Patent Publication Number: US-2016225959-A1

Title: LED Packaging Structure And Method For Manufacturing The Same

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Application No. 62/112,053 filed on Feb. 4, 2015. 
    
    
     TECHNICAL FIELD 
     The present disclosure relates to light-emitting diode (LED) and, more particularly, to an LED package and a method for manufacturing the same. 
     BACKGROUND 
     Conventionally, to make the light emitted from a LED package have an uniform light-emitting area, a wavelength converting layer (which is usually a resin containing phosphor) is disposed above the LED chip so that the light emitted from the LED chip excite the phosphor in the resin to produce white light, thereby providing desired light sources for users. 
     To achieve the aforesaid objectives of providing white light and providing a uniform light-emitting area, a known process of manufacturing a LED package includes affixing a phosphor sheet to a top surface of an LED chip, molding with a resin around the LED chip along with the phosphor sheet, and curing the resin so that the LED chip along with the affixed phosphor sheet is surrounded by the first resin with a portion of the phosphor sheet is exposed (i.e., not fully covered by the resin). 
     However, when affixing the phosphor sheet to the top surface of the LED chip in LED package, the top surface of the LED chip is firstly fully dispensed with adhesive. Such that when the phosphor sheet is placed on and affixed to the top surface of the chip, the adhesive between the top surface of the LED chip along with the phosphor sheet will be pressed and be squeezed out, and thus inevitably smears side surfaces of the chip and the subsequent molding space. This may cause problems such as non-uniform light emission, an opaque periphery of the chip and a thinner resin layer, which lead to lower reliability and yield of the LED package. 
     Accordingly, providing an LED package and a method for manufacturing the same, which can overcome the non-uniform light emission problem caused by spillover of the resin in the manufacturing process, provide a more uniform light-emitting area and meanwhile improving the reliability and the process yield, as well as provide an LED package which can achieve the same effect without using the phosphor sheet, is needed. 
     SUMMARY 
     The present disclosure describes various implementations of an LED package and fabrication methods thereof. 
     In one aspect, the light emitted from an LED chip of the LED package may excite a phosphor sheet or a phosphor resin to generate desired white light and provide a uniform light-emitting area. 
     In another aspect, a phosphor sheet is well adhesive to the LED chip without adhesive spillover, thereby avoiding the contamination problem in the manufacturing process. 
     Yet in one aspect, a molded phosphor resin instead of a phosphor sheet is used as the material of a wavelength converting layer in an LED packages. 
     In one aspect, an LED package may include: a substrate, an LED chip disposed on the substrate, a phosphor sheet, a first resin, and an adhesive, wherein the phosphor sheet is affixed to an upper surface of the LED chip via the adhesive. 
     In some implementations, the first resin may be deposited on the substrate such that the LED chip along with the affixed phosphor sheet is surrounded by the first resin with a portion of the phosphor sheet being exposed. 
     In some implementations, when affixing the phosphor sheet to the LED chip with the adhesive, the adhesive may not extend over the upper surface of the LED chip. 
     In one aspect, an LED may include a substrate, an LED chip disposed on the substrate, a phosphor resin disposed on the substrate to cover the LED chip, and a first resin disposed on the substrate to surround the phosphor resin with a part of the phosphor resin being exposed. 
     In some implementations, the first resin may not be in contact with the LED chip. 
     In another aspect, an LED package may include a substrate, an LED chip disposed on the substrate, a phosphor coating covering the LED chip, a transparent resin disposed on the substrate to cover the LED chip and the phosphor coating, and a first resin disposed on the substrate to surround the transparent resin with a part of the transparent resin being exposed 
     In some implementations, the first resin may not be in contact with the LED chip. 
     In one aspect, a method of fabrication of an LED package may involve operations including the following: providing a substrate; bonding an LED chip onto the substrate; dispensing an adhesive to an upper surface of the LED chip to affix a phosphor sheet to the LED chip; and using a mold to apply pressure onto the phosphor sheet and filling a gap between the substrate and the mold with a first resin. When the mold applies the pressure to the phosphor sheet, the adhesive between the LED chip and the phosphor may not extend over the upper surface of the LED chip, and the first resin may cover the LED chip along with the phosphor sheet and may expose at least a part of the phosphor sheet. 
     In one aspect, a method of fabrication of an LED package may involve operations including the following: providing a substrate; bonding an LED chip onto the substrate; depositing a phosphor resin on the substrate to cover the LED chip; cutting the phosphor resin along the periphery of the LED chip; and further molding with a first resin on the substrate so that the first resin surrounds the periphery of the phosphor resin with at least a part of the phosphor resin being exposed and the first resin not being in contact with the LED chip. 
     In one aspect, a method of fabrication of an LED package may involve operations including the following: providing a substrate; bonding an LED chip and a Zener Diode chip adjacent to the LED chip onto the substrate; molding with a phosphor resin on the substrate to cover the LED chip and the Zener Diode chip; cutting the phosphor resin along the periphery of the LED chip and the periphery of the Zener Diode chip; and further molding with a first resin on the substrate so that the first resin surrounds the periphery of the phosphor resin with at least a part of the phosphor resin on the LED chip being exposed and the first resin being not in contact with the LED chip and the Zener Diode chip. 
     In one aspect, a method of fabrication of an LED package may involve operations including the following: providing a substrate; bonding an LED chip onto the substrate; spraying a phosphor coating on the LED chip; molding with a transparent resin on the substrate to cover the LED chip and the phosphor coating; cutting the transparent resin along the periphery of the LED chip; and further molding with a first resin on the substrate so that the first resin surrounds the periphery of the transparent resin with at least a part of the transparent resin being exposed and the first resin being not in contact with the LED chip. 
