Source: https://patents.google.com/patent/JP4989614B2/en
Timestamp: 2020-01-18 10:37:04
Document Index: 705674166

Matched Legal Cases: ['art 15', 'art 15', 'art 15', 'art 15', 'art 15', 'art 15', 'art 15', 'art 112', 'art 112', 'art 130', 'art 112', 'art 112', 'art 112', 'art 112', 'art 112', 'art 112', 'art 112', 'art 112', 'art 112', 'art 112', 'art 145', 'art 112', 'art 114', 'art 131']

JP4989614B2 - High power LED package manufacturing method - Google Patents
High power LED package manufacturing method Download PDF
JP4989614B2
JP4989614B2 JP2008302920A JP2008302920A JP4989614B2 JP 4989614 B2 JP4989614 B2 JP 4989614B2 JP 2008302920 A JP2008302920 A JP 2008302920A JP 2008302920 A JP2008302920 A JP 2008302920A JP 4989614 B2 JP4989614 B2 JP 4989614B2
JP2008302920A
JP2009164583A (en
ク キム、イル
ヨー コ、クン
ホアン チョイ、スン
2007-12-28 Priority to KR20070140549 priority Critical
2007-12-28 Priority to KR10-2007-0140549 priority
2008-10-02 Priority to KR10-2008-0097213 priority
2008-10-02 Priority to KR1020080097213A priority patent/KR20090072941A/en
2008-11-27 Application filed by サムソン エルイーディー カンパニーリミテッド． filed Critical サムソン エルイーディー カンパニーリミテッド．
2009-07-23 Publication of JP2009164583A publication Critical patent/JP2009164583A/en
2012-08-01 Publication of JP4989614B2 publication Critical patent/JP4989614B2/en
There is provided a high power LED package and a method of manufacturing the same. The method includes: forming at least one chip mounting part and at least one through hole in a metal plate; forming an insulating layer of a predetermined thickness on an entire outer surface of the metal plate; forming an electrode part to be electrically connected to a light emitting chip mounted on the chip mounting part; and cutting the metal plate along a trimming line to separate the package. The LED package is free from thermal impact resulting from different thermal coefficients among components, thus ensuring stable heat radiation characteristics in a high temperature atmosphere. Also, the LED package is minimized in optical loss to improve optical characteristics. In addition, the LED package is simplified in a manufacturing and assembly process and thus can be manufactured in mass production at a lower cost.
The present invention relates to a method of producing a high output LED package.
Generally, a light emitting diode (LED) is a semiconductor element that emits light when an electric current flows, and changes electrical energy into light energy by a PN junction diode made of a GaAs or GaN optical semiconductor.
The region of light emitted from such LEDs ranges from red (630 nm to 700 nm) to blue-violet (400 nm), including blue, green and white, and LEDs are existing light sources such as incandescent bulbs and fluorescent lamps. Compared to the above, it has advantages such as low power consumption, high efficiency, and long operating life, so that the demand continues to increase.
Recently, the application range of LEDs has gradually expanded from small lighting of mobile terminals to indoor / outdoor general lighting, automotive lighting, and backlights for large LCDs (Liquid Crystal Display).
As a result, the power applied to the light-emitting chip of the light-emitting source increases in proportion to the intensity of light generated when a current is applied. It is common to employ a heat dissipation structure so as to prevent heat from being heated.
FIG. 1A is a cross-sectional perspective view of the center of a body of a conventional high-power LED package, and FIG. 1B is a cross-sectional view of the conventional high-power LED package assembled on a substrate. As illustrated, the package 10 includes a light-emitting chip 11 serving as a light-emitting source and a heat radiator 12 that mounts the light-emitting chip 11 in the center of the upper surface.
The light emitting chip 11 is electrically connected to a plurality of lead frames 14 via a plurality of metal wires 13 so as to be connected to an external power source and to be applied with current.
The heat radiating body 12 is a means for releasing and cooling the heat generated when the light emitting chip 11 emits light, and is mounted on the substrate 19 through an adhesive means 12a made of a material having excellent heat conductivity.
The lead frame 14 is provided integrally with the mold part 15, the heat radiator 12 is inserted into an assembly hole 15 a formed in the center of the body of the mold part 15, and the mold part 15 is connected to the wire 13. One end of the lead frame 14 is exposed so that wire bonding is performed, and the other end of the lead frame 14 is electrically connected to a pattern circuit 19a printed on the substrate 19 through a pad 14a.
The upper surface of the mold part 15 is provided with a lens 16 for widely diverging light generated when the light emitting chip 11 emits light to the outside, and in the space between the mold part 15 and the lens 16 the light emitting chip 11 and Filler 17 made of a transparent silicon resin is filled so that the emitted light is projected as it is while protecting the wire 13.
However, in the conventional LED package 10 having such a structure, the mold part 15 made of a polymer material may deteriorate in a high temperature environment to deteriorate the thermal characteristics, and a large heat between the lead frame 14 and the mold part 15 may occur. There is a risk of damage due to repeated thermal shock due to the difference in expansion coefficient.
In addition, when the mold portion 15 is injection molded, one end of the lead frame 14 is exposed to the outside, and at the same time, an assembly hole 15a into which the heat radiating body 12 is inserted must be formed in the center of the body, so that a precise mold is used. Therefore, the injection process and the assembly process are complicated, and the manufacturing cost is increased.
Accordingly, the present invention has been devised to solve the above-mentioned problems, and its purpose is to prevent thermal shock due to the difference in thermal expansion coefficient between components and to prevent stable heat dissipation in a high temperature environment. Provided is a high-power LED package that can improve optical characteristics by minimizing optical loss, simplify the manufacturing process and assembly process, enable mass production, and reduce the manufacturing cost, and its manufacturing method There is to do.
As a specific means for achieving the above object, the present invention includes a step of forming at least one chip mounting portion and at least one through hole in the metal plate, and a constant amount on the entire outer surface of the metal plate. A method of manufacturing a high-power LED package, comprising: forming an insulating layer having a thickness; and forming an electrode portion electrically connected to a light emitting chip mounted on the chip mounting portion.
