# Patent

## Title
Light emitting diode package and method of manufacturing the same

## Abstract

A light emitting diode (LED) package is provided. According to an embodiment, a light emitting apparatus includes a substrate; at least two distinct electrodes on the substrate; a light emitting device on one of the at least two distinct electrodes, wherein the at least two distinct electrodes are electrically separated from each other and spaced from each other; a guide unit on the substrate and around the light emitting device, wherein the guide unit includes an inner side surface, an outer side surface, a top surface and a bottom surface; and lenses including a first lens and a second lens on the substrate, wherein at least one of the lenses includes a convex shape and a portion of the at least one of the lenses is located higher than the top surface of the guide unit.

## Background
This application is a Continuation of co-pending U.S. application Ser. No. 11/585,855 filed Oct. 25, 2006, and for which priority is claimed under 35 U.S.C. §120; and this application claims priority of Application No. 10-2005-0101772 filed in the Republic of Korea on Oct. 27, 2005 under U.S.C. §119; the entire contents of all are hereby incorporated by reference.


BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a light emitting diode package and a method of manufacturing the same.
2. Description of the Related Art
A light emitting diode (LED) is a semiconductor device that can realize a light source of various colors using a compound semiconductor material such as GaAs, AlGaAs, GaN, InGaN, and AlGaInP.
Generally, color, brightness, luminosity, etc. determine a characteristic of an LED. The characteristic of the LED is generally determined by a compound semiconductor material used in the LED, but is greatly influenced by a package structure for mounting chips.
In particular, as information telecommunication devices have become small-sized and slim, elements such as a resistor, a condenser, and a noise filter have become small-sized even more and been directly mounted in a printed circuit board (PCB) (a surface mount device (SMD) type).
FIG. 1 is a view illustrating an LED package structure according to a related art.
Referring to FIG. 1, an LED package according to a related art includes a PCB 200 having a reflective hole 202 in which an LED 210 is mounted, a reflective coating layer 201 coated with Ag in the reflective hole 202, a cathode electrode 220 and an anode electrode 230 connected with the reflective coating layer 201, and wires 218 connecting the LED 210 with the reflective coating layer 201.
A central region of the reflective coating layer 201 is electrically cut and the reflective coating layer 201 is electrically connected with the cathode electrode 220 and the anode electrode 230. That is, a P electrode and an N electrode of the LED 210 are electrically connected with the reflective coating layer 201 such that the P and N electrodes are connected with the cathode electrode 220 and the anode electrode 230.
The cathode electrode 220 and the anode electrode 230 may be formed by solder bonding. The cathode electrode 220 and the anode electrode 230 are formed, and then a mold lens 250 is formed on the reflective coating layer 201 of the PCB 200 in order to prevent an oxidation of the wires 218, reduce a light loss due to an air resistance, improve thermal conductivity.
Meanwhile, light emitted from the LED 210 is reflected a lot inside the mold lens 250, that is, internal reflection occurs a lot inside the mold lens, decreasing the transmittance and eventually decreasing the light efficiency.
SUMMARY OF THE INVENTION
Accordingly, the present invention is related to a light emitting diode and a method of manufacturing the same that substantially obviates one or more problems due to limitations and disadvantages of the related art.
The invention provides an LED package with an excellent light efficiency.
The invention provides an LED package with a simplified manufacturing method thereof.
The invention provides an LED package with an excellent physical stability.
Additional advantages, objects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention. The objectives and other advantages of the invention may be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
The embodiment of the invention provides an LED package, comprising: a PCB; an electrode pad formed on the PCB; an LED formed on the PCB; a first molding formed on the LED; and a second molding formed on the first molding.
The embodiment of the invention provides an LED package comprising: a PCB; an electrode pad formed on the PCB; an LED formed on the electrode pad; a first molding formed on the LED; and a second molding formed on the electrode pad and the first molding.
An embodiment of the invention provides a method of manufacturing an LED package, the method comprising: forming an electrode pad on a PCB; forming an LED on the PCB; forming a first molding on the LED by a dispensing method; and forming a second molding on the first molding by a dispensing method.
According to an embodiment, the invention provides a light emitting apparatus comprising: a substrate; at least two distinct electrodes on the substrate; a light emitting device on one of the at least two distinct electrodes, wherein the at least two distinct electrodes are electrically separated from each other and spaced from each other; a guide unit on the substrate and around the light emitting device, wherein the guide unit includes an inner side surface, an outer side surface, a top surface and a bottom surface; and lenses including a first lens and a second lens on the substrate, wherein at least one of the lenses includes a convex shape and a portion of the at least one of the lenses is located higher than the top surface of the guide unit, wherein the at least one of the lenses is in contact with the inner side surface of the guide unit and spaced from the top surface of the guide unit, and wherein the first lens is in contact with the at least two distinct electrodes and the light emitting device.
According to an embodiment, the invention provides a light emitting apparatus comprising: a substrate; at least two distinct electrodes on the substrate; a light emitting device on one of the at least two distinct electrodes, wherein the at least two distinct electrodes are electrically separated from each other and spaced from each other; a guide unit on the substrate and around the light emitting device; and at least one lens on the substrate, wherein the lens has a convex shape and a portion of the lens is located higher than a top surface of the guide unit, wherein the lens is in contact with an inner side surface of the guide unit and spaced from the top surface of the guide unit, and wherein each of the at least two distinct electrodes includes a first portion disposed outside of the guide unit, a second portion between the guide unit and the substrate, and a third portion disposed inside of the guide unit.
According to an embodiment, the invention provides a light emitting apparatus comprising: a substrate, wherein an entire top surface of the substrate is substantially planar; at least two distinct electrodes including at least one of Ag, Au, or Cu on the substrate; a light emitting device on the substrate or one of the at least two distinct electrodes, wherein the at least two distinct electrodes are electrically separated from each other and spaced from each other; a guide unit on the substrate and around the light emitting device, wherein the guide unit includes an inner side surface, an outer side surface, a top surface and a bottom surface; and at least one lens on the substrate, wherein the lens has a convex shape and a portion of the lens is located higher than the top surface of the guide unit, wherein the lens is in contact with the inner side surface of the guide unit and spaced from the top surface of the guide unit.
It is to be understood that both the foregoing general description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.



BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the principle of the invention. In the drawings:
FIG. 1 is a view illustrating an LED package structure according to a related art;
FIG. 2 is a sectional view of an LED package according to an embodiment of the present invention;
FIG. 3 is a flowchart illustrating a method of forming an LED package according to an embodiment of the present invention; and
FIG. 4 is a view illustrating a first molding and a second molding of another shape in an LED package according to an embodiment of the present invention.



DETAILED DESCRIPTION OF THE INVENTION
It will be understood that when an element is referred to as being ‘on’ a layer, it can be directly on the layer, and one or more intervening layers may also be present.
Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
FIG. 2 is a sectional view of an LED package according to an embodiment of the present invention.
Referring to FIG. 2, the present invention exemplarily illustrates a SMD type LED package manufactured using a metal core printed circuit board (MCPCB) as an LED package.
An LED package according to an embodiment of the present invention includes an MCPCB 1, two electrode pads 2 formed on the MCPCB 1, an LED 3 formed on the electrode pads 2, two wires 4 connecting the LED 3 with the electrode pads 2, and a first molding (lens) 6 formed outside the LED 3 and the wires 4 and a second molding (lens) 7 formed outside the first molding 6.
The LED package may further include a guide unit 5 guiding the first and second moldings 6 and 7 to be easily formed.
The electrode pads 2 may be formed of a conductive metal material such as Ag, Au, and Cu on the MCPCB 1 and are connected with the LED 3 through the wires 4. The two electrode pads 2 are not electrically connected, power is supplied to the LED 3 through the two wires 4.
Also, the electrode pads 2 reflect light emitted from the LED 3 to increase the light efficiency.
Also, the LED 3 may be formed on the MCPCB 1 or may be formed on the electrode pads 2, as illustrated in FIG. 2.
In the present invention, the LED 3 is mounted on a planar PCB. That is, the LED 3 is formed on a planar portion of the PCB, and the portion in which the LED 3 is formed and the electrode pads 2 connected with the wires 4 are on the same plane. The MCPCB 1 may be used as the PCB.
In the present invention, the second molding 7 is formed in a hemispheric shape. That is, an outer circumference of a contact surface between the second molding 7 and the MCPCB 1 is formed in a circular shape.
In particular, a maximum distance of the contact surface between the second molding 7 and the MCPCB 1, that is, a diameter of a circle formed of the outer circumference of the contact surface is 1.6-2.4 times larger than a maximum distance between the MCPCB 1 and the second molding 7, that is, a height of the second molding 7. In such a condition, the light efficiency may be maximized.
In other words, a contact surface between the first and second moldings 6 and 7 and the MCPCB 1 is formed in a circular shape, and a diameter of the circular contact surface is formed 1.6-2.4 times larger than the height of the second molding 7.
FIG. 4 is a view illustrating a first molding and a second molding of another shape in an LED package according to an embodiment of the present invention.
Referring to FIG. 4, the first molding 6 may be formed to contact the MCPCB 1 and the second molding 7 may be formed to contact only a surface of the first molding 6 without contacting the MCPCB 1.
In this case, a maximum distance of a contact surface between the first molding 6 and the MCPCB 1, that is, a diameter of a circle formed of an outer circumference of the contact surface is formed 1.6-2.4 times larger than a maximum distance between the MCPCB 1 and the second molding 7, that is, a height of the second molding 7.
In other words, the contact surface between the first molding 6 and the MCPCB 1 is formed in a circular shape, and a diameter of the circular contact surface is formed 1.6-2.4 times larger than the height of the second molding 7.
Meanwhile, a jig may be used to form the second molding 7 in a hemispheric shape having a height and a diameter in the ratio of 1:1.6-2.4, but a manufacturing method using a jig is complicated.
