LED chip package structure with high-efficiency light emission by rough surfaces and method of making the same

• US 20090152570A1
• Filed: 09/25/2008
• Published: 06/18/2009
• Est. Priority Date: 12/12/2007
• Status: Active Grant

• Current Assignee: Harvatek Corporation
• Original Assignee: Harvatek Corporation
• Inventors: Wang, Bily, Wu, Wen-Kuei, Wu, Shih-Yu
• Granted Patent: US 8,017,969 B2
• Time in Patent Office: Days
• US Class Current: 257/88
• CPC Class Codes: F21K 9/90 Methods of manufacture
• CPC Class Codes: F21Y 2103/10 comprising a linear array of point-like light-generating elements
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: G02B 6/0031 Reflecting element, sheet or layer
• CPC Class Codes: G02B 6/0073 Light emitting diode [LED]
• CPC Class Codes: H01L 2224/48091 Arched
• CPC Class Codes: H01L 24/97 the devices being connected to a common substrate, e.g. interposer, said common substrate being separable into individual assemblies after connecting
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/00014 the subject-matter covered by the group, the symbol of which is combined with the symbol of this group, being disclosed without further technical details
• CPC Class Codes: H01L 2924/15747 Copper [Cu] as principal constituent
• CPC Class Codes: H01L 2924/15787 Ceramics, e.g. crystalline carbides, nitrides or oxides
• CPC Class Codes: H01L 2933/0091 Scattering means in or on the semiconductor body or semiconductor body package H01L33/22 takes precedence
• CPC Class Codes: H01L 33/54 having a particular shape

Abstract

An LED chip package structure with high-efficiency light emission by rough surfaces includes a substrate unit, a light-emitting unit, and a package colloid unit. The substrate unit has a substrate body, and a positive electrode trace and a negative electrode trace respectively formed on the substrate body. The light-emitting unit has a plurality of LED chips arranged on the substrate body. Each LED chip has a positive electrode side and a negative electrode side respectively and electrically connected with the positive electrode trace and the negative electrode trace of the substrate unit. The package colloid unit has a plurality of package colloids respectively covering the LED chips. Each package colloid has a cambered colloid surface and a light-emitting colloid surface respectively formed on its top surface and a lateral surface thereof.

Claims

1. A method of making an LED chip package structure with high-efficiency light emission by rough surfaces, comprising:

providing a substrate unit, wherein the substrate unit has a substrate body, and a positive electrode trace and a negative electrode trace respectively formed on the substrate body;

arranging a plurality of LED chips on the substrate body by a matrix method to form a plurality of longitudinal LED chip rows, wherein each LED chip has a positive electrode side and a negative electrode side respectively and electrically connected with the positive electrode trace and the negative electrode trace of the substrate unit;

longitudinally and respectively covering the longitudinal LED chip rows with a plurality of longitudinal package colloids using a first mold unit, wherein each longitudinal package colloid has a plurality of cambered colloid surfaces that are formed on its top side and correspond to the LED chips;

transversely cutting the longitudinal package colloids along a line between each two adjacent and longitudinal LED chips to form a plurality of package colloids that are separated from each other and respectively covering the corresponding LED chips, wherein the top surface of each package colloid is the cambered colloid surface;

respectively covering and filling a frame unit on the substrate body, on the package colloids, and between each two adjacent package colloids using a second mold unit; and

transversely cutting the frame unit, the package colloids and the substrate body along a line between each two adjacent and longitudinal LED chips to form a plurality of light bars, wherein each package colloid is cut into two half package colloids, each half package colloid has a half cambered colloid surface and a rough light-emitting colloid surface formed in front of its cambered colloid surface, and each light bar has a frame layer for exposing the rough light-emitting colloid surfaces of the half package colloids.

2. The method as claimed in claim 1, wherein the substrate unit is a PCB (Printed Circuit Board), a flexible substrate, an aluminum substrate, a ceramic substrate, or a copper substrate.

3. The method as claimed in claim 1, wherein the substrate body has a metal layer and a Bakelite layer formed on the metal layer, and both the positive electrode trace and the negative electrode trace are aluminum circuits or silver circuits.

4. The method as claimed in claim 1, wherein the positive electrode side and the negative electrode side of each LED chip are respectively and electrically connected with the positive electrode trace and the negative electrode trace of the substrate unit via two corresponding leading wires using a wire-bounding method.