Preferably, the step of forming the chip mounting portion and the through hole is lower than the chip mounting portion after forming the chip mounting portion having a certain height on the upper surface of the metal plate by chemical etching or mechanical polishing process. A through hole is formed in the upper bottom surface of the metal plate.
Preferably, step, after passing through a through hole on the upper surface of the metal plate, a certain height by chemical etching or mechanical polishing the top surface of the metal plate forming the through hole and the chip mounting portion The chip mounting portion is formed.
Preferably, the step of forming the chip mounting portion and the through hole is higher than the chip mounting portion after forming the chip mounting portion of a certain depth on the upper surface of the metal plate by chemical etching or mechanical polishing process. A through hole is formed in the upper surface of the metal plate.
Preferably, the step of forming a through-hole and the chip mounting portion, after passing through a through hole on the upper surface of the metal plate, fixed by chemical etching or mechanical polishing the top surface of the metal plate depth The chip mounting portion is formed.
Preferably, the step of forming the chip mounting portion and the through hole forms the chip mounting portion on the upper surface of the metal plate on which the through hole is formed.
Preferably, in the step of forming the chip mounting portion and the through hole , a trench having a certain depth is formed on the upper surface of the metal plate by chemical etching or mechanical polishing, and the trench is formed as an outer peripheral surface. After the chip mounting portion to be formed is formed, a through hole is formed through the upper surface of the metal plate.
Preferably, the step of forming a through-hole and the chip mounting portion, after passing through a through hole on the upper surface of the metal plate, fixed by chemical etching or mechanical polishing the top surface of the metal plate depth A chip mounting portion having the trench as an outer peripheral surface is formed.
Preferably, the metal plate is made of a metal material that can be anodized.
More preferably, the metal plate is made of any one of aluminum, aluminum alloy, magnesium (Mg), magnesium alloy (Mg Alloy), titanium (Ti), and titanium alloy (Ti Alloy).
Preferably, the insulating layer is formed by any one of an anodic oxidation method, PEO (Plasma Electrolyte Oxidation), and a dry oxidation method.
Preferably, the insulating layer is made of any one of Al2O3, TiO2, and MgO.
Preferably, the step of forming the electrode portion includes a step of filling or applying a conductive material to a through hole in which the insulating layer is applied to an inner peripheral surface to form a conductive via hole, and an external exposure from the insulating layer. Forming an external electrode connected and connected to the upper and lower ends of the conductive via hole; and electrically connecting a light emitting chip mounted on the chip mounting portion to the external electrode.
Preferably, the step of forming the electrode portion includes forming at least one metal layer on the entire outer surface of the insulating layer and simultaneously forming a through-type via hole, and removing a portion of the metal layer to Forming an external electrode connected to the upper and lower ends of the conductive via hole, and electrically connecting a light emitting chip mounted on the chip mounting portion to the external electrode.
More preferably, the step of electrically connecting the light emitting chip and the external electrode includes the light emitting chip mounted on a chip mounting portion formed to protrude from the upper surface of the metal plate at a certain height and the metal wire. Wire bonding the external electrode.
More preferably, the step of electrically connecting the light emitting chip and the external electrode may be performed through the light emitting chip and the metal wire mounted on the chip mounting portion that is recessed at a certain depth on the upper surface of the metal plate. Wire bonding the external electrode.
More preferably, in the step of electrically connecting the light emitting chip and the external electrode, the light emitting chip is flip-chip bonded to the external electrode extended to the chip mounting portion.
More preferably, the step of electrically connecting the light emitting chip and the external electrode includes: a light emitting chip mounted on a chip mounting portion having an outer peripheral surface of a trench recessed to a predetermined depth on the upper surface of the metal plate; The external electrode is wire-bonded through a metal wire.
More preferably, the external electrode is formed by any one of a process of printing and baking a conductive paste, a process of metallizing and then plating the surface of the insulating layer, and a vacuum deposition process.
Preferably, the method further includes a step of providing a sealing material containing a phosphor so as to cover the light emitting chip on an upper surface of the chip mounting portion.
More preferably, the step of providing the sealing material is transparent so as to protect the light emitting chip, the sealing material covering the light emitting chip, and a part of the electrode part electrically connected to the light emitting chip from the external environment. The method further includes providing a lens portion or a mold portion made of a material.
Preferably, the method further includes a step of providing a lens part or a mold part made of a transparent material on the upper surface of the metal plate to protect the light emitting chip from the external environment.
Preferably, the method further includes separating the package by cutting the metal plate along a cutting line.
More preferably, the step of cutting the metal plate is performed along a cutting line passing between the conductive via hole and another conductive via hole adjacent thereto.
More preferably, the step of cutting the metal plate is performed along a cutting line passing through the center of the conductive via hole formed between the chip mounting portion and another chip mounting portion adjacent thereto.
Further, the present invention provides a chip mounting portion on which at least one light emitting chip is mounted, a heat dissipating body provided with at least one conductive via hole, an insulating layer provided at a constant thickness on the outer surface of the heat dissipating body, Provided is a high-power LED package including a conductive via hole and an electrode portion that electrically connects the light emitting chip.
Preferably, the radiator is made of a metal material that can be anodized.
More preferably, the radiator is made of any one of aluminum, aluminum alloy, magnesium (Mg), magnesium alloy (Mg Alloy), titanium (Ti), and titanium alloy (Ti Alloy).
Preferably, the chip mounting part is provided with a protruding type that is formed to protrude from the upper surface of the heat radiator at a certain height, or is provided with a depressed type that is formed to be depressed from the upper surface of the heat radiator with a certain depth. Or a substrate type provided on the upper surface of the radiator, or a trench type provided on the upper surface of the radiator by a trench recessed from the upper surface of the radiator to a certain depth. Provided.
Preferably, the insulating layer is provided at a constant thickness on the outer surface of the radiator by any one of an anodic oxidation method, PEO (Plasma Electrolyte Oxidation), and a dry oxidation method.