     In one aspect, a method of fabrication of an LED package may involve operations including the following: providing a substrate; bonding an LED chip and a Zener Diode chip adjacent to the LED chip onto the substrate; spraying a phosphor coating on the LED chip; molding with a transparent resin on the substrate to cover the LED chip and the Zener Diode chip; and cutting the transparent resin along the periphery of the LED chip and the periphery of the Zener Diode chip; and further molding with a first resin on the substrate so that the first resin surrounds the periphery of the transparent resin with at least a part of the transparent resin on the LED chip being exposed and the first resin being not in contact with the LED chip and the Zener Diode chip. 
     The foregoing summary is illustrative only and is not intended to be limiting in any way. That is, the foregoing summary is provided to introduce concepts, highlights, benefits and advantages of the novel and non-obvious techniques described herein. Select implementations are further described below in the detailed description. Thus, the foregoing summary is not intended to identify essential features of the claimed subject matter, nor is it intended for use in determining the scope of the claimed subject matter. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings are included to provide a further understanding of the disclosure, and are incorporated in and constitute a part of the present disclosure. The drawings illustrate implementations of the disclosure and, together with the description, serve to explain the principles of the disclosure. It is appreciable that the drawings are not necessarily in scale as some components may be shown to be out of proportion than the size in actual implementation in order to clearly illustrate the concept of the present disclosure. 
         FIG. 1  shows a top view of an LED package in accordance with a first implementation of the present disclosure. 
         FIG. 2  shows a cross-sectional view of a first aspect of the LED package of  FIG. 1 . 
         FIG. 2A  shows a partially schematic view of a phosphor sheet covering an LED chip in the LED package of  FIG. 2 . 
         FIG. 2B  shows a partially schematic view of another aspect of the phosphor sheet covering the LED chip in the LED package of  FIG. 2 . 
         FIG. 3  shows a cross-sectional view of a second aspect of the LED package of  FIG. 1 . 
         FIG. 4A  shows a top view of an LED package in accordance with a second implementation of the present disclosure. 
         FIG. 4B  shows a cross-sectional view of the LED package in accordance with the second implementation of the present disclosure. 
         FIG. 5A  shows a top view of an LED package in accordance with a third implementation of the present disclosure. 
         FIG. 5B  shows a cross-sectional view of the LED package in accordance with the third implementation of the present disclosure. 
         FIG. 6  shows a top view of an LED package in accordance with a fourth implementation of the present disclosure. 
         FIG. 6A  shows a cross-sectional view of a first aspect of the LED package of  FIG. 6 . 
         FIG. 6B  shows a cross-sectional view of a second aspect of the LED package of  FIG. 6 . 
         FIG. 6C  shows a cross-sectional view of a third aspect of the LED package of  FIG. 6 . 
         FIG. 7A  shows a top view of an LED package in accordance with a fifth implementation of the present disclosure. 
         FIG. 7B  shows a cross-sectional view of the LED package in accordance with the fifth implementation of the present disclosure. 
         FIG. 8  shows a top view of an LED package in accordance with a sixth implementation of the present disclosure. 
         FIG. 8A  shows a cross-sectional view of a first aspect of the LED package of  FIG. 8 . 
         FIG. 8B  shows a cross-sectional view of a second aspect of the LED package of  FIG. 8 . 
         FIG. 8C  shows a cross-sectional view of a third aspect of the LED package of  FIG. 8 . 
         FIG. 9  shows a process of fabricating an LED package in accordance with a first implementation of the present disclosure. 
         FIG. 10  shows a process of fabricating an LED package in accordance with a second implementation of the present disclosure. 
         FIG. 11A  shows a process of fabricating an LED package in accordance with a third implementation of the present disclosure. 
         FIG. 11B  shows a process of fabricating an LED package in accordance with yet another implementation of the present disclosure. 
         FIG. 12  shows a process of fabricating an LED package in accordance with yet another implementation of the present disclosure. 
         FIG. 13  shows a process of fabricating an LED package in accordance with yet another implementation of the present disclosure. 
         FIG. 14  shows a process of fabricating an LED package in accordance with yet another implementation of the present disclosure. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     An LED package disclosed in the present disclosure uses an LED chip (e.g., a blue-light LED or an ultraviolet (UV) LED) to emit a light (e.g., blue light or ultraviolet light) so that the emitted light excites a phosphor sheet or a phosphor resin to generate white light and to further render an uniform light-emitting area. 
     Firstly referring to  FIG. 1  and  FIG. 2 , which respectively shows a top view and a cross-sectional view of an LED package  100  in accordance with a first implementation of the present disclosure. As shown in  FIG. 1  and  FIG. 2 , the LED package  100  comprises a substrate  110 , an LED chip  120 , a phosphor sheet  130  and a first resin  140 . The LED chip  120  is disposed on the substrate  110  and has an upper surface  122 . The phosphor sheet  130  has a first area and through which the phosphor sheet  130  is affixed to the upper surface  122  of the LED chip  120 . The first resin  140  is disposed on the substrate  110  and surround the LED chip  120  along with the phosphor sheet  130  with at least a part of the phosphor sheet being exposed. 
     In the present implementation, the applying area of the adhesive for affixing the phosphor sheet  130  to the LED chip  120  is smaller than or equal to an upper surface of the LED chip  120 . 
     In the present implementation, the first area of the phosphor sheet  130  is slightly larger than the area of the upper surface  122  of the LED chip  120 . That is, the periphery of the phosphor sheet  130  extends beyond the upper surface  122  of the LED chip  120  to ensure that all lights emitted from the LED chip  120  emit through the phosphor sheet  130  and excite the phosphor particle contained within to generate white light. 
