Abstract:
A manufacture method of light emitting diode (LED) module includes: providing a carrier board including a carrying area and a shaping area; arranging at least one substrate having at least one circuit layer in the carrying area of the carrier board; arranging at least one LED in the carrying area of the carrier board; electrically connecting the LED to the circuit layer of the substrate; encapsulating the LED and at least part of the circuit layer by at least one light transmissive encapsulation element; and fabricating the shaping area of the carrier board into a desired appearance. The above-mentioned carrier board not only can be a heat sink but also can be easily fabricated into various types of design shapes. Therefore, a light emitting diode module manufactured by the above-mentioned method has preferred heat dissipation effects and a better appearance with relatively low production costs.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates to a LED module and a manufacture method thereof, particularly to a LED module that can be easily processed into various shapes and a manufacture method thereof. 
         [0003]    2. Description of the Related Art 
         [0004]    LED (Light Emitting Diode) has advantages of compactness, long lifetime and high energy efficiency. Therefore, LED is extensively applied to illuminators, traffic lights and decorative lights. However, heat dissipation is always a challenge for LED, particularly for high-power LED. 
         [0005]    In the conventional LED module, LED is encapsulated beforehand, and then the encapsulated LED is installed on a heat sink. With the increasing power consumption of LED, the volume of the heat sink is also increased to enhance the heat-dissipation effect. However, the existing fabrication platforms are unsuitable to fabricate a LED module containing a heat sink having a bulky volume or fins. Therefore, the manufacturers have to purchase additional fabrication platforms meeting the requirements. Thus is increased the fabrication cost. Besides, heat sinks normally have fixed shapes. Thus, heat sinks usually limit the flexibility of design, especially the heat sinks having a bulky volume or fins. 
         [0006]    Therefore, many manufacturers are eager to develop a LED module, which not only dissipates heat effectively but also provides flexibility for appearance design. 
       SUMMARY OF THE INVENTION 
       [0007]    The present invention is directed to a LED module and a manufacture method thereof, wherein LED is arranged in a relatively thinner carrier board and encapsulated there and the carrier board is then machined to have a desired shape, wherefore the appearance of the LED module can be arbitrarily designed. In one embodiment, the carrier board including high thermal conductivity material can be a heat sink to effectively dissipate heat. 
         [0008]    In one embodiment, the proposed LED module comprises a carrier board, at least one substrate, at least one LED, and at least one light-transmissive encapsulation element. The carrier board has a carrying area and a shaping area. The shaping area is used to form a desired shape. The substrate is arranged in the carrying area and has at least one circuit layer. The LED is also arranged in the carrying area and electrically connected with the circuit layer of the substrate. The light-transmissive encapsulation element is used to encapsulate the LED and at least one part of the circuit layer. 
         [0009]    In another embodiment, the proposed manufacture method of a LED module comprises: providing a carrier board having a carrying area and a shaping area; arranging at least one substrate in the carrying area of the carrier board, wherein the substrate has at least one circuit layer; arranging at least one LED in the carrying area of the carrier board; electrically connecting the LED with the circuit layer; encapsulating the LED and at least one part of the circuit layer with at least one light-transmissive encapsulation element; and fabricating the shaping area of the carrier board into a desired appearance. 
         [0010]    Below, the embodiments are described in detail in cooperation with the attached drawings to make easily understood the objectives, technical contents, characteristics and accomplishments of the present invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]      FIG. 1   a  is a sectional view of a LED module according to a first embodiment of the present invention; 
           [0012]      FIG. 1   b  is a top view of a LED module, whose light-transmissive encapsulation element is removed, according to the first embodiment of the present invention; 
           [0013]      FIG. 2   a  is a sectional view of a LED module according to a second embodiment of the present invention; 
           [0014]      FIG. 2   b  is a top view of a LED module, whose light-transmissive encapsulation element is removed, according to the second embodiment of the present invention; 
           [0015]      FIG. 3   a  is a sectional view of a LED module according to a third embodiment of the present invention; 
           [0016]      FIG. 3   b  is a top view of a LED module, whose light-transmissive encapsulation element is removed, according to the third embodiment of the present invention; 
           [0017]      FIG. 4  and  FIG. 5  are sectional views of the appearances of different LED modules respectively according to different embodiments of the present invention; 
           [0018]      FIG. 6  is a sectional view of a LED module according to a fourth embodiment of the present invention; 
           [0019]      FIG. 7  is a sectional view of a LED module according to a fifth embodiment of the present invention; 
           [0020]      FIG. 8  shows a flowchart of a manufacture method of a LED module according to one embodiment of the present invention; and 
           [0021]      FIG. 9  is a top view of a carrier board of a LED module according to a sixth embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0022]    Refer to  FIG. 1   a  and  FIG. 1   b .  FIG. 1   a  is a sectional view of a LED module according to one embodiment of the present invention.  FIG. 1   b  is a top view of a LED module, whose light-transmissive encapsulation element is removed, according to one embodiment of the present invention. In one embodiment, the LED module  1  of the present invention comprises a carrier board  11 , at least one substrate  12 , at least one LED  13  and at least one light-transmissive encapsulation element  14 . The carrier board  11  has a carrying area  111  and a shaping area  112 . The shaping area  112  can be arbitrarily machined to achieve the designed appearance. The substrate  12  is arranged in the carrying area  111  of the carrier board  11  and has at least one circuit layer. In one embodiment, the circuit layer has at least one conductive contact point  121 . The substrate  12  may be but is not limit to a copper foil substrate, an insulating substrate, a glass fiber reinforced substrate, a ceramic substrate, a composite substrate, a flexible substrate, a glass fiber reinforced prepreg, or a polymeric substrate. The present invention does not limit the number of the circuit layers. In one embodiment, the several substrates are stacked vertically. 