Therefore, in the present invention, the first and second moldings 6 and 7 are formed by dispensing silicone of different kinds, respectively.
Silicone having a high strength and an excellent interfacial adhesion may be used for the first molding 6 in order to protect the LED 3 and the wires 4, and silicone having an excellent adhesion with respect to the first molding 6 may be used as the second molding 7 in order to protect the first molding 6 against external impact.
The first molding 6 may be formed by dispensing a resin including siloxane and phenyl, and the second molding 7 may be formed by dispensing a resin including siloxane, platinum, and silica to the outside of the first molding 6.
The guide unit 5 may be selectively formed to prevent the resin from flowing down during the forming of the second molding 7 using a dispensing method.
The guide unit 5 may be formed of a nonconductive material in a predetermined shape, for example, a shape of a circular ring or a rectangular ring with a predetermined height on the electrode pads 2.
As described above, the LED package according to the present invention includes the LED 3 formed on the planar MCPCB 1 and the first and second moldings 6 and 7 formed in a hemispheric shape outside the LED 3 using a dispensing method.
In the present invention, when a material with a high refraction index (RI) is used in the first molding, compared to the second molding, for example, when a material with an RI of 1.51 is used in the first molding and a material with an RI of 1.46 is used in the second molding, the transmittance is improved and thus the light efficiency is improved. This is because the first molding serves as a buffer, improving the transmittance since an RI of air is 1. On the other hands, in a molding structure of the related art, although a material with an RI of 1.51 or 1.46 is used, internal reflection occurs a lot inside the molding, compared to the present invention, and thus the light efficiency decreases by approximately 10%.
Therefore, the light efficiency of the LED package may be maximized and a manufacturing method thereof is simple.
In particular, the present invention uses materials with an excellent adhesion with respect to each other for the first and second moldings 6 and 7 and thus may prevent a decrease in an adhesion between the first and second moldings 6 and 7 caused by heat generated from the LED 3.
Therefore, a physical stability of the LED is excellent.
Hereinafter, a method of forming an LED package according to the present invention will be described.
FIG. 3 is a flowchart illustrating a method of forming an LED package according to an embodiment of the present invention.
Conductive electrode pads 2 of a predetermined thickness are formed on an MCPCB 1 (S301). The electrode pads 2 are formed by plating a conductive metal material such as Ag, Au, and Cu to a predetermined thickness on the MCPCB 1 using electroplating and etching the metal material such that the electrode pads are spaced from each other by a predetermined distance as illustrated in FIG. 2.
Next, an LED 3 is mounted on the electrode pads 2. The LED 3 is connected with the electrode pads 2 through wires 4 (S302).
Here, the LED 3 is mounted and connected with the wires 4, and then a guide unit 5 of a shape of circular ring may be additionally formed around the LED 3 on the electrode pads 2.
A first molding 6 is formed on the LED 3 using a dispensing method (S303). Silicone having a high strength and a good interfacial adhesion may be used for the first molding 6.
Next, a second molding 7 is formed on the first molding 6 (S304). Silicone having an excellent adhesion with respect to the first molding 6 may be used for the second molding 7.
The present invention exemplarily illustrates the SMD type LED package, but is not limited thereto and may be applied to an LED package where an LED is formed in a reflective hole formed in an MCPCB.
According to the LED package of the present invention, since the first and second moldings are easily formed using a dispensing method, additional processes are not necessary. Also, adherence between the first and second moldings is improved to increase the physical stability.
It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention. Thus, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.