     It shall be appreciated that, the first resin  140  is made of an opaque material in accordance with the first implementation of the present invention. Therefore, when the first resin  140  is disposed on the substrate  110  and surrounds the LED chip  120  along with the periphery of the phosphor sheet  130  with at least one part of the phosphor sheet  130  being exposed, the white light is only emitted through the at least one exposed part of the phosphor sheet  130 . 
     Specifically, referring to  FIG. 1  and  FIG. 2 . In the LED package  100  in accordance with the first implementation, the substrate  110  is below the LED chip  120 , the phosphor sheet  130  is above the LED chip  120 , and the first resin  140  surrounds the periphery of the LED chip  120  and the periphery of the phosphor sheet  130 . 
     In other words, in the first implementation, the first resin  140  surrounding the periphery of the LED chip  120  and the periphery of the phosphor sheet  130  is not in contact with the upper surface  122  of the LED chip  120  that is used for emitting light. Thus, in the LED package  100  of the present implementation, the LED chip  120  is isolated from outside because it is covered by the substrate  110 , the phosphor sheet  130  and the first resin  140 . Moreover, the lights emitted from the LED chip  120  may only be emit through the phosphor sheet  130  and may be converted into the desired white light while phosphor particle contained in the phosphor sheet  130  is excited, and then the white light is emitted to outside. 
     Similarly, since the periphery of the phosphor sheet  130  is also covered by the opaque first resin  140 , the excited light may be intensively emitted towards the direction away from the phosphor sheet  130 . 
     It shall be particularly appreciated that, to achieve better bonding between the LED chip  120  and the phosphor sheet  130 , the first area of the phosphor sheet  130  may be slightly larger than the upper surface  122  of the LED chip  120  as shown in  FIG. 2A ; and preferably, part of the first area of the phosphor sheet  130  that extends beyond the upper surface  122  of the LED chip  120  is inclined inwards towards the LED chip  120  to prevent the phosphor sheet  130  from being damaged or separated from the LED chip  120  due to thermal expansion and contraction or the contraction stress generated during the curing of the first resin  140  in the manufacturing process. 
     On the other hand, when the first area of the phosphor sheet  130  is slightly larger than the upper surface  122  of the LED chip  120 , part of the first area of the phosphor sheet  130  that extends beyond the upper surface  122  of the LED chip  120  may also be a curved surface that is concave downwards as shown in  FIG. 2B , and this can also prevent the phosphor sheet  130  from being damaged or separated from the LED chip  120  due to thermal expansion and contraction or the contraction stress generated during the curing of the first resin  140  in the manufacturing process. 
     Moreover, such arrangement, by making the phosphor sheet  130  overly cover the LED chip  120 , can effectively ensure the lights of the LED chip  120  be emitted through the phosphor sheet  130  to generate desired white light no matter the lights are emitted from the upper surface  122  or from the side surfaces, thereby improving the illuminance and light uniformity of the LED package  100  of the present implementation. 
     Next, referring to  FIG. 3 , which is a cross-sectional view of a second aspect of the LED package  100  according to the first implementation of the present disclosure. In the aspect shown in  FIG. 3 , the LED package  100  comprises a substrate  110 , an LED chip  120 , a translucent sheet  150  and a first resin  140 . The LED chip  120  is disposed on the substrate  110 , and the translucent sheet  150  is disposed on the substrate  110  and covers the LED chip  120 . The first resin  140  is disposed on the substrate  110  and is adapted to surround a periphery of the translucent sheet  150  and expose at least a part of the translucent sheet  150 . The translucent sheet  150  has at least one phosphor deposition sub-layer  130 ′, and the first resin  140  is not in contact with the LED chip  120 . 
     Specifically, as shown in  FIG. 3 , the translucent sheet  150  is disposed on the upper surface of the LED chip  120 . Because the periphery of the translucent sheet  150  is covered by the opaque first resin  140 , the lights emitted from the LED chip  120  are emitted to the translucent sheet  150  and are converted to the desired white light after the phosphor deposition sub-layer  130 ′ in the translucent sheet  150  is excited, and then the white light is transmitted to the outside in a direction away from the phosphor sheet  120 . 
     Next, please refer to  FIG. 4A  and  FIG. 4B , which are respectively a top view and a cross-sectional view of a second implementation of an LED package according to the present disclosure. 
     As shown in  FIG. 4A  and  FIG. 4B , the second implementation of the LED package  100  of the present disclosure, which is similar to the aforesaid first implementation of  FIG. 1  and  FIG. 2 , may also comprise a substrate  110 , an LED chip  120 , a phosphor sheet  130  or a translucent sheet  150  having at least one phosphor deposition sub-layer  130 ′, and a first resin  140 . 
     The difference between the first implementation and the second implementation of the LED package  100  lies in that: the LED package  100  of the second implementation further comprises a Zener Diode chip  400  to additionally provide a voltage stabilizing function for the LED package  100 . 
     In detail, as shown in  FIG. 4A  and  FIG. 4B , the Zener Diode chip  400  is disposed on the substrate  110  and is parallel to the LED chip  120  in the second implementation. The Zener Diode chip  400  may be electrically connected with the substrate  110  through wire bonding, soldering, or eutectic or flip chip technology. Additionally, as shown in  FIG. 4B , because the Zener Diode chip  400  is covered by the first resin  140 , the Zener Diode chip  400  is isolated from the outside after the first resin  140  is provided. Moreover, because the first resin  140  is made of an opaque material, the Zener Diode chip  400  cannot be seen from the top view of  FIG. 4A . 