5. The method as claimed in claim 1, wherein the positive electrode side and the negative electrode side of each LED chip are respectively and electrically connected with the positive electrode trace and the negative electrode trace of the substrate unit via a plurality of corresponding solder balls using a flip-chip method.

6. The method as claimed in claim 1, wherein each longitudinal LED chip row is arranged on the substrate body of the substrate unit along a straight line.

7. The method as claimed in claim 1, wherein the first mold unit is composed of a first upper mold and a first lower mold for supporting the substrate body, the first upper mold has a plurality of first channels corresponding to the longitudinal LED chip rows, each first channel has a plurality of grooves, each groove has a cambered mold surface formed on its top side and corresponding to the corresponding cambered colloid surface, and the size of each first channel is the same as the size of each longitudinal package colloid.

8. The method as claimed in claim 1, wherein the first mold unit is composed of a first upper mold and a first lower mold for supporting the substrate body, the first upper mold has a plurality of first channels corresponding to the longitudinal LED chip rows, each first channel has a cambered mold surface formed on its top side, and the size of each first channel is the same as the size of each longitudinal package colloid.

9. The method as claimed in claim 1, wherein each longitudinal package colloid is a fluorescent resin that is formed by mixing silicone and fluorescent powders.

10. The method as claimed in claim 1, wherein each longitudinal package colloid is a fluorescent resin that is formed by mixing epoxy and fluorescent powders.

11. The method as claimed in claim 1, wherein the second mold unit is composed of a second upper mold and a second lower mold for supporting the substrate body, the second upper mold has a second channel corresponding to the frame unit, and the height of the second channel is the same as the height of package colloids and the width of the second channel is the same as the width of the frame unit.

12. The method as claimed in claim 1, wherein the frame layer is an opaque frame layer.

13. The method as claimed in claim 12, wherein the opaque frame layer is a white frame layer.

14. A method of making an LED chip package structure with high-efficiency light emission by rough surfaces, comprising:

providing a substrate unit, wherein the substrate unit has a substrate body, and a positive electrode trace and a negative electrode trace respectively formed on the substrate body;

arranging a plurality of LED chips on the substrate body by a matrix method to form a plurality of longitudinal LED chip rows, wherein each LED chip has a positive electrode side and a negative electrode side respectively and electrically connected with the positive electrode trace and the negative electrode trace of the substrate unit;

longitudinally and respectively covering the longitudinal LED chip rows with a plurality of longitudinal package colloids using a first mold unit, wherein each longitudinal package colloid has a plurality of cambered colloid surfaces that are formed on its top side and correspond to the LED chips;

transversely cutting the longitudinal package colloids along a line between each two adjacent and longitudinal LED chips to form a plurality of package colloids that are separated from each other and respectively covering the corresponding LED chips, wherein the top surface of each package colloid is the cambered colloid surface;

respectively, longitudinally covering and filling a plurality of longitudinal frame layers on the substrate body, on the package colloids, and between each two longitudinal and adjacent package colloids via a third mold unit; and

transversely cutting the longitudinal frame layers, the package colloids and the substrate body along a line between each two adjacent and longitudinal LED chips to form a plurality of light bars, wherein each package colloid is cut into two half package colloids, each half package colloid has a half cambered colloid surface and a rough light-emitting colloid surface formed in front of its cambered colloid surface, and each light bar has a frame layer for exposing the rough light-emitting colloid surfaces of the half package colloids.

15. The method as claimed in claim 14, wherein the substrate unit is a PCB (Printed Circuit Board), a flexible substrate, an aluminum substrate, a ceramic substrate, or a copper substrate.

16. The method as claimed in claim 14, wherein the substrate body has a metal layer and a Bakelite layer formed on the metal layer, and both the positive electrode trace and the negative electrode trace are aluminum circuits or silver circuits.

17. The method as claimed in claim 14, wherein the positive electrode side and the negative electrode side of each LED chip are respectively and electrically connected with the positive electrode trace and the negative electrode trace of the substrate unit via two corresponding leading wires using a wire-bounding method.

18. The method as claimed in claim 14, wherein the positive electrode side and the negative electrode side of each LED chip are respectively and electrically connected with the positive electrode trace and the negative electrode trace of the substrate unit via a plurality of corresponding solder balls using a flip-chip method.

19. The method as claimed in claim 14, wherein each longitudinal LED chip row is arranged on the substrate body of the substrate unit along a straight line.

