Abstract:
A method for manufacturing a light emitting diode (LED) package, the method includes providing an LED chip and forming electrodes on a top surface of the LED chip; forming a first electric insulation layer on the top surface of the LED chip, the first electric insulation layer adapted to enclose the electrodes therein; etching the first electric insulation layer to define a plurality of second through holes; forming a substrate on a top surface of the first electric insulation layer, the substrate adapted to fill in the plurality of second through holes, the substrate directly contacting the electrodes; dividing the substrate into a plurality of spaced heat dissipation parts; and forming a packaging layer on a bottom surface of the substrate, the packaging layer adapted to enclose the LED chip therein.

Description:
FIELD 
     The subject matter herein generally relates to a method for manufacturing a light emitting diode (LED) package with a proved heat dissipation efficiency. 
     BACKGROUND 
     A typical LED package includes an LED chip and a packaging layer enclosing the LED chip therein. When the LED chip is acted to emit, a plurality of heat generated from the LED chip is accumulated in the packaging layer. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Implementations of the present technology will now be described, by way of example only, with reference to the attached figures. 
         FIG. 1  is a flow chart of a method for manufacturing an LED package in accordance with an exemplary embodiment of the present disclosure. 
         FIGS. 2-5  are diagrammatic views showing a step of forming electrodes on a top surface of an LED chip of the method for manufacturing the LED package. 
         FIG. 6  is diagrammatic view showing a step of forming a first electric insulation layer on the top surface of the LED chip. 
         FIG. 7-8  are diagrammatic views showing a step of etching the first electric insulation layer to define two second through holes to expose the electrodes from the first electric insulation layer. 
         FIG. 9  is diagrammatic view showing a step of forming a substrate on the top surface of the first electric insulation layer. 
         FIGS. 10-13  are diagrammatic views showing a step of dividing the substrate into two spaced heat dissipation parts. 
         FIG. 14  is a cross-sectional view of the LED package. 
     
    
    