     A top view and a cross-sectional view of a third implementation of an LED package according to the present disclosure are as shown in  FIG. 5A  and  FIG. 5B . As shown in  FIG. 5A  and  FIG. 5B , an LED package  200  of the third implementation comprises a substrate  210 , an LED chip  220 , a phosphor resin  230  and a first resin  240 . The LED chip  220  is disposed on the substrate  210 , and the phosphor resin  230  is disposed on the substrate  210  and is adapted to cover the LED chip  220 . The first resin  240  is disposed on the substrate  210  and is adapted to surround a periphery of the phosphor resin  230  and expose at least a part of the phosphor resin  230  so that the first resin  240  is not in contact with the LED chip  220 . 
     In the present implementation, the phosphor resin  230  is a resin doped with a phosphor material or is directly made of a phosphor material. Because the phosphor resin  230  is disposed on the substrate  210  and covers the LED chip  220 , the LED chip  220  is isolated from the outside. 
     Furthermore, the first resin  240  is also made of an opaque material, and when the first resin  240  is disposed on the substrate  210  and is adapted to surround the periphery of the phosphor resin  230  and expose at least a part of the phosphor resin  230 , the first resin  240  is not in contact with the LED chip  220  because the LED chip  220  is isolated from the outside by the substrate  210  and the phosphor resin  230 . 
     In this way, because the LED chip  220  and the phosphor resin  230  are surrounded and covered by the opaque first resin  240 , the white light generated after the phosphor resin  230  is excited by the lights emitted from the LED chip  220  will be intensively emitted in the direction perpendicular to and away from the phosphor resin  230 . 
     It shall be appreciated that, in the third implementation, the phosphor resin  230  may have a rectangular cross section, a cross section that is narrower at the top thereof and wider at the bottom thereof or a trapezoid cross section to ensure centralization of the light-emitting surface and to improve the illuminance. 
     Thus, the LED package  200  of the third implementation has the following benefits: all the lights emitted from the LED chip  220  can be absorbed by the phosphor resin  230  to generate the desired white light; and a required height of the LED package  300  can be customized by directly changing the thickness of the phosphor resin  230  that is used, thereby simplifying the required processing procedures. 
     A top view and a cross-sectional view of a fourth implementation of an LED package according to the present disclosure are as shown in  FIG. 6  and  FIG. 6A . The LED package  200  of the fourth implementation is similar to that of the third implementation and may also comprise a substrate  210 , an LED chip  220 , a phosphor resin  230  and a first resin  240 . The difference between the LED package  200  of the fourth implementation and that of the third implementation lies in that: the LED package  200  of the fourth implementation further comprises a Zener Diode chip  400 . 
     In detail, in a first aspect of the fourth implementation as shown in  FIG. 6A , the Zener Diode chip  400  is disposed on the substrate  210  adjacent to the LED chip  220  and is covered by the phosphor resin  230 . Therefore, the Zener Diode chip  400  of the fourth implementation is also isolated from the outside because the Zener Diode chip  400  is also covered by the phosphor resin  230 . 
     It shall be particularly appreciated that, in the first aspect of the fourth implementation shown in  FIG. 6A , the phosphor resin  230  covering the Zener Diode chip  400  and the phosphor resin  230  covering the LED chip  220  communicate with each other. That is, the phosphor resin  230  disposed between the LED chip  220  and the Zener Diode chip  400  is continuous. In other words, in the cross-sectional view of  FIG. 6A , the phosphor resin  230  covers the substrate  210  between the LED chip  220  and the Zener Diode chip  400  so that the first resin  240  is not in contact with the substrate  210  between the LED chip  220  and the Zener Diode chip  400 . 
     A second aspect of the fourth implementation of the LED package according to the present disclosure is as shown in  FIG. 6B . The difference between the second aspect and the aforesaid first aspect of the fourth implementation lies in that: the phosphor resin  230  covering the Zener Diode chip  400  and the phosphor resin  230  covering the LED chip  220  do not communicate with each other. 
     That is, as shown in a cross-sectional view of  FIG. 6B , there is an gap between the phosphor resin  230  covering the LED chip  220  and the phosphor resin  230  covering the Zener Diode chip  400 . Thus, the first resin  240  can fill the gap and be in contact with the substrate  210  between the LED chip  220  and the Zener Diode chip  400 . 
     In this way, through the structural arrangement as shown in  FIG. 6B , the lights emitted from the LED chip  220  only propagate in the phosphor resin  230  surrounding the LED chip  220  and cannot travel to the phosphor resin  230  surrounding the Zener Diode chip  400 . Thereby, light loss can be avoided to further improve the illuminance. 
     A third aspect of the fourth implementation of the LED package according to the present disclosure is as shown in  FIG. 6C . The difference between the third aspect and the first aspect of the fourth implementation lies in that: the phosphor resin  230  covering the Zener Diode chip  400  and the phosphor resin  230  covering the LED chip  220  do not communicate with each other, and moreover, a recessed portion  212  is further formed on the substrate  210  between the phosphor resin  230  covering the Zener Diode chip  400  and the phosphor resin  230  covering the LED chip  220 , and the bottom of the recessed portion  212  may be in a chamfered form to actually avoid light loss and further improve the illuminance. 