Preferably, the electrode portion is connected and connected to a conductive via hole formed by filling or applying a conductive material to a through hole in which the insulating layer is applied to an inner peripheral surface, and an upper end and a lower end of the conductive via hole, respectively. As described above, an external electrode provided on the insulating layer and a metal wire for wire bonding between the light emitting chip and the external electrode are included.
Preferably, the electrode portion is connected and connected to a conductive via hole formed by filling or applying a conductive material to a through hole in which the insulating layer is applied to an inner peripheral surface, and an upper end and a lower end of the conductive via hole, respectively. And an external electrode provided on the insulating layer, and a solder ball for flip chip bonding between the light emitting chip and the external electrode.
Preferably, the electrode portion is connected and connected to a through-type conductive via hole formed by applying a metal layer to a through- hole in which the insulating layer is applied to an inner peripheral surface, and an upper end and a lower end of the conductive via hole, respectively. An external electrode formed by removing at least a part of the metal layer applied to the entire outer surface of the insulating layer, and a metal wire for wire bonding between the light emitting chip and the external electrode. Including.
Preferably, the electrode portion is connected and connected to a through-type conductive via hole formed by applying a metal layer to a through- hole in which the insulating layer is applied to an inner peripheral surface, and an upper end and a lower end of the conductive via hole, respectively. An external electrode formed by removing at least a part of the metal layer applied to the entire outer surface of the insulating layer, and a solder ball for flip chip bonding between the light emitting chip and the external electrode. Including.
Preferably, the conductive via hole is provided inside the fuselage body or at a corner or an edge of the heat radiator.
Preferably, the heat radiator further includes a lens part or a mold part made of a transparent material so as to protect the light emitting chip from an external environment.
Preferably, the heat radiator protects the light emitting chip, the sealing material, and a part of the electrode part from an external environment, including a phosphor provided on the chip mounting portion so as to cover the light emitting chip. The lens unit or the mold unit made of a transparent material is further included.
According to the present invention having the above-described configuration, stable heat dissipation characteristics can be ensured in a high-temperature environment by easily releasing heat generated from the light-emitting chip to the outside through a heat dissipation body made of a metal material having excellent thermal conductivity.
Also, by providing the chip mounting part with a protruding type that protrudes from the heat sink at a certain height, the mounting height of the light emitting chip is made relatively higher than the height of the upper surface of the heat sink and optically emitted. Loss can be minimized, optical brightness can be increased, and optical characteristics can be improved.
Also, by eliminating the conventional injection process in the manufacturing process and minimizing the distance between the packages, the mounting density is increased, the manufacturing process and the assembling process are simplified, mass production is possible, and the manufacturing cost is reduced. I can do it.
In addition, the mechanical strength of the package can be improved by the insulating layer provided on the external surface of the radiator, and the electrical connection between the light emitting chip and the external electrode can be stably performed to improve the reliability of the product. I can do it.
2A to 2I are cross-sectional views illustrating a process of manufacturing a high-power LED package according to the present invention, and FIGS. 3A to 3H are perspective views illustrating a process of manufacturing a high-power LED package according to the present invention.
The high power LED package 100 according to the preferred embodiment of the present invention is manufactured through the following steps a to e.
a. Forming at least one chip mounting portion and at least one via hole in the metal plate;
As shown in FIGS. 2A to 2C and FIGS. 3A to 3C, the metal plate 110 having a certain size is used to form a chip mounting portion 112 on which the light emitting chip 101 is mounted and a conductive via hole when power is applied. At least one through hole 114 is provided.
As shown in FIGS. 2 a and 3 a, the chip mounting part 112 patterns or attaches a mask M having a certain size on the upper surface of the metal plate 110 corresponding to the chip mounting part 112.
Next, when the upper surface of the metal plate 110 is chemically etched, as shown in FIGS. 2b and 3b, the upper surface of the metal plate 110 excluding the mask M is uniformly removed, whereby the metal plate 110 is removed. Thus, the chip mounting portion 112 having a certain height relatively higher than the upper bottom surface 113 is formed.
Here, the chip mounting portion 112 is illustrated and described as being formed by a chemical etching method. However, the present invention is not limited to this, and the metal plate 110 is excluded except for a region where only the chip mounting portion 112 is to remain. The chip mounting portion 112 having a certain height relatively higher than the upper bottom surface 113 of the metal plate 110 can also be formed by mechanically polishing the upper surface.
Further, as shown in FIGS. 2c and 3c, a through- hole 114 having a predetermined size is formed on the bottom surface of the metal plate 110 on which the chip mounting portion 112 is formed. At least one is formed.
At this time, the metal plate 110 in which the chip mounting portion 112 and the through hole 114 are formed is made of copper (Cu), copper alloy (Cu Alloy), aluminum (Al), aluminum alloy (Al Alloy) having high thermal conductivity, Any one of magnesium (Mg), magnesium alloy (Mg Alloy), titanium (Ti), titanium alloy (Ti Alloy), steel, and stainless steel (Stainless Steel) can be selectively provided.
In an embodiment of the present invention, the metal plate 110 may be made of aluminum, aluminum alloy, magnesium (Mg), magnesium alloy (Mg Alloy), titanium (Ti), titanium alloy (Ti Alloy) or the like so that anodization is possible. It is preferable that it consists of a metal material.
Meanwhile, as shown in FIGS. 2 a to 2 c, the metal plate 110 may have an upper portion having a height lower than the upper surface of the chip mounting portion 112 after the chip mounting portion 112 is formed by a chemical etching or mechanical polishing process. Although it has been illustrated and described that the through hole 114 is formed in the bottom surface 113, the present invention is not limited thereto, and the chip mounting portion 112 is formed after the through hole 114 is formed through the upper surface of the metal plate 110. Chemical etching or mechanical polishing processes can be performed.
Further, the step of forming the chip mounting portion 112a and the through hole 114a is performed by applying a mask M on the upper surface of the metal plate 110 except for the region where the chip mounting portion 112 is formed, as shown in FIGS. 4a to 4c. After forming the chip mounting portion 112a having a certain depth on the upper surface of the metal plate 110 by chemical etching or mechanical polishing process, the upper surface 113a of the metal plate 110 higher than the chip mounting portion 112a. It can be formed through holes 114a constant, not limited to this, after passing through a through hole 114a on the top surface of the metal plate 110, the upper surface of the metal plate 110 by chemical etching or mechanical polishing process It is also possible to form a chip mounting portion 112a having a depth of 5 mm.
