致跟LED燈泡500b的旋轉軸(Z方向)垂直。當然的,第27A與27B圖中的LED組件300或600,都可以用先前所介紹的LED組件200替換,其細節與可能之變化,可以參考此說明書中其他實施例之描述而推知,不再累述。
LED組件300a與300b的下表面104只有大面積、不太懼怕刮傷的導電電極板120以及122,製程良率可以獲得相當之改善。LED組件600a與600b的下表面104完全沒有圖案,更不怕刮傷。LED組件300a、300b、600a與600b一樣可以適用於全周光光場之應用、較無藍光漏光問題。
儘管以上的實施例都採用藍光LED晶片108作為光源,但本發明不限於此。在其他實施例中,有一些或是全部的LED晶片並不是藍光,而是紅光或是綠光。
本發明的一些實施例,因為有透明基板106與透明黏著層132的存在,可以朝四面八方發光,所以可適用於全周光的應用。在一些實施例中,所有的藍光LED晶片108都大致被透明黏著層132以及透明膠體112所包裹,所以沒有藍光漏光問題。一些實施例中的LED組件可以只要固定一終端就可以同時接受電源供電以及機構支撐;一些實施例中的LED組件可以在機構地固定兩終端時,同時從兩終端接受電源供電;一些實施例中的LED組件的下表面沒有細緻圖案或是電路,比較不怕刮傷,可以方便製造過程中的拿取或固定,提高製程良率。
以上所述僅為本發明之數個實施例,惟各個實施例在彼此不相衝突下當可以彼此參照、合併或替換,凡依本發明申請專利範圍所做之均等變化與修飾,皆應屬本發明之涵蓋範圍。
100a‧‧‧LED組件
102‧‧‧上表面
104‧‧‧下表面
106‧‧‧透明基板
107‧‧‧導通孔
108、108b‧‧‧藍光LED晶片
110‧‧‧焊線
112‧‧‧透明膠體
114、116‧‧‧終端
118‧‧‧導電電極板
120‧‧‧導電電極板
130‧‧‧垂直導通元件
132‧‧‧透明黏著層

Claims (10)

  1. 一種發光二極體組件,包含有:一透明基板,具有面對相反方向之一第一表面以及一第二表面;複數發光二極體晶片,固定於該第一表面上;一線路,電性連接該等發光二極體晶片;一透明封裝體,具有螢光粉,該透明封裝體設於該第一表面上,大致包裹該等發光二極體晶片與該線路;以及二電極板,貼附於該第一表面或該第二表面,透過該線路電連接至該等發光二極體晶片,作為該發光二極體組件之二電源輸入端。
  2. 如申請專利範圍第1項所述之發光二極體組件,其中,該透明封裝體包含有一透明黏著層,係具有螢光粉且設於該等發光二極體晶片其中之一與該透明基板之間。
  3. 如申請專利範圍第1項所述之發光二極體組件,其中,該透明封裝體包含有複數個透明黏著層,該等發光二極體晶片係一對一的設於該等透明黏著層上。
  4. 如申請專利範圍第1項所述之發光二極體組件,其中,該透明封裝體包含一單一透明黏著層,所有的該等發光二極體晶片均設於該透明黏著層上。
  5. 如申請專利範圍第1項所述之發光二極體組件,其中,該透明封裝體包含有一透明膠體,包覆在該等發光二極體晶片之上方與四周,該透明膠體具有螢光粉。
  6. 如申請專利範圍第2項所述之發光二極體組件,另包含有一次基板,設於該等發光二極體與該透明黏著層之間。
  7. 如申請專利範圍第6項所述之發光二極體組件,其中,該等發光二極體晶片係以覆晶方式,固著於該次基板上。
  8. 如申請專利範圍第1項所述之發光二極體組件,其中,該線路包含有至少一焊線,電性連接該等發光二極體晶片其中之二。
  9. 如申請專利範圍第1項所述之發光二極體組件,其中,該透明基板係為一長條,具有一第一終端以及一第二終端,該等電極板分別設於該第一終端之該第一表面與該第二表面。
  10. 如申請專利範圍第1項所述之發光二極體組件,其中,該透明基板係為一長條,具有一第一終端以及一第二終端,該等電極板分別設於該第一終端與該第二終端。
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US11543081B2 (en) 2023-01-03
CN104253200B (zh) 2020-04-07
CN111457260A (zh) 2020-07-28
TWI651871B (zh) 2019-02-21
JP2015012292A (ja) 2015-01-19
CN111457260B (zh) 2022-06-07

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