         [0023]    The LED  13  is also arranged in the carrying area  111  of the carrier board  11 . In one embodiment, the substrate  12  has a hole  122 , as shown in  FIG. 1   b . The LED  12  is arranged in the hole  122  and thus secured in the carrying area  111  of the carrier board  11 . Each hole  122  can receive one or more LEDs  13 . In other words, the side wall of the hole  122  encircles one or more LEDs  13 . Refer to  FIG. 2   a  and  FIG. 2   b . The LED  13  is arranged in the carrying area  111  of the carrier board  11  and beside the substrate  12 ′. 
         [0024]    Refer to  FIG. 1   a  and  FIG. 1   b  again. The LED  13  is electrically connected with the circuit layer of the substrate  12 . In one embodiment, the LED  13  is electrically connected with the conductive contact points  121  of the substrate  12  via at least one wire  131 . The light-transmissive encapsulation element  14  is used to encapsulate the LED  13  and at least one part of the circuit layer, such as the conductive contact points  121 . In one embodiment, the light-transmissive encapsulation element  14  is made of a polymeric material. In one embodiment, the LED module of the present invention may further comprise a fluorescent material. The fluorescent material is arranged on the surface of the LED  13 , or mixed with a polymeric material, or in form of a fluorescent film arranged over the LED  13 . 
         [0025]    In one embodiment, the carrier board  11  may be a high thermal conductivity material, such as a metallic material, or a composite material. In such a case, the carrier board  11  can function as a heat sink. The size of the carrier board  11  is far greater than that of the substrate  12  so as to increase heat dissipation effect and benefit appearance design. Refer to  FIG. 3   a  and  FIG. 3   b . In one embodiment, the shaping area  112  of the carrier board  11  is bent far away from the substrate  12  to function as a heat dissipating fin  112   a . In one embodiment, the shaping area  112  of the carrier board  11  is bent toward the substrate  12  to function as a reflecting structure  112   b  and/or a heat dissipating structure. 
         [0026]    Refer to  FIG. 5 . In one embodiment, the carrier board  11  may be a multi-layer structure. One layer of the shaping area  112  of the carrier board  11  is bent far away from the substrate  12  to function as a heat-dissipating fin  112   a . Another layer of the shaping area  112  is bent toward the substrate  12  to function as a reflecting structure  112   b  and/or a heat dissipating structure. In one embodiment, the substrate-facing surface of the reflecting structure  112   b  is treated with an anodic process to enhance the reflecting effect. In one embodiment, a reflecting layer is coated on the substrate-facing surface of the reflecting structure  112   b  to enhance the reflecting effect. 
         [0027]    In one embodiment, the carrier board  11  also includes an electrically-conductive material, whereby the carrier board  11  is electrically connected with the LED  13  and the circuit layer of the substrate  12 . Thus, the LED  12  and the circuit layer are electrically connected with the external circuits via the carrier board  11 . In one embodiment, the carrier board  11  functions as the electric-conduction element between the LED  13  and the circuit layer of the substrate  12 . For example, the LED  13  is electrically with the carrier board  11  via at least one conductive bump, and the carrier board  11  is electrically connected with the circuit layer of the substrate  12 , whereby the LED  12  is electrically connected with the circuit layer of the substrate  12  via the carrier board  11 . 