The step of forming the chip mounting portion 112b and the through hole 114b includes forming the chip mounting portion 112b in a planar shape on the upper surface of the metal plate 110 where the through hole 114b is formed, as shown in FIG. Thus, the upper end of the through hole 114b and the chip mounting portion 112b are positioned on the same plane.
The step of forming the chip mounting portion 112c and the through- hole 114c is performed in the metal plate 110 in the region where the chip mounting portion 112c and the electrode portion described later are formed as shown in FIGS. With the mask M formed on the upper surface of the metal plate 110, a trench 115 having a certain depth is formed on the upper surface of the metal plate 110 by a chemical etching or mechanical polishing process. After forming the chip mounting portion 112 c to be formed, a through hole 114 c is formed in the upper surface of the metal plate 110.
However, the present invention is not limited to this, and after the through hole 114c is formed through the upper surface of the metal plate 110, the upper surface of the metal plate 110 is fixed to a certain depth by chemical etching or mechanical polishing process. It is also possible to form the chip mounting portion 112c having the trench 115 as an outer peripheral surface by forming the trench 115.
b. Forming an insulating layer on the outer surface of the metal plate;
The metal plate 110 on which the chip mounting portion 112 and the through hole 114 are formed is immersed in an electrolytic bath filled with an electrolytic solution, and then an external surface, an upper bottom surface, and a through hole of the chip mounting portion 112 by an anodic oxidation process. An insulating layer 120, which is an anodized layer, is formed with a constant thickness on the entire outer surface of the metal plate 110 including the inner peripheral surface.
It is preferable that the insulating layer 120 is uniformly provided on the entire outer surface of the metal plate 110 with a thickness of 10 to 30 μm.
At this time, the through hole 114 is provided with an inner diameter relatively larger than the thickness of the insulating layer 120, and should not be blocked by the insulating layer 120 after the insulating layer 120 is formed.
That is, when the metal plate 110 is made of aluminum or an aluminum alloy, an insulating layer 120 such as Al2O3 is formed on the outer surface of the metal plate 110, and the insulating layer 120 has a ceramic material characteristic and has a mechanical property. It is possible to improve the mechanical strength, to form a columnar form with many voids, and to proceed with subsequent processes such as coloring, coating and printing more stably.
In addition, when the metal plate 110 is made of titanium or a titanium alloy, an insulating layer 120 such as TiO 2 is formed on the outer surface of the metal plate 110. Since the insulating layer 120 is highly reflective, the light emitting chip 101 is used. The efficiency of reflecting the light emitted from the LED is improved, and the light efficiency of the high-power LED package 100 is improved.
Here, the step of forming the insulating layer 120 on the metal plate 110 has been exemplified and explained by an anodic oxidation method, but is not limited thereto, and is also formed by a dry oxidation method using PEO (Plasma Electrolyte Oxidation) or high-temperature oxidizing gas. Can be done.
The insulating layer 120 is illustrated and described as being provided with Al2O3 or TiO2, but is not limited thereto, and may be provided with MgO.
c. Forming an electrode part electrically connected to the light emitting chip mounted on the chip mounting part;
The step of forming the electrode unit 130 includes a step of forming the conductive via hole 131, a step of forming the external electrodes 132 and 133, and a step of electrically connecting the light emitting chip 101 and the external electrodes 132 and 133. .
That is, the conductive via hole 131 is formed in the through hole 114 of the metal plate 110 having the insulating layer 120 formed on the outer surface with a certain thickness, as shown in FIGS. 2e and 3e. A conductive via hole 131 for supplying power is formed by filling or applying a conductive material such as paste.
In addition, as shown in FIGS. 2f and 3f, the external electrodes 132 and 133 are formed at the upper and lower ends of the conductive via hole 131 on the insulating layer 120 where the conductive via hole 131 is exposed to the outside. External electrodes 132 and 133 connected to each other are provided.
Here, since the insulating layer 120 is made of an insulating film having an excellent bonding force, the external electrodes 132 and 133 are plated after a conductive paste is printed and then baked, and the surface of the insulating layer is metallized and then plated. It can be formed by any one of a process of vacuuming and a vacuum deposition process.
Next, in the step of electrically connecting the light emitting chip 101 and the external electrodes 132 and 133, as shown in FIGS. 2g and 3g, the chip mounting portion 112 protruding at a certain height emits light through an adhesive. After the chip 101 is mounted, the external electrodes 132 formed on the upper side of the metal plate 110 are wire-bonded via the metal wires 134 and 135 and are electrically connected.
Meanwhile, in the step of forming the electrode part 130, as shown in FIGS. 7a and 7b, the external electrodes 132 and 133 are simultaneously formed while forming the through-type conductive via hole 131, and then the light emitting chip 101 and the external electrode 132 are formed. , 133 are electrically connected.
That is, in the step of forming the through-type conductive via hole 131, the conductive metal layer 136 having a certain thickness is uniformly formed on the entire outer surface of the insulating layer 120 as shown in FIG. To do.
The metal layer 136 may be provided by a vapor deposition method using a conductive metal such as palladium (Pd) or zinc (Zn) as a material, or may be plated with a metal material such as Ag after Ni / Cu plating. The metal layer 136 may include a metal seed layer formed by a vapor deposition method and a plating layer stacked on an upper surface thereof.
As a result, the through hole 114 is not filled and filled with the conductive material as described above, and a through-type conductive via hole 131 in which the insulating layer 120 and the metal layer 136 are applied is formed on the inner peripheral surface of the through hole 114. It will be.
The step of forming the external electrodes 132 and 133 includes a predetermined circuit pattern of the entire metal layer 136 formed on the entire outer surface of the insulating layer 120 and exposed to the outside, as shown in FIG. 7b. External electrodes 132 and 133 connected to the upper and lower ends of the conductive via hole 131 are removed by removing the remaining part of the conductive via hole 131 except for the part corresponding to the above.