       FIG. 7A  and  FIG. 7B  are respectively a top view and a cross-sectional view of a fifth implementation of an LED package according to the present disclosure. As shown in  FIG. 7A  and  FIG. 7B , an LED package  300  of the fifth implementation has a substrate  310 , an LED chip  320 , a phosphor coating  330 , a transparent resin  340  and a first resin  350 . The LED chip  320  is disposed on the substrate  310 , the phosphor coating  330  covers the LED chip  320 , and the transparent resin  340  is disposed on the substrate  310  and is adapted to cover the LED chip  320  and the phosphor coating  330 . The first resin  350  is disposed on the substrate  310  and is adapted to surround the periphery of the transparent resin  340  and expose at least a part of the transparent resin  340 , and the first resin  350  is not in contact with the LED chip  320 . 
     In detail, in the present implementation, the phosphor coating  330  is made of a highly volatile and transparent coating doped with a phosphor material or is directly made of a phosphor material, and the phosphor coating  330  is adapted to cover the surface of the LED chip  320 . That is, the phosphor coating  330  is in the form of a coating layer or a thin film, and it at least covers the upper surface of the LED chip  320 . 
     The transparent resin  340  is a resin of high transmittance and is disposed on the substrate  310  and adapted to cover the LED chip  320  and the phosphor coating  330 . Specifically, the transparent resin  340  covers the periphery and the upper surface of both the LED chip  320  and the phosphor coating  330  so that the LED chip  320  and the phosphor coating  330  are isolated from the outside. Thus, in the fifth implementation, the first resin  350  is not in contact with the LED chip  310 . 
     Moreover, the benefits of using the phosphor coating  330  and the transparent resin  340  are as follows: the possible damage to the phosphor sheet as in the prior art can be avoided by coating the phosphor coating  330  on the LED chip  320 , and a required height of the LED package  300  can be customized by controlling the thickness of the transparent resin  340 . 
     On the other hand, the transparent resin  340  may also have a rectangular cross section, a cross section that is narrower at the top thereof and wider at the bottom thereof or a trapezoid cross section to ensure centralization of the light-emitting surface and improve the illuminance. 
     It shall be appreciated that, when the phosphor coating  330  is coated on the LED chip  320  to cover the upper surface of the LED chip  320  in practice, the phosphor coating  330 , after being cured, is slightly collapsed to be attached on the surface of the LED chip  320  due to the action of gravity. 
     The difference between the LED package  300  of the fifth implementation and the LED package  100  of the first implementation lies in that: the LED package  300  of the fifth implementation uses the combination of the phosphor coating  330  and the transparent resin  340  instead of the phosphor sheet  130  comprised in the LED package  100  of the first implementation. 
       FIG. 8  and  FIG. 8A  are respectively a top view and a cross-sectional view of a sixth implementation of an LED package according to the present disclosure. The LED package  300  of the sixth implementation is similar to that of the fifth implementation, and it may also comprise a substrate  310 , an LED chip  320 , a phosphor coating  330 , a transparent resin  340  and a first resin  350 . The difference between the LED package  300  of the sixth implementation and that of the fifth implementation lies in that: the LED package  300  of the sixth implementation may further comprise a Zener Diode chip  400 . 
     In detail, in a first aspect of the sixth implementation as shown in  FIG. 8A , the Zener Diode chip  400  is disposed on the substrate  310 , and the Zener Diode chip  400  can also be covered by the transparent resin  340  because it is disposed adjacent to the LED chip  320 . 
     It shall be particularly appreciated that, in the first aspect of the sixth implementation shown in  FIG. 8A , a portion of the transparent resin  340  covering the Zener Diode chip  400  and another portion of the transparent resin  340  covering the LED chip  320  link together. That is, the transparent resin  340  disposed between the LED chip  320  and the Zener Diode chip  400  is continuous. In other words, in the cross-sectional view of  FIG. 8A , the transparent resin  340  covers the substrate  310  between the LED chip  320  and the Zener Diode chip  400  so that the first resin  350  is not in contact with the substrate  310  between the LED chip  320  and the Zener Diode chip  400 . 
     A second aspect of the sixth implementation of the LED package according to the present disclosure is as shown in  FIG. 8B . The difference between the second aspect and the aforesaid first aspect of the sixth implementation lies in that: a portion of the transparent resin  340  covering the Zener Diode chip  400  and another portion of the transparent resin  340  covering the LED chip  320  do not link together. 
     That is, as shown in a cross-sectional view of  FIG. 8B , there is a gap between the transparent resin  340  covering the LED chip  320  and the transparent resin  340  covering the Zener Diode chip  400 . Thus, the first resin  350  can fill the gap and be in contact with the substrate  310  between the LED chip  320  and the Zener Diode chip  400 . 
     In this way, through the structural arrangement as shown in  FIG. 8B , the lights emitted from the LED chip  320  only propagate in the transparent resin  340  surrounding the LED chip  320  and cannot travel to the transparent resin  340  surrounding the Zener Diode chip  400 . Thereby, light loss can be avoided to further improve the illuminance. 
     A third aspect of the sixth implementation of the LED package according to the present disclosure is as shown in  FIG. 8C . The difference between the third aspect and the aforesaid first aspect of the sixth implementation lies in that: a portion of the transparent resin  340  covering the Zener Diode chip  400  and another portion of the transparent resin  340  covering the LED chip  320  do not link together, and moreover, a recessed portion  312  is further formed on the substrate  310  between the transparent resin  340  covering the Zener Diode chip  400  and the transparent resin  340  covering the LED chip  320 , and the bottom of the recessed portion  312  may be in a chamfered form to surely prevent the lights emitted by the LED chip  320  from traveling to the Zener Diode chip  400  to cause light loss and to further improve the illuminance. 
     The methods of fabrication an LED package and the operations involved will be described hereinafter. 
