TW201304115A - Light-emitting diode package structure manufacturing method - Google Patents

Abstract

The light-emitting diode package structure of the present invention can form a phosphor colloid or a phosphor layer using a photosensitive material, so that a batch process of a phosphor colloid or a phosphor layer can be performed by a semiconductor process. In addition, since the present invention can accurately and easily adjust the distribution density of the phosphor powder by using the light perforation or laser printing process formed by the exposure and development process, the optical effect of the LED package structure can be accurately adjusted.

Description

Light-emitting diode package structure manufacturing method

The present invention relates to a light emitting diode package structure and a manufacturing method thereof, and more particularly to a light emitting diode which utilizes a semiconductor substrate as a package substrate and can adjust the distribution density of the phosphor powder of the phosphor colloid or the phosphor layer. Body package structure, and its manufacturing method.

Please refer to FIG. 1 , which is a schematic diagram of a glue dispensing process for forming a light emitting diode package structure. As shown in FIG. 1 , the conventional LED package structure 1 includes a base 2 formed by injection molding, and the lead frame 3 is fixed on the base 2 to form a package substrate 4 . The light-emitting diode wafer 5 is then crystallized on the lead frame 3. The one electrode of the LED chip 5 is directly electrically connected to the lead frame 3 on the side of the package substrate 4, and the other electrode is electrically connected to the package substrate through the bonding wire 7 by wire bonding. 4 lead frame 3 on the other side. Then, a dispensing process is performed, and the encapsulant 6 is sealed on the package substrate 4 by using a glue device 8.

However, the conventional method for forming a light-emitting diode chip package structure may have disadvantages such as uneven glue amount, unstable glue discharge, difficulty in controlling flatness of the seal surface, and low process efficiency. Especially in terms of efficiency, since the conventional dispensing process can only process one LED package structure at a time, the conventional method must take a large amount of time to complete a large number of LED package structures.

One of the objects of the present invention is to provide a light emitting diode package structure and a method of fabricating the same to overcome the problems caused by the above conventional methods.

In order to achieve the above object, the present invention provides a method for fabricating a light emitting diode package structure, comprising: providing a substrate and a plurality of light emitting diode chips, and respectively fixing the light emitting diode chips to the substrate Forming a phosphor layer on the substrate and the LED chips; and patterning the phosphor layer to form the phosphor layer into a plurality of phosphor colloids, wherein the phosphor colloids are disposed on the phosphors Above the diode wafer, each of the phosphor colloids has a plurality of light perforations, and each of the light perforations vertically penetrates each of the phosphor colloids.

In order to achieve the above object, the present invention further provides a light emitting diode package structure comprising: a substrate; at least one light emitting diode chip fixed on the substrate; and at least one phosphor colloid disposed on the substrate On the LED body, the phosphor colloid has a plurality of light perforations, and each of the light perforations vertically penetrates each of the phosphor colloids.

In the light emitting diode package structure of the present invention, a fluorescent material can be formed using a photosensitive material, so that a batch manufacturing and patterning step of the fluorescent colloid can be performed by a semiconductor process. Moreover, since the phosphor colloid of the present invention has a plurality of light perforations, it is effective The phosphor powder distribution density of the phosphor colloid or the phosphor layer is adjusted to improve the optical effect of the LED package structure.

The present invention will be further understood by those skilled in the art to which the present invention pertains. The effect.

Please refer to Figures 2 to 6. 2 to 6 are schematic views of a preferred embodiment of a method for fabricating a light emitting diode package structure, wherein FIGS. 2a to 6a are top views, and FIGS. 2b to 6b are schematic cross-sectional views. And FIG. 5c is a top view of the entire substrate 30. As shown in Figures 2a and 2b