Here, the external electrodes 132 and 133 may be formed by a wet etching method or a dry etching method for removing an unnecessary metal layer using a mask (not shown) provided on the external surface of the metal layer.
Next, in the step of electrically connecting the light emitting chip 101 and the external electrodes 132 and 133, as shown in FIG. 7c, the light emitting chip 101 is attached to the chip mounting part 112 protruding at a certain height via an adhesive. After mounting, the external electrodes 132 formed on the upper side of the metal plate 110 are wire-bonded and electrically connected through the metal wires 134 and 135, respectively.
On the other hand, when the chip mounting portion 112a is formed to be depressed in the metal plate 110 at a certain depth, the step of electrically connecting the light emitting chip 101 and the external electrodes 132 and 133 is constant as shown in FIG. After the light emitting chip 101 is mounted on the chip mounting portion 112a protruding at a depth of 5 mm via an adhesive, the external electrode 132 formed at a position higher than the chip mounting portion 112a via the metal wires 134 and 135 emits light. The chips 101 are electrically connected by wire bonding.
In addition, when the chip mounting part 112b is formed on the plane of the metal plate 110, the step of electrically connecting the light emitting chip 101 and the external electrodes 132 and 133 is performed on the metal plate 110 as illustrated in FIG. After extending the external electrode 132 connected to the formed conductive via hole 131 to the chip mounting part 112b, the light emitting chip 101 is flip-chip bonded via the solder ball 102 mounted on the external electrode 132 to be electrically connected. Connected.
In addition, when the chip mounting part 112c is formed on the plane of the metal plate 110 with the trench 115 formed as a recess in the plane of the metal plate 110 as an outer peripheral surface, the light emitting chip 101 and the external electrode 132, As shown in FIG. 10, the step of electrically connecting 133 is performed by mounting the light emitting chip 101 on the chip mounting portion 112 c via an adhesive and then on the upper side of the metal plate 110 via the metal wires 134 and 135. Each of the formed external electrodes 132 is electrically connected by wire bonding.
At this time, the external electrode 133 formed on the lower side of the metal plate 110 is electrically connected to a power supply pad formed on a substrate (not shown), whereby the conductive via hole 131 and the external electrode 132 are connected. 133 and the metal wires 134 and 135 or the solder balls 102, an external power source is supplied to the light emitting chip 101 to generate light.
d. Providing a sealing material on the upper surface of the chip mounting portion so as to cover the light emitting chip;
As shown in FIGS. 2 h and 3 h, the sealing material 140 is disposed on the upper surface of the chip mounting unit 112 in a state where the light emitting chip 101 and the electrode unit 130 are electrically connected to each other. Is provided.
Here, the sealing material 140 preferably contains a phosphor in order to improve the light efficiency emitted from the light emitting chip 101.
The sealing material 140 is formed by mounting the light emitting chip 101 on the chip mounting portion 112, supplying a liquid resin so that the mounted light emitting chip 101 is covered, and curing the liquid resin.
Further, when the liquid resin is supplied onto the chip mounting portion 112 so as to cover the light emitting chip 101, the sealing material 140 is a dome whose outer surface forms a curved surface due to surface tension and whose central portion swells upward. It is formed into a shape.
Specifically, the liquid resin is supplied such that the outer end is located up to the edge of the upper surface of the chip mounting part 112, that is, the sharp edge. As described above, when the outer end of the liquid resin is positioned at the sharp end of the chip mounting portion 112, the surface tension is formed larger than when the outer end of the liquid resin is positioned on a plane. The resin does not spread beyond the sharp end portion of the chip mounting portion 112 to the outside of the chip mounting portion 112 but has a shape swelled upward.
Meanwhile, on the upper surface of the metal plate 110, the light emitting chip 101 wire-bonded to the metal wires 134 and 135 of the electrode unit 130, the sealing material 140 covering the light emitting chip 101, and the metal wires 134 and 135 are provided. A lens portion 145 made of a transparent material is attached so as to cover these and protect them from the external environment.
Although such a lens unit 145 is illustrated and described as being provided with a convex lens mounted on the upper surface of the metal plate 110 so that light generated from the light emitting chip 101 can be emitted to a wider angle to the outside, However, the present invention is not limited thereto, and may be provided with a light-transmitting transparent resin applied in a dome shape to the upper surface of the metal plate 110.
Here, when the lens unit 145 is a convex lens, the fluorescent material of any one of the wavelength conversion means of AG type, TAG type, and silicate type is included between the metal plate 110 and the lens unit 145. When the lens portion is made of a light-transmitting transparent resin, the fluorescent material can be further included.
In a preferred embodiment of the present invention, after the sealing material 140 covering the light emitting chip 101 is provided on the chip mounting portion 112, the lens portion 145 covering the sealing material 140 together with the light emitting chip 101 is replaced with the metal plate 110. However, the present invention is not limited to this, and it is possible to provide only the lens portion 145 without the sealing material 140.
e. Cutting the metal plate along a cutting line to separate the package;
When the light emitting chip 101 is mounted on the chip mounting unit 112 and electrically connected to the electrode unit 130, and the mounting of the sealing material 140 and the lens unit 145 is completed, the metal plate 110 is formed as illustrated in FIG. The high-power LED package 100 is manufactured and completed by cutting the metal plate 110 using a cutting tool (not shown) along the virtual cutting line C drawn in FIG.
Here, as shown in FIGS. 2h and 3h, the cutting line C passes along the cutting line so as to pass between the conductive via hole 131 and another conductive via hole 131 adjacent thereto. When cut, the conductive via hole 131 may be positioned inside the body of the heat radiating body 110a cut and separated from the metal plate 110 as shown in FIG. 11a.
The cutting line C passes through the center of the conductive via hole 131 formed between the chip mounting part 112 and another chip mounting part 112 adjacent to the chip mounting part 112, and cut along this line. The conductive via hole 131 may be located at a corner or an edge of the radiator 110a cut and separated from the metal plate 110, as illustrated in FIG. 11b.