       FIG. 9  shows a process of fabricating an LED package in accordance with a first implementation of the present disclosure. As shown in  FIG. 9 , the method for manufacturing the LED package  100  may comprise the following steps. 
     First, in step S 1 , a substrate  110  is provided. Next, in step S 2 , an LED chip  120  is disposed on the substrate  110  through adhesive, soldering, or die bonding. In step S 3 , a phosphor sheet  130  is affixed to an upper surface  122  of the LED chip  120 . An area of the affixed phosphor sheet  130  is larger than an area of the upper surface  122  of the LED chip  120  (and is approximately equal to an area of the substrate  110 ). Then, in step S 4 , the phosphor sheet  130  is cut so that the area of the phosphor sheet  130  finally is slightly larger than the area of the upper surface  122  of the LED chip  120 . Finally, in step S 5 , a first resin  140  is provided to cover the LED chip  120  along with the phosphor sheet  130  with at least a part of the phosphor sheet  130  being exposed. In this way, the LED package  100  as shown in  FIG. 2  can be correspondingly obtained. 
     It shall be appreciated that, after the step S 2 , a phosphor sheet  130  of which the area is slightly larger than the area of the upper surface  122  of the LED chip  120  can be directly affixed on the LED chip  120 , and thereby the step S 3  is omitted and the step S 4  is directly executed after the step S 2 . 
     Additionally in the step S 4 , when a pressure is applied to the phosphor sheet  130 , the phosphor sheet  130  may be disposed on the upper surface  122  of the LED chip  120  in such a way that the phosphor sheet  130  is inclined inwards towards the LED chip  120  (as shown in  FIG. 2A ) or a curved surface that is concave downwards is formed by part of the phosphor sheet  130  that extends beyond the upper surface  122  of the LED chip  120  (as shown in  FIG. 2B ) under the pressure. This prevents the phosphor sheet  130  from being damaged or separated from the LED chip  120  due to thermal expansion and contraction or the contraction stress generated during the curing of the first resin  140  in the subsequent manufacturing process. Meanwhile, this can ensure that the lights of the LED chip  120  can be emitted to the phosphor sheet  130  to generate the desired white light no matter the lights are emitted from the upper surface  122  or from the side surfaces of the LED chip  120 , thereby improving the illuminance and light uniformity of the LED package  100  of the present implementation. 
     Moreover, before the step S 5  is executed, a translucent sheet  150  may be disposed on the phosphor sheet  130 , and then a mold is used to apply a pressure to the translucent sheet  150 , and next the first resin  140  is provided to cover the aforesaid LED chip  120 , the phosphor sheet  130  and the translucent sheet  150  so that the LED package  100  can have the aforesaid structure as shown in  FIG. 3 . In other words, through the arrangement of the translucent sheet  150 , the overall height of the LED package  100  can be adjusted depending on different customized requirements. 
     On the other hand, in the process of the step S 5 , a mold (not shown) may be used to apply a pressure to the phosphor sheet  130 , and a gap formed between the mold and the substrate  110 /the phosphor sheet  130  is filled with the first resin  140 . In this way, after the mold is removed, the LED package  100  of the first implementation in this application is formed. Moreover, because the first resin  140  only covers the upper surface of the substrate  110 , the periphery of the LED chip  120  and the periphery of the phosphor periphery  130 , the first resin  140  does not shield the upper surface of the phosphor sheet  130 . 
     In mass production of the LED package  100  as shown in  FIG. 2 , the steps of  FIG. 9  may be adopted. First, a substrate  110  having a large area is provided, then a plurality of LED chips  120  are disposed on the substrate  110  in a matrix form, then a phosphor sheet  130  having an area approximately equal to the area of the substrate  110  is placed on the LED chips  120  and then cut into a plurality of small phosphor sheets  130 , the first resin  140  is provided so that the first resin  140  covers the LED chips  120  and the phosphor sheets  130 , and finally the overall structure is cut by a cutting tool into individual LED packages  100  as shown in  FIG. 2 . 
     Similar steps may also be adopted for mass production of the LED package  100  as shown in  FIG. 3 , and the only difference is a further step of disposing the translucent sheet  150 , so this will not be further described herein. 
       FIG. 10  shows a process of fabricating an LED package in accordance with a second implementation of the present disclosure. As shown in  FIG. 10 , the method for manufacturing the LED package  100  may comprise the following steps. 
     First, in step Si, a substrate  110  is provided. Next, in step S 2 , an LED chip  120  is disposed on the substrate  110  through adhesive, soldering, or die bonding. In step S 3 , a phosphor sheet  130  is affixed on an upper surface  122  of the LED chip  120 . An area of the affixed phosphor sheet  130  is larger than an area of the upper surface  122  of the LED chip  120  (and is approximately equal to an area of the substrate  110 ). Then, in step S 4 , the phosphor sheet  130  is cut so that the area of the phosphor sheet  130  is slightly larger than the area of the upper surface  122  of the LED chip  120 . In step S 5 , a Zener Diode chip  400  is disposed on the substrate  110 . Finally, in step S 6 , a first resin  140  is provided to cover the LED chip  120 , the phosphor sheet  130  and the Zener Diode chip  400 , and to expose at least a part of the phosphor sheet  130 . In this way, the LED package  100  as shown in  FIG. 4A  and  FIG. 4B  can be correspondingly obtained. 
     In other words, the steps of  FIG. 10  are generally the same as those of  FIG. 9 , the only difference therebetween lies in that: the steps of  FIG. 10  further include a step of disposing the Zener Diode chip  400  before providing the first resin  140 . In addition to the aforesaid difference, the steps of  FIG. 10  are the same as those of  FIG. 9 , and thus will not be further described herein. 
