Patent ID: 7329942
Filing Date: 2008-02-12
Classification: H01L

Abstract:
1. A method for packaging an array-type modularized light-emitting diode structure, comprising steps of: manufacturing an upper substrate, a material with high heat conductivity being selected as the material of the upper substrate, by means of one of molding, injection molding and etching, the upper substrate being made from the material to have multiple arrayed dents and at least two through holes passing though the bottom of each dent, a conductive material being implanted in each though hole; manufacturing a lower substrate, a material with high heat conductivity being selected as the material of the lower substrate, by means of one of halftone printing and etching, a surface of the lower substrate being formed with a predetermined circuit layout card, the circuit layout card having multiple contact electrodes and multiple connecting sections along a periphery of the lower substrate for connecting with outer side, the circuit layout card further having conductive wires between the contact electrodes and the connecting sections; fixing the upper and lower substrates with each other, the bottom face of the upper substrate being placed on the upper face of the lower substrate with the through holes of the dents of the upper substrate respectively corresponding to the contact electrodes of the circuit layout card of the lower substrate, the connecting sections of the circuit layout card being exposed to the periphery of the upper substrate, then the upper and lower substrates being fixed with each other; fixing light-emitting diode crystallites, multiple light-emitting diode crystallites being respectively fixed on the bottoms of the dents of the upper substrate, via the through holes of the bottoms of the dents, the electrodes of the light-emitting diode crystallites being electrically connected with the contact electrodes of the circuit layout card of the lower substrate; and sealing the dents of the upper substrate, the dents of the upper substrate being sealed to prevent the light-emitting diode crystallites from being oxidized. wherein in the step of manufacturing the upper substrate, the upper substrate is made by means of etching, a single-crystal silicon chip being selected as the material of the upper substrate, the single-crystal silicon chip being placed in a furnace and heated to respectively form two etching-protective layers on upper face and lower face of the single-crystal silicon chip, the etching regions of the dents and through holes of the upper and lower faces of the single-crystal silicon chip being defined by means of micro-image manufacturing procedure, the protective layers of the etching regions being removed by means of etching to expose the etching regions to outer side, then, by means of non-isotropic wet etching, the etching regions being etched to a certain depth so as to simultaneously form multiple arrayed dents in the single-crystal silicon chip and at the same time form two through holes on the bottom of each dent, then, the single-crystal silicon chip etched with the dents and through holes being placed into the furnace and heated to form an insulating layer on the surface of each of the dents and through holes, a tin ball being implanted into each through hole and then the upper substrate being placed into a baker and heated to soften the tin ball and fill up the through hole with the tin ball.