Light emitting diode package and method for manufacturing same

An LED packaging includes a substrate having a top surface and a bottom surface opposite to the top surface, a recess defined in the top surface, an LED mounted on the top surface of the substrate, a zener diode received in the recess, and a reflecting layer formed in the recess and enclosing the zener diode therein.

FIELD

The present disclosure generally relates to solid state light emitting sources and, more particularly, to a light emitting diode (LED) package and a method for manufacturing the LED package.

BACKGROUND

LEDs have many advantages, such as high luminosity, low operational voltage, low power consumption, compatibility with integrated circuits, easy driving, long term reliability, and environmental friendliness which have promoted the wide use of LEDs as a light source.

A typical LED package includes a substrate, a circuit mounted on a top surface of the substrate, an LED chip and a zener diode electrically connecting the circuit respectively.

However, because the LED chip and the zener diode are arranged on one flat surface of the substrate, the LED chip and the zener diode are often in substantially the same plane. As such, some amount of light emitted from the LED chip will be absorbed by the zener diode, resulting in a decrease of a light output efficiency of the LED package.

Therefore, what is needed, is an LED package and a method for manufacturing the LED package which can overcome the limitations described above.

DETAILED DESCRIPTION

Embodiments of an LED package100in accordance with the present disclosure will now be described in detail below and with reference to the drawings.

Referring toFIGS. 1-2, an LED package100in accordance with an example embodiment of the disclosure includes a substrate10, an LED20and a zener diode30arranged on a top side of the substrate10, and a packaging layer40enveloping the LED20and the zener diode30therein.

The substrate10is cuboidal and includes a first electrode11, a second electrode12and an electrically insulating layer13. The second electrode12is cuboidal and located at a corner of the substrate10. The first electrode11has an L-shaped configuration and is spaced from and surrounds the second electrode12. The insulating layer13is sandwiched between the first electrode11and the second electrode12to make the first electrode11and the second electrode12electrically insulate from each other. The insulating layer13has an L-shaped configuration. In this embodiment, the first electrode11is a p-type electrode and the second electrode12is an n-type electrode.

Top surfaces of the first electrode11, the second electrode12and the insulating layer13are coplanar and cooperatively form a flat top surface10aof the substrate10. Bottom surfaces of the first electrode11, the second electrode12and the insulating layer13are coplanar and cooperatively form a flat bottom surface10bof the substrate10. A left end of the top surface10ais recessed towards the bottom surface10bto define a recess10ctherein. The recess10cextends through a top portion of the substrate10along a width direction of the substrate10to expose side parts of the first electrode11, the second electrode12and the insulating layer13.

The LED20is arranged on the top surface of the first electrode11and electrically connects the first electrode11and the second electrode12via wires. The zener diode30is received in the recess10cand electrically connects the exposed side parts of the first electrode11and the second electrode12. A top end of the zener diode30is below the top surface10aof the substrate10.

A reflecting layer50is filled in the recess10cand envelopes the zener diode30therein. The reflecting layer50is made of a mixture mixed by opaque glue and a plurality of reflection particle51such as TiO2 or SiO2. A top surface of the reflecting layer50is coplanar to the top surface10aof the substrate10.

The packaging layer40is formed on the top surface10aof the substrate10and covers the LED20and the reflecting layer50. The packaging layer40is transparent and made of silicon or epoxy resin. In other embodiments, a plurality of phosphorus powder can be doped in the packaging layer40. The phosphorus powder can be selected from one of garnet, silicates, nitride, nitrogen oxides, phosphide, sulphide or a compound thereof.

In this embodiment, because the zener diode30is below the top surface10aof the substrate10and enveloped by the opaque reflecting layer50, light emitted from the LED20is not absorbed by the zener diode30and reflected outwardly by the reflecting layer50. Thus, a light output efficiency of the LED package100is improved.

The present disclosure further provides a method for manufacturing the LED package100ofFIG. 1.

Referring toFIGS. 3-4, in the first step, the substrate10is provided, the first electrode11and the second electrode12are formed by plating or sputtering, and the insulating layer13is formed between the first electrode11and the second electrode12by injecting. The first electrode11and the second electrode12are formed firstly and a gap14is defined between the first electrode11and the second electrode12. When the insulating layer13is formed, a plurality of liquid insulating mixture (not shown) is provided. The insulating mixture is filled in the gap14and solidified to obtain the insulating layer13. The left end of the substrate10is etched to define the recess10cReferring toFIGS. 5-6, in the second step, the LED20is provided and arranged on the top surface of the first electrode11. The LED20electrically connects the first electrode11and the second electrode12via the wires.

Also referring toFIGS. 5-6, in the third step, the zener diode30is arranged in the recess10c.

Referring toFIGS. 7-8, in the fourth step, a mixture mixed by glue53and the reflection particle51is filled in the recess10cand dried to obtain the reflecting layer50.

Referring toFIGS. 1-2again, in the fifth step, the packaging layer40is formed on the top surface10aof the substrate10.

It is to be further understood that even though numerous characteristics and advantages of the present embodiments have been set forth in the foregoing description, together with details of the structures and functions of the embodiments, the disclosure is illustrative only, and changes may be made in detail, including in matters of shape, size, and arrangement of parts within the principles of the disclosure to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.