       FIG. 11A  is shows a process of fabricating an LED package in accordance with a third implementation of the present disclosure. As shown in  FIG. 11A , the method for manufacturing the LED package  200  may comprise the following steps. 
     First, in step S 1 , a substrate  210  is provided. Next, in step S 2 , an LED chip  220  is disposed on the substrate  210 . In step S 3 , a phosphor resin  230  is molded on the substrate  210  to cover the LED chip  220 . In step S 4 , the phosphor resin  230  is cut along the periphery of the LED chip  220 . In step S 5 , a first resin  240  is molded on the substrate  210  so that the first resin  240  covers the phosphor resin  230  and exposes at least a part of the phosphor resin  230 , and the first resin  240  is not in contact with the LED chip  220 . 
     In other words, after the step S 5  of  FIG. 11A  is finished, the LED package  200  as shown in  FIG. 5A  and  FIG. 5B  is obtained. 
     It shall be noted that, in the step S 4  of  FIG. 11A , a cutting tool (not shown) is used to cut the phosphor resin  230  from top to bottom along the periphery of the LED chip  220 , so the phosphor resin  230  still has side walls perpendicular to the substrate  210  after being cut in an ideal status. 
     However, as shown in  FIG. 11  B, the cutting angle of the cutting tool may also be controlled so that the phosphor resin  230  surrounding the LED chip  220  has a cross section that is narrower at the top thereof and wider at the bottom thereof after being cut. This effectively controls the light path of the lights emitted from the LED chip  220  as they excite the phosphor resin  230 , thereby avoid light loss and further improve the illuminance. 
       FIG. 12  shows a process of fabricating an LED package in accordance with a fourth implementation of the present disclosure. As shown in  FIG. 12 , the method for manufacturing the LED package  200  may comprise the following steps. 
     First, as shown in step S 1 , a substrate  210  is provided. As shown in step S 2 , an LED chip  220  and a Zener Diode chip  400  adjacent to the LED chip  220  are disposed on the substrate  210 . As shown in step S 3 , a phosphor resin  230  is molded on the substrate  210  to cover the LED chip  220  and the Zener Diode chip  400 . As shown in step S 4 , the phosphor resin  230  is cut along the periphery of the LED chip  220  and the periphery of the Zener Diode chip  400 . Finally, as shown in step S 5 , a first resin  240  is molded on the substrate  210  so that the first resin  240  surrounds the periphery of the phosphor resin  240  and exposes at least a part of the phosphor resin  240  on the LED chip  220 , and the first resin  240  is not in contact with the LED chip  220  and the Zener Diode chip  400 . 
     It shall be appreciated that, in the step S 4  of  FIG. 12 , when a cutting tool (not shown) is used to cut the phosphor resin  230  disposed between the LED chip  220  and the Zener Diode chip  400 , the cutting tool is not in contact with the substrate  210 . Therefore, similar to  FIG. 6A  described above, the phosphor resin  230  disposed between the LED chip  220  and the Zener Diode chip  400  is continuous. 
     As shown in the step S 5  of  FIG. 12 , preferably, both the phosphor resin  230  covering the LED chip  220  and the phosphor resin  230  covering the Zener Diode chip  400  have a cross section that is narrower at the top thereof and wider at the bottom thereof in the present implementation, so white light generated after the lights emitted from the LED chip  220  excite the phosphor resin  230  will be intensively emitted from the LED package  200 . 
     Additionally, when the cutting tool is controlled to cut the phosphor resin  230  in the step S 5  of  FIG. 12 , the cutting tool may also cut until it is in contact with the substrate  210  or even cut into the substrate  210 . Thus, the first resin  240  provided later can fill the space between the LED chip  220  and the Zener Diode chip  400  and make contact with the substrate  210  between the LED chip  220  and the Zener Diode chip  400 , thereby presenting an LED package in the aforesaid form shown in  FIG. 6B  and  FIG. 6C . 
     In this way, when the LED package  200  is in the form shown in  FIG. 6B  and  FIG. 6C , the lights emitted from the LED chip  220  only propagate in the phosphor resin  230  surrounding the LED chip  220  and cannot travel to the phosphor resin  230  surrounding the Zener Diode chip  400 . In other words, with such arrangement, light loss can be avoided to further improve the illuminance. 
     The aforesaid step S 4  of cutting the phosphor resin  230  with a cutting tool may further be done by cutting the phosphor resin  230  in one time and cutting the phosphor resin  230  in several times. That is, if the cutting tool used is wide, then the unnecessary phosphor resin  230  can be cut and removed in one time. If the cutting tool used is narrow, then the unnecessary phosphor resin  230  can be cut and removed in several times. 
     It shall be noted that, even if the surface of the phosphor resin  230  above the Zener Diode chip  400  becomes serrated or wavy instead of being a flat surface shown in the step S 4  in  FIG. 12  when the phosphor resin  230  is cut and removed in several times, it still falls within the scope of the technical features claimed in this application. 
       FIG. 13  is a schematic view of a method and steps thereof for manufacturing the fifth implementation of the LED package according to the present disclosure. As shown in  FIG. 13 , the method for manufacturing the LED package  300  may comprise the following steps. 