     DETAILED DESCRIPTION 
     It will be appreciated that for simplicity and clarity of illustration, where appropriate, reference numerals have been repeated among the different figures to indicate corresponding or analogous elements. In addition, numerous specific details are set forth in order to provide a thorough understanding of the embodiments described herein. However, it will be understood by those of ordinary skill in the art that the embodiments described herein can be practiced without these specific details. In other instances, methods, procedures and components have not been described in detail so as not to obscure the related relevant feature being described. Also, the description is not to be considered as limiting the scope of the embodiments described herein. The drawings are not necessarily to scale and the proportions of certain parts may be exaggerated to better illustrate details and features of the present disclosure. 
     Several definitions that apply throughout this disclosure will now be presented. 
     The term “coupled” is defined as connected, whether directly or indirectly through intervening components, and is not necessarily limited to physical connections. The connection can be such that the objects are permanently connected or releasably connected. The term “comprising,” when utilized, means “including, but not necessarily limited to”; it specifically indicates open-ended inclusion or membership in the so-described combination, group, series and the like. 
     Referring to  FIG. 1 , a flowchart is presented in accordance with an example embodiment which is being thus illustrated. The example method  200  is provided by way of example, as there are a variety of ways to carry out the method. The method  200  described below can be carried out using the configurations illustrated in  FIGS. 2-13 , for example, and various elements of these figures are referenced in explaining example method  200 . Each block shown in  FIG. 1  represents one or more processes, methods or subroutines, carried out in the exemplary method  200 . Furthermore, the illustrated order of blocks is by example only and the order of the blocks can change according to the present disclosure. Additional blocks may be added or fewer blocks may be utilized, without departing from this disclosure. The exemplary method  200  can begin at block  201 . 
     At block  201 , provides an LED chip  10  and forms electrodes  20  on a top surface of the LED chip  10 . 
     Referring to  FIG. 2 , when the LED chip  10  is provided, a first photoresist layer  11  is formed on the top surface of the LED chip  10 . In this embodiment, the LED chip  10  is an UV LED chip. 
     Referring to  FIG. 3 , opposite ends of the first photoresist layer  11  is etched by photolithography etching to define two first through holes  13  in the first photoresist layer  11 . The first through holes  13  are spaced from each other and a part of the top surface of the LED chip  10  are exposed therefrom. 
     Referring to  FIG. 4 , a metallic film  15  is formed on a top surface of the first photoresist layer  11  and fills in the first through holes  13  by plating or sputter. 
     Referring to  FIG. 5 , the metallic film  15  and the first photoresist layer  11  are removed from the LED chip  10  by organic solvent except a part thereof filled in the first through holes  13 . The remained part of metallic film  15  forms the electrodes  20 . In this embodiment, a material of the electrode  20  is selected from nickel, copper, brass, bronze or an alloy thereof. 
     At block  202 , forms a first electric insulation layer  30  on the top surface of the LED chip  10  which encloses the electrodes  20  therein. 
     Referring to  FIG. 6 , in this embodiment, the first electric insulation layer  30  is formed by chemical vapor deposition. A material of the first electric insulation layer  30  is selected from silicon dioxide, silicon nitride, aluminum oxide, aluminum nitride and so on. A periphery of the first electric insulation layer  30  is coplanar with a periphery of the LED chip  10 . 
     At block  203 , etches the first electric insulation layer  30  to define two second through holes to expose the electrodes  20  therefrom. 
     Referring to  FIG. 7 , to carry out the above step, a second photoresist layer  31  is formed on the top surface of the first electric insulation layer  30  and opposite ends of the second photoresist layer  31  are etched to define two through holes therein and then the first electric insulation layer  30  is etched along the through holes of the second photoresist layer  31  from top to bottom until the top surfaces of the electrodes  20  exposed. Thus, two spaced second through holes  33  are defined in the first electric insulation layer  30 . Referring to  FIG. 8 , the second photoresist layer  31  is removed. The electrodes  20  are below the second through holes  33  and aligned with the second through holes  33 . A size of a bottom end of the second through hole  33  is the same that of a top end of the electrode  20 . 
     At block  204 , forms a substrate  40  on the top surface of the first electric insulation layer  30  which fills in the second through holes  33  to directly contact the electrodes  20 . 
     Referring to  FIG. 9 , the substrate  40  is formed by plating. A material of the substrate  40  is selected from nickel, copper or alloy thereof. A thickness of the substrate  40  is less than 50 micron. A top end of the first electric insulation layer  30  is received in the substrate  40 . A width of the substrate  40  is larger than that of the LED chip  10 . The LED chip  10  is below the substrate  40  and aligned with a central portion of the substrate  40 . The substrate  40  has an improved heat dissipation efficiency. 
     At block  205 , divides the substrate  40  into two spaced heat dissipation parts  41 . 
     Referring to  FIG. 10 , in this process, forms a third photoresist layer  43  on a top surface of the substrate  20  and etches a central portion of the third photoresist layer  43  to define a first channel  45  in the third photoresist layer  43 . The first channel  45  is a through hole and a part of the top surface of the substrate  40  exposed therefrom. 
     Referring to  FIG. 11 , the substrate  40  is etched along the first channel  45  from top to bottom until the top surface of the first electric insulation layer  30  exposed, then the third photoresist layer  43  is removed. In this state, a second channel  47  is defined in the substrate  40 . The second channel  47  extends through the substrate  40  from top to bottom to divide the substrate  40  into the two spaced heat dissipation parts  41 . 
     Referring to  FIG. 12 , a second electric insulation layer  50  is formed in the second channel  47  to ensure the two heat dissipation parts  41  electric insulating from each other. The second insulation layer  50  includes a first insulation portion  51  filling the second channel  47  and a second insulation portion  53  covering top surfaces of the heat dissipation parts  41 . Referring to  FIG. 13 , the second insulation portion  53  then is removed to expose the top surfaces of the heat dissipation parts  41 . 
     At block  206 , forms a packaging layer  60  on a bottom surface of the substrate  40  which encloses the LED chip  10  therein. 
     Referring to  FIG. 14 , the packaging layer  60  is made of glue and encloses the LED chip  10  and a bottom end of the first electric insulation layer  30  therein. The glue is a pure optical encapsulant material or a mixture mixed by a pure optical encapsulant material and phosphor powder. 
     In this state, the LED packaging is manufactured completely. The LED package includes the LED chip  10 , the first electric insulation layer  30  formed on a side of the LED chip  10 , the electrodes  20  extending through the first electric insulation layer  30  and directly formed on the LED chip, the spaced heat dissipation parts  41  and the packaging layer  60 . 
     In this disclosure, the heat dissipation parts  41  expose from the packaging layer  60  and has improved heat dissipation efficiency, heat generated from the LED chip  10  may be dissipated directly and efficiently. The thickness of the first electric insulation layer  30  is less than 20 micron and has good heat conductive efficiency. Therefore, the first electric insulation layer  30  may transmits the heat of the LED chip  10  to the heat dissipation parts  41  quickly. 
     The embodiments shown and described above are only examples. Many details are often found in the art such as the other features of an LED package manufacturing method. Therefore, many such details are neither shown nor described. Even though numerous characteristics and advantages of the present technology have been set forth in the foregoing description, together with details of the structure and function of the present disclosure, the disclosure is illustrative only, and changes may be made in the detail, especially in matters of shape, size and arrangement of the parts within the principles of the present disclosure up to, and including the full extent established by the broad general meaning the terms used in the claims. It will therefore be appreciated that the embodiments described above may be modified within the scope of the claims.