12 is a cross-sectional view illustrating an embodiment of a high-power LED package according to the present invention, FIG. 13 is a cross-sectional view illustrating another embodiment of the high-power LED package according to the present invention, and FIG. 14 is a high-power LED package according to the present invention. 15 is a cross-sectional view illustrating still another embodiment of the LED package, FIG. 15 is a cross-sectional view illustrating a modified embodiment of the high-power LED package according to the present invention, and FIG. 16 is another variation of the high-power LED package according to the present invention. It is sectional drawing which illustrated the Example.
The high-power LED packages 100, 100a, 100b, 100c, and 100d according to the embodiment of the present invention include a radiator 110a, an insulating layer 120, and an electrode unit 130.
The heat radiating body 110a is a metal structure including a chip mounting portion 112 on which at least one light emitting chip 101 is mounted on an upper surface, and including at least one conductive via hole 131.
The heat radiating body 110a includes copper (Cu), copper alloy (Cu Alloy), aluminum (Al), aluminum alloy (Al Alloy), magnesium (Mg), magnesium alloy (Mg Alloy), and titanium having high thermal conductivity. Any one of (Ti), titanium alloy (Ti Alloy), steel, and stainless steel can be selectively provided.
In the embodiment of the present invention, the heat dissipator 110a may be made of aluminum, aluminum alloy, magnesium (Mg), magnesium alloy (Mg Alloy), titanium (Ti), titanium alloy (Ti Alloy) so as to be anodized. It is preferable to consist of a metal material.
The mounting portion 112 formed on the heat dissipating body 110a for mounting the light emitting chip 101 is chemically etched or mechanically polished except for the region where the light emitting chip 101 is mounted, as shown in FIG. Thus, a protruding chip mounting portion 112 that is partially removed and protrudes upward at a certain height can be provided.
Alternatively, as illustrated in FIG. 13, the chip mounting unit 112 a includes a recessed chip formed by recessing the region where the light emitting chip 101 is mounted by partial removal by a chemical etching or mechanical polishing process. The mounting part 112a can be provided.
Further, as shown in FIG. 14, the chip mounting portion 112b includes a substrate-type chip mounting portion 112b in which a region where the light emitting chip 101 is mounted is formed on the upper surface of the radiator 110a where the external electrode 132 is formed. Can be done.
Further, as shown in FIG. 15, the chip mounting part 112c is partially removed by chemical etching or mechanical polishing along the periphery of the region where the light emitting chip 101 is mounted, and is formed to have a certain depth. The trench-type chip mounting portion 112c having the trench 115 as the outer peripheral surface can be provided.
The conductive via hole 131 has an upper end and a lower end at the upper and lower ends in a state where the insulating layer 120 is applied to the inner peripheral surfaces of the through holes 114, 114 a, 114 b, and 114 c formed through the heat radiating body 110 a. A conductive material such as a conductive paste is filled or applied so as to be exposed on the upper and lower surfaces of 110a.
The insulating layer 120 is an insulating member provided with a constant thickness on the outer surface of the heat radiating body 110a and the inner surfaces of the through holes 114, 114a, 114b, and 114c.
The insulating layer 120 may be uniformly provided with a thickness of 10 μm to 30 μm, and the through holes 114, 114 a, 114 b, and 114 c may be provided with an inner diameter larger than the thickness of the insulating layer 120. After the formation of 120, it should be prevented from being blocked by the insulating layer 120.
The chip mounting portions 112, 112a, 112b, and 112c and the metal plate 110 in which the through holes 114, 114a, 114b, and 114c are formed are immersed in an electrolytic bath filled with an electrolytic solution in an anodic oxidation process. An insulating layer 120, which is an anodized layer, is formed with a constant thickness on the entire outer surface of the metal plate 110 including the outer surface of the mounting portions 112, 112a, 112b, and 112c, the upper bottom surface, and the inner peripheral surface of the through hole. .
Such an insulating layer 120 is preferably provided uniformly on the entire outer surface of the metal plate 110 with a thickness of 10 μm to 30 μm.
At this time, the through holes 114, 114 a, 114 b, 114 c are provided with an inner diameter larger than the thickness of the insulating layer 120, and must always be opened so as not to be blocked by the insulating layer 120.
In addition, since the insulating layer 120 is formed differently depending on the type of metal material constituting the radiator 110a, when the radiator 110a is made of aluminum or an aluminum alloy, the outer surface of the radiator 110a is made of Al2O3. Insulating layer 120 such as TiO 2 may be formed on the outer surface of metal plate 110 when heat radiator 110a is made of titanium or a titanium alloy. However, the present invention is not limited to this, and an insulating layer made of an oxide layer such as MgO can be provided.
At this time, since the insulating layer 120 such as TiO 2 is highly reflective, the efficiency of reflecting the light emitted from the light emitting chip 101 can be improved, and the light efficiency of the package can be improved.
The insulating layer 120 is formed on the heat radiating body 110a by any one of an anodic oxidation method, PEO (Plasma Electrolyte Oxidation), and a dry oxidation method using a high-temperature oxidizing gas.
Meanwhile, the electrode unit 130 electrically connects the conductive via hole 131 provided in the heat radiating body 110a and the light emitting chip 101 provided in the chip mounting units 112, 112a, 112b, and 112c.
In the conductive via hole 131, the light emitting chip 101 is mounted by wire bonding or flip chip bonding, and external electrodes 132 and 133 are formed so as to be easily electrically connected to an external power source.
The external electrodes 132 and 133 are formed by printing and baking a conductive paste so as to be connected and connected to the upper and lower ends of the conductive via holes 131 exposed from the insulating layer 120, and the surface of the insulating layer. It is provided by any one of the process of plating after metallization and the vacuum deposition process.
As a result, the external electrode 132 formed on the upper surface of the heat radiating body 110a is connected to the light emitting chip 101 mounted on the chip mounting portion 112 protruding above at a certain height, as shown in FIG. Wire bonding can be performed via the wires 134 and 135.