20. The method as claimed in claim 14, wherein the first mold unit is composed of a first upper mold and a first lower mold for supporting the substrate body, the first upper mold has a plurality of first channels corresponding to the longitudinal LED chip rows, each first channel has a plurality of grooves, each groove has a cambered mold surface formed on its top side and corresponding to the corresponding cambered colloid surface, and the size of each first channel is the same as the size of each longitudinal package colloid.

21. The method as claimed in claim 14, wherein the first mold unit is composed of a first upper mold and a first lower mold for supporting the substrate body, the first upper mold has a plurality of first channels corresponding to the longitudinal LED chip rows, each first channel has a cambered mold surface formed on its top side, and the size of each first channel is the same as the size of each longitudinal package colloid.

22. The method as claimed in claim 14, wherein each longitudinal package colloid is a fluorescent resin that is formed by mixing silicone and fluorescent powders.

23. The method as claimed in claim 14, wherein each longitudinal package colloid is a fluorescent resin that is formed by mixing epoxy and fluorescent powders.

24. The method as claimed in claim 14, wherein the third mold unit is composed of a third upper mold and a third lower mold for supporting the substrate body, the third upper mold has a third channel corresponding to the longitudinal LED chip rows, and the height of the third channel is the same as the height of package colloids and the width of the third channel is larger than the width of each package colloid.

25. The method as claimed in claim 14, wherein the frame layer is an opaque frame layer.

26. The method as claimed in claim 25, wherein the opaque frame layer is a white frame layer.

27. An LED chip package structure with high-efficiency light emission by rough surfaces, comprising:

a substrate unit having a substrate body, and a positive electrode trace and a negative electrode trace respectively formed on the substrate body;

a light-emitting unit having a plurality of LED chips arranged on the substrate body, wherein each LED chip has a positive electrode side and a negative electrode side respectively and electrically connected with the positive electrode trace and the negative electrode trace of the substrate unit; and

a package colloid unit having a plurality of half package colloids respectively covering the LED chips, wherein each half package colloid has a half cambered colloid surface and a rough light-emitting colloid surface respectively formed on its top surface and a lateral surface thereof.

28. The LED chip package structure as claimed in claim 27, wherein the substrate unit is a PCB (Printed Circuit Board), a flexible substrate, an aluminum substrate, a ceramic substrate, or a copper substrate.

29. The LED chip package structure as claimed in claim 27, wherein the substrate body has a metal layer and a Bakelite layer formed on the metal layer, and both the positive electrode trace and the negative electrode trace are aluminum circuits or silver circuits.

30. The LED chip package structure as claimed in claim 27, wherein the positive electrode side and the negative electrode side of each LED chip are respectively and electrically connected with the positive electrode trace and the negative electrode trace of the substrate unit via two corresponding leading wires using a wire-bounding method.

31. The LED chip package structure as claimed in claim 27, wherein the positive electrode side and the negative electrode side of each LED chip are respectively and electrically connected with the positive electrode trace and the negative electrode trace of the substrate unit via a plurality of corresponding solder balls using a flip-chip method.

32. The LED chip package structure as claimed in claim 27, wherein each longitudinal LED chip row is arranged on the substrate body of the substrate unit along a straight line.

33. The LED chip package structure as claimed in claim 27, wherein the LED chips are arranged on the substrate body of the substrate unit along a plurality of straight lines.

34. The LED chip package structure as claimed in claim 27, wherein each half package colloid is a fluorescent resin that is formed by mixing silicone and fluorescent powders.

35. The LED chip package structure as claimed in claim 27, wherein each half package colloid is a fluorescent resin that is formed by mixing epoxy and fluorescent powders.

36. The LED chip package structure as claimed in claim 27, further comprising a frame unit that is a frame layer covering the substrate body and disposed around whole lateral sides of each half package colloid for exposing the rough light-emitting colloid surfaces of the half package colloids.

37. The LED chip package structure as claimed in claim 36, wherein the frame layer is an opaque frame layer.

38. The LED chip package structure as claimed in claim 37, wherein the opaque frame layer is a white frame layer.

39. The LED chip package structure as claimed in claim 27, further comprising a frame unit has a plurality of frame bodies, wherein each frame body covers the half package colloid for exposing each rough light-emitting surface of each half package colloid, and the frame bodies are separated from each other.

40. The LED chip package structure as claimed in claim 39, wherein each frame body is an opaque frame body.

41. The LED chip package structure as claimed in claim 40, wherein the opaque frame body is a white frame body.