## Claims

1. A light emitting apparatus comprising:
a substrate, wherein an entire top surface of the substrate is substantially planar;
at least two metal layers on the substrate;
a light emitting device directly on one of the at least two metal layers, wherein the at least two metal layers are spaced from each other;
a guide unit on the substrate and around the light emitting device, wherein the guide unit includes an inner side surface, a flat outer side surface perpendicular to the top surface of the substrate, a top surface, and a bottom surface parallel to the top surface of the substrate; and
lenses including a first lens and a second lens on the substrate, wherein at least one of the lenses includes a convex shape and a portion of the at least one of the lenses is located higher than the top surface of the guide unit,
wherein the at least one of the lenses is in contact with the inner side surface of the guide unit and spaced from the top surface of the guide unit,
wherein the first lens is in contact with the at least two metal layers,
wherein the first lens contacts and surrounds the light emitting device,
wherein an entire top surface of the first lens contacts a bottom surface of the second lens,
wherein a thickness of a center portion of the second lens is greater than thicknesses of opposite side portions of the second lens, and
wherein the first lens and the second lens are formed of different materials.

2. The light emitting apparatus according to claim 1, wherein a cross-sectional view of the light emitting apparatus includes the guide unit, the first lens, and the light emitting device on a same horizontal plane.

3. The light emitting apparatus according to claim 1, wherein the first lens and the second lens are formed of silicone of different kinds, respectively.

4. The light emitting apparatus according to claim 1, wherein the at least two metal layers include at least one of Ag, Au, or Cu.

5. The light emitting apparatus according to claim 1, wherein the first lens is formed of a material with a higher refraction index than a refraction index of the second lens.

6. The light emitting apparatus according to claim 1, further comprising at least one wire electrically connecting the light emitting device to one of the at least two metal layers, and wherein the at least one wire is in contact with the first lens.

7. The light emitting apparatus according to claim 1,
wherein the at least one of the lenses cover the entire inner side surface of the guide unit,
wherein the inner side surface of the guide unit is perpendicular to the top surface of the substrate,
wherein the guide unit defines a diameter of the at least one of the lenses, and has a shape of circular ring,
wherein each of the at least two metal layers includes a first portion disposed outside of the guide unit, a second portion between the guide unit and the substrate, and a third portion disposed inside of the guide unit.

8. The light emitting apparatus according to claim 1, wherein the at least two metal layers reflect light emitted from the light emitting device.

9. The light emitting apparatus according to claim 1, wherein at least two wires are contacted with an upper surface of the light emitting device.

10. A light emitting apparatus comprising:
a substrate including a top surface and a bottom surface, both the top surface and the bottom surface being planar and parallel to each other;
a metal layer disposed on the substrate, a top surface of the metal layer being planar;
a light emitting device disposed on the metal layer;
a guide unit having an opening so as to surround the light emitting device, the guide unit including an outer side surface perpendicular to the top surface of the substrate, and an inner side surface parallel to the outer side surface;
a first optical member covering the light emitting device on the substrate; and
a second optical member disposed directly on the first optical member without a gap between the first optical member and the second optical member, wherein the first optical member and the second optical member are formed of different materials,
wherein the metal layer extends from the opening of the guide unit to beyond the guide unit so as to include a first portion disposed between the guide unit and the substrate, and a second portion disposed on the top surface of the substrate beyond the guide unit, and
wherein a maximum distance between a top surface of the first optical member and a top surface of the second optical member becomes shorter in going from a center of the first optical member and a center of the second optical member to opposite perimeters of the first optical member and the second optical member.

11. The light emitting apparatus according to claim 10, wherein one of the first optical member and the second optical member has a hemispheric shape.

12. The light emitting apparatus according to claim 11, wherein the hemispheric shape has a height and a diameter in a ratio of 1:1.6-2.4.

13. The light emitting apparatus according to claim 10, wherein the opening of the guide unit has a circular shape.

14. The light emitting apparatus according to claim 10, wherein an entire top surface of the first optical member contacts a bottom surface of the second optical member.

15. The light emitting apparatus according to claim 10, wherein the guide unit includes a planar bottom surface disposed on the top surface of the metal layer and a top surface parallel to the planar bottom surface.

16. The light emitting apparatus according to claim 10, wherein the inner side surface of the guide unit contacts an outer surface of the second optical member.

17. The light emitting apparatus according to claim 10, wherein the guide unit surrounds the first optical member.

18. The light emitting apparatus according to claim 10, wherein the guide unit surrounds the second optical member.

19. The light emitting apparatus according to claim 10, wherein a height of the guide unit is less than a height of at least one of the first optical member and the second optical member.

20. The light emitting apparatus according to claim 10, wherein the first optical member and the second optical member are formed of silicone of different kinds, respectively.