Further, the external electrode 132 formed on the upper surface of the heat radiating body 110a has a light emitting chip 101 and a metal wire 134 mounted on a chip mounting portion 112a protruding at a certain depth below as shown in FIG. , 135 can be wire bonded.
The external electrode 132 formed on the upper surface of the heat radiating body 110a is mounted on the chip mounting portion 112b provided on the plane of the heat radiating body 110a on which the external electrode 132 is formed, as shown in FIG. The light emitting chip 101 and the solder ball 102 can be flip-chip bonded.
The external electrode 132 formed on the upper surface of the heat radiating body 110a is mounted on a chip mounting portion 112c having an outer peripheral surface of a trench 115 recessed at a certain depth in the lower portion, as shown in FIG. The light emitting chip 101 and the metal wires 134 and 135 can be wire bonded.
Further, the external electrode 132 on the upper surface of the heat radiating body 110a has been illustrated and described as being directly formed on the external surface of the insulating layer 120 as illustrated in FIGS. 12 to 15, but the present invention is not limited thereto. It is not a thing.
That is, as shown in FIG. 16, the penetration metal layer 136 is uniformly formed on the entire outer surface of the insulating layer 120 by a vacuum deposition method or a plating method to form the through-hole. A through-type conductive via hole 131 in which the insulating layer 120 and the metal layer 136 are applied in multiple layers is formed on the inner peripheral surface of the hole 114.
Subsequently, the metal layer 136 formed on the entire outer surface of the insulating layer 120 and exposed to the outside is removed by a wet etching process or a dry etching process, so that the conductive via hole is removed. The external electrodes 132 and 133 connected and connected to the upper end and the lower end of 131 are formed in a pattern.
As a result, the external electrode 132 formed on the upper surface of the heat radiating body 110a is wire-bonded to the light emitting chip 101 mounted on the chip mounting portion 112a via the metal wires 134 and 135 in the same manner as described above.
The external electrode 133 formed on the lower side of the heat radiating body 110a is electrically connected to a power supply pad formed on a substrate (not shown).
Here, the conductive via hole 131 electrically connected to the external electrodes 132 and 133 may be provided in an internal type or an external type along a cutting line for cutting the metal plate. The via hole 131 is provided as an internal mold located inside the fuselage of the radiator 110a as shown in FIG. 11a, or as an external mold located at a corner or edge of the radiator 110a as shown in FIG. 11b. Can be provided.
Meanwhile, a sealing material 140 is provided on the upper surface of the chip mounting portion so as to cover the light emitting chip 101 in a state where the light emitting chip 101 and the electrode unit 130 are electrically connected. Here, the sealing material 140 preferably contains a phosphor in order to improve the light efficiency emitted from the light emitting chip 101.
As shown in FIGS. 12, 13, 15, and 16, the top surface of the radiator 110a protects the light emitting chip 101, the sealing material 140, and the metal wires 134 and 135 from the external environment. A lens portion 145 made of a transparent material is attached.
The lens unit 145 may be provided with a convex lens mounted on the upper surface of the heat radiating body 110a, or may be provided with a light-transmitting transparent resin applied in a dome shape on the upper surface of the heat radiating body 110a. .
Further, as shown in FIG. 14, the lens part 145b is a transparent mold part made of a transparent light projecting resin so as to protect the light emitting chip 101 flip-chip bonded to the chip mounting part 112b from the external environment. Can be molded.
Although the present invention has been illustrated and described in connection with specific embodiments, those skilled in the art will be able to depart from the spirit and scope of the present invention described in the appended claims. It will be apparent that various modifications and changes can be made to the present invention.
(A) is the cross-sectional perspective view of the center of the fuselage | body of the conventional high output LED package, (b) is sectional drawing by which the conventional high output LED package was assembled on the board | substrate. FIG. 5 is a cross-sectional view illustrating a process of manufacturing a high-power LED package according to the present invention. FIG. 5 is a cross-sectional view illustrating a process of manufacturing a high-power LED package according to the present invention. FIG. 5 is a cross-sectional view illustrating a process of manufacturing a high-power LED package according to the present invention. FIG. 5 is a cross-sectional view illustrating a process of manufacturing a high-power LED package according to the present invention. FIG. 5 is a cross-sectional view illustrating a process of manufacturing a high-power LED package according to the present invention. FIG. 5 is a cross-sectional view illustrating a process of manufacturing a high-power LED package according to the present invention. FIG. 5 is a cross-sectional view illustrating a process of manufacturing a high-power LED package according to the present invention. FIG. 5 is a cross-sectional view illustrating a process of manufacturing a high-power LED package according to the present invention. FIG. 5 is a cross-sectional view illustrating a process of manufacturing a high-power LED package according to the present invention. FIG. 5 is a perspective view illustrating a process of manufacturing a high-power LED package according to the present invention. FIG. 5 is a perspective view illustrating a process of manufacturing a high-power LED package according to the present invention. FIG. 5 is a perspective view illustrating a process of manufacturing a high-power LED package according to the present invention. FIG. 5 is a perspective view illustrating a process of manufacturing a high-power LED package according to the present invention. FIG. 5 is a perspective view illustrating a process of manufacturing a high-power LED package according to the present invention. FIG. 5 is a perspective view illustrating a process of manufacturing a high-power LED package according to the present invention. FIG. 5 is a perspective view illustrating a process of manufacturing a high-power LED package according to the present invention. FIG. 5 is a perspective view illustrating a process of manufacturing a high-power LED package according to the present invention. FIG. 6 is a process diagram for forming a recessed chip mounting portion in a high-power LED package according to the present invention. FIG. 6 is a process diagram for forming a recessed chip mounting portion in a high-power LED package according to the present invention. FIG. 6 is a process diagram for forming a recessed chip mounting portion in a high-power LED package according to the present invention. FIG. 5 is a process diagram for forming a substrate-type chip mounting portion in a high-power LED package according to the present invention. FIG. 5 is a process diagram for forming a trench type chip mounting portion in a high-power LED package according to the present invention. FIG. 5 is a process diagram for forming a trench type chip mounting portion in a high-power LED package according to the present invention. FIG. 5 is a process diagram for forming a trench type chip mounting portion in a high-power LED package according to the present invention. FIG. 6 is a state diagram in which a light emitting chip is mounted by forming a metal layer in a high-power LED package according to the present invention. FIG. 6 is a state diagram in which a light emitting chip is mounted by forming a metal layer in a high-power LED package according to the present invention. FIG. 6 is a state diagram in which a light emitting chip is mounted by forming a metal layer in a high-power LED package according to the present invention. FIG. 6 is a state diagram in which a light emitting chip is mounted on a recessed chip mounting portion in a high-power LED package according to the present invention. FIG. 5 is a state diagram in which a light emitting chip is mounted on a substrate type chip mounting portion in a high power LED package according to the present invention. FIG. 6 is a state diagram in which a light emitting chip is mounted on a trench type chip mounting portion in a high-power LED package according to the present invention. FIG. 2 is a view showing a heat radiating body employed in a high-power LED package according to the present invention, which is a heat radiating body in which an internal conductive via hole is formed. FIG. 3 is a diagram illustrating a heat dissipation body employed in a high-power LED package according to the present invention, in which an external conductive via hole is formed. 1 is a cross-sectional view illustrating an embodiment of a high-power LED package according to the present invention. FIG. 6 is a cross-sectional view illustrating another embodiment of a high-power LED package according to the present invention. FIG. 6 is a cross-sectional view illustrating still another embodiment of a high-power LED package according to the present invention. FIG. 6 is a cross-sectional view illustrating a modified example of a high-power LED package according to the present invention. FIG. 6 is a cross-sectional view illustrating another modified example of the high-power LED package according to the present invention.