         [0028]    Refer to  FIG. 6 . In one embodiment, the light-transmissive encapsulation element  14  of the LED module  1 ′ further comprises a spacer  141  and a light-transmissive plate  142 . The spacer  141  is arranged on the substrate  12 , and the light-transmissive plate  142  is arranged over the spacer  141 , whereby a gap exists between the LED  13  and the light-transmissive plate  142 . Thus, the light-transmissive plate  142  is less affected by the heat generated by the LED  13 . Then, the fluorescent material, which is stuck to or coated on the inner or outer surface of the light-transmissive plate  142  or mixed within the light-transmissive plate  142 , is less likely to be deteriorated by the heat generated by the LED  13 . 
         [0029]    Refer to  FIG. 7 . In one embodiment, the LED module of the present invention further comprises a reflecting cup  70  arranged on one surface (of the carrier board  11 ) where the LED  13  is installed. The reflecting cup  70  may be a high thermal conductivity material, a metallic material, a composite material. Therefore, the heat generated by the LED  13  can be conducted to the reflecting cup  70  by the carrier board  11  and then dissipated by the reflecting cup  70 . In one embodiment, the LED module of the present invention further comprises a diffusion element  72 , such as a diffusion film. The diffusion element  72  is arranged on the light exiting side of the LED  13 , such as the opening of the reflecting cup  70  or reflecting structure  112   b  (shown in  FIG. 4 ). The diffusion element  72  can homogenize or milden the light emitted by the LED  13 . 
         [0030]    In one embodiment, the LED module of the present invention further comprises a driver adaptor (not shown in the drawings). The driver adaptor is electrically connected with the LED  13  and used to drive the LED  13 . The driver adaptor has a connector able to electrically connect with a conventional lamp socket. Thus, the LED module of the present invention can electrically connect with any arbitrary conventional lamp socket through the driver adaptor and obtain power from the lamp socket. In one embodiment, the driver adaptor is electrically connected with the LED  13  in a plug-in way. When the LED  13  is damaged, the user needn&#39;t replace the whole lamp assembly but just replaces the damaged LED  13 . In one embodiment, the driver adaptor is electrically connected with the LED  13  by at least one wire, whereby the LED module of the present invention is compatible with the conventional lamp socket, which is parallel or vertical to the light exiting direction. 
         [0031]    Refer to  FIG. 8  and  FIG. 1   a . Below is described a manufacture method of a LED module according to the present invention. In Step S 81 , provide a carrier board  11  firstly, wherein the carrier board  11  has a carrying area  111  and a shaping area  112 . In Step S 82 , arrange a substrate  12  having a circuit layer in the carrying area  111  of the carrier board  11 . In Step S 83 , arrange a LED  13  in the carrying area  111  of the carrier board  11 . In Step S 84 , electrically connect the LED  13  with the circuit layer of the substrate  12 . In Step S 85 , encapsulate the LED  13  and at least one part of the circuit layer of the substrate  12  with a light-transmissive encapsulation element  14 , such as conductive contact points  121 . In Step S 85 , fabricate the shaping area  112  of the carrier board  11  into a desired appearance, such as a heat dissipating fin  112   a  shown in  FIG. 3   a , or a reflecting structure  112   b  and/or a heat dissipating structure shown in  FIG. 4 . 
         [0032]    Refer to  FIG. 9 . In one embodiment, the method of the present invention further comprises a step of forming at least one pre-bent portion  113  in the shaping area  112  of the carrier board  11  (Step S 86 ). Later, the user can form the predetermined appearance via merely bending shaping area  112  along the pre-bent portions  113 . For example, the substrate and LED are installed in the carrying area  111  beforehand, and then the carrier board  11  is bent along the pre-bent portions  113  to form a dice-shape LED module. The dice-shape semi-product of a LED module with relatively flatter shape is favorable for storage and transportation. Thus, the related cost is reduced. 
         [0033]    In one embodiment, the LED module is applied to a backlight module of an LCD device. In one embodiment, the two sides of the shaping area  111  are bent toward the LED  13  to form a U-shape side-emitting backlight module. Besides, the LED module of the present invention is also applied to the bottom-emitting backlight modules. 
         [0034]    In conclusion, the present invention proposes a LED module and a manufacture method thereof, wherein the LED is arranged in a relatively thinner carrier board and encapsulated there and the carrier board is then machined to have a desired shape. Therefore, the LED module of the present invention can be fabricated without using any special specification platform. Further, the carrier board is favorable for the succeeding fabrication and can be fabricated into various shapes. In one embodiment, the carrier board is made of a high thermal conductivity material and functions as a heat sink able to dissipate heat appropriately. In other words, the heat-dissipating component can be fabricated into different shapes to implement the LED modules of various appearances in the present invention.