     First, as shown in step S 1 , a substrate  310  is provided. As shown in step S 2 , an LED chip  320  is disposed on the substrate  310 . As shown in step S 3 , a phosphor coating  330  is coated on the LED chip  320 . As shown in step S 4 , a transparent resin  340  is molded on the substrate  310  to cover the LED chip  320  and the phosphor coating  330 . As shown in step S 5 , the transparent resin  340  is cut along the periphery of the LED chip  320 . Finally, as shown in step S 6 , a first resin  350  is molded on the substrate  310  so that the first resin  350  surrounds the periphery of the transparent resin  340  and exposes at least a part of the transparent resin  340 , and the first resin  350  is not in contact with the LED chip  320 . 
     Therefore, similar to the description of the fifth implementation shown in  FIG. 7A  and  FIG. 7B , the transparent resin  340  is a resin of high transmittance, so the LED chip  320  and the phosphor coating  330  are all isolated from outside and the first resin  350  is not in contact with the LED chip  310  when the transparent resin  340  is disposed on the substrate  310  and covers the LED chip  320  and the phosphor coating  330 . Moreover, a required height of the LED package  300  can also be customized by directly changing the thickness of the transparent resin  340 . 
       FIG. 14  is a schematic view of a method and steps thereof for manufacturing the sixth implementation of the LED package according to the present disclosure. As shown in  FIG. 14 , the method for manufacturing the LED package  300  may comprise the following steps. 
     First, as shown in step S 1 , a substrate  310  is provided. As shown in step S 2 , an LED chip  320  and a Zener Diode chip  400  adjacent to the LED chip  320  are disposed on the substrate  310 . As shown in step S 3 , a phosphor coating  330  is coated on the LED chip  320 . As shown in step S 4 , a transparent resin  340  is molded on the substrate  310  to cover the LED chip  320  and the Zener Diode chip  400 . As shown in step S 5 , the transparent resin  340  is cut along the periphery of the LED chip  310  and the periphery of the Zener Diode chip  400 . Finally, as shown in step S 6 , a first resin  350  is molded on the substrate  310  so that the first resin  350  surrounds the periphery of the transparent resin  340  and exposes at least a part of the transparent resin  340  on the LED chip  320 , and the first resin  350  is not in contact with the LED chip  320  and the Zener Diode chip  400 . 
     Therefore, similar to the description of the sixth implementation shown in  FIG. 8  and  FIG. 8A , the transparent resin  340  is a resin of high transmittance, so the LED chip  320 , the Zener Diode chip  400  and the phosphor coating  330  are all isolated from the outside and the first resin  350  is not in contact with the LED chip  310  and the Zener Diode chip  400  when the transparent resin  340  is disposed on the substrate  310  and covers the LED chip  320 , the Zener Diode chip  400  and the phosphor coating  330 . Meanwhile, a required height of the LED package  300  can also be customized by directly changing the thickness of the transparent resin  340 . 
     Additionally, similar to  FIG. 12 , when the cutting tool is controlled to cut the transparent resin  340  in the step S 5  of  FIG. 13 , the cutting tool may also cut until it is in contact with the substrate  310  or even cut into the substrate  310 . Thus, the first resin  350  provided later can fill the space between the LED chip  320  and the Zener Diode chip  400  and be in contact with the substrate  310  between the LED chip  320  and the Zener Diode chip  400 , thereby presenting an LED package in the aforesaid form shown in  FIG. 8B  and  FIG. 8C . 
     In this way, when the LED package is in the form as shown in  FIG. 8B  and  FIG. 8C , the lights emitted from the LED chip  320  only propagate in the transparent resin  340  surrounding the LED chip  320  and cannot travel to the transparent resin  340  surrounding the Zener Diode chip  400 . In other words, with such arrangement, light loss can be avoided to further improve the illuminance. 
     According to the above descriptions, all the LED packages disclosed in the implementations of the present disclosure can be produced by machines required in the current processes. Meanwhile, the LED packages can also provide a more uniform light-emitting area, prevent the phosphor sheet from being damaged or separated from the LED chip, improve the reliability of products and provide better protection for the LED chip and the Zener Diode chip. 
     Additional Notes 
     Implementations of the present disclosure are not limited to those described herein. The actual design and implementation of each component of the LED package in accordance with the present disclosure may vary from the implementations described herein. Those ordinarily skilled in the art may make various deviations and improvements based on the disclosed implementations, and such deviations and improvements are still within the scope of the present disclosure. Accordingly, the scope of protection of a patent issued from the present disclosure is determined by the claims as follows. 
     In the above description of exemplary implementations, for purposes of explanation, specific numbers, materials configurations, and other details are set forth in order to better explain the present disclosure, as claimed. However, it will be apparent to one skilled in the art that the claimed subject matter may be practiced using different details than the exemplary ones described herein. In other instances, well-known features are omitted or simplified to clarify the description of the exemplary implementations. 
     Moreover, the word “exemplary” is used herein to mean serving as an example, instance, or illustration. Any aspect or design described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other aspects or designs. Rather, use of the word exemplary is intended to present concepts and techniques in a concrete fashion. The term “techniques,” for instance, may refer to one or more devices, apparatuses, systems, methods, articles of manufacture, and/or computer-readable instructions as indicated by the context described herein. 
     As used in this application, the term “or” is intended to mean an inclusive “or” rather than an exclusive “or.” That is, unless specified otherwise or clear from context, “X employs A or B” is intended to mean any of the natural inclusive permutations. That is, if X employs A; X employs B; or X employs both A and B, then “X employs A or B” is satisfied under any of the foregoing instances. In addition, the articles “a” and “an” as used in this application and the appended claims should generally be construed to mean “one or more,” unless specified otherwise or clear from context to be directed to a singular form. 
     For the purposes of this disclosure and the claims that follow, the terms “coupled” and “connected” may have been used to describe how various elements interface. Such described interfacing of various elements may be either direct or indirect.