110 Metal plate 110a Radiator 112, 112a, 112b, 112c Chip mounting part 114, 114a, 114b, 114c Through hole 120 Insulating layer 130 Electrode part 131 Conductive via hole 132, 133 External electrode 134, 135 Metal wire 145 Lens part
Forming at least one chip mounting portion and at least one through hole in the metal plate;
Forming an insulating layer having a constant thickness on the entire outer surface of the metal plate;
Forming an electrode part electrically connected to the light emitting chip mounted on the chip mounting part;
Providing a sealing material on the upper surface of the chip mounting portion to cover the light emitting chip ;
A step of providing a lens part or a mold part made of a transparent material on the upper surface of the metal plate to protect the light emitting chip from the external environment;
Cutting the metal plate along a cutting line and separating the package after the step of providing the lens part or the mold part , and
The step of forming the chip mounting portion and the through-hole includes forming a chip mounting portion of a certain height on the upper surface of the metal plate by chemical etching or mechanical polishing process, and then lowering the metal plate lower than the chip mounting portion. A through hole is formed in the upper bottom of the
The step of providing the sealing material includes
Supplying the liquid resin so that the liquid resin covers the light emitting chip and the outer end of the liquid resin is positioned up to the edge of the upper surface of the chip mounting portion;
Forming the encapsulant by curing the supplied liquid resin. A method for producing a high-power LED package.
The method for manufacturing a high-power LED package according to claim 1, wherein the metal plate is made of a metal material that can be anodized.
The metal plate is made of any one of aluminum, aluminum alloy, magnesium (Mg), magnesium alloy (Mg Alloy), titanium (Ti), and titanium alloy (Ti Alloy). Manufacturing method of high power LED package.
4. The high insulation layer according to claim 1, wherein the insulating layer is formed by any one of an anodic oxidation method, PEO (Plasma Electrolyte Oxidation), and a dry oxidation method. 5. Manufacturing method of output LED package.
The method of claim 4, wherein the insulating layer is made of any one of Al2O3, TiO2, and MgO.
The step of forming the electrode part includes:
Filling or applying a conductive material to a through hole in which the insulating layer is applied to the inner peripheral surface to form a conductive via hole;
Forming external electrodes connected to the upper and lower ends of the conductive via holes exposed from the insulating layer;
The method of manufacturing a high-power LED package according to claim 1, further comprising electrically connecting a light-emitting chip mounted on the chip mounting portion to the external electrode. Method.
Forming at least one metal layer on the entire outer surface of the insulating layer and simultaneously forming a through-type conductive via hole;
Removing a part of the metal layer to form external electrodes connected to the upper and lower ends of the conductive via holes,
The step of electrically connecting the light emitting chip and the external electrode includes connecting the external electrode through a light emitting chip and a metal wire mounted on a chip mounting portion formed to protrude from the upper surface of the metal plate at a certain height. The method for manufacturing a high-power LED package according to claim 6 or 7, wherein wire bonding is performed.
The external electrode is formed by any one of a process of printing a conductive paste and then baking, a process of metallizing and then plating a surface of the insulating layer, and a vacuum deposition process. 6. A method for producing a high-power LED package according to 6.
The method for manufacturing a high-power LED package according to claim 1, wherein the sealing material contains a phosphor.
11. The method according to claim 1, wherein the step of cutting the metal plate is performed along a cutting line passing between the conductive via hole and another conductive via hole adjacent thereto. A method for producing a high-power LED package according to claim 1 .
The step of cutting the metal plate is performed along a cutting line passing through the center of a conductive via hole formed between the chip mounting portion and another chip mounting portion adjacent to the chip mounting portion. The manufacturing method of the high output LED package of any one of Claim 1 to 10 .
JP2008302920A 2007-12-28 2008-11-27 High power LED package manufacturing method Expired - Fee Related JP4989614B2 (en)
KR20070140549 2007-12-28
KR10-2007-0140549 2007-12-28
KR10-2008-0097213 2008-10-02
KR1020080097213A KR20090072941A (en) 2007-12-28 2008-10-02 High Power LED Package and Fabricating Method thereof
JP2009164583A JP2009164583A (en) 2009-07-23
JP4989614B2 true JP4989614B2 (en) 2012-08-01
ID=40797021
JP2008302920A Expired - Fee Related JP4989614B2 (en) 2007-12-28 2008-11-27 High power LED package manufacturing method
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US20090166664A1 (en) 2009-07-02
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2012-08-22 FPAY Renewal fee payment (prs date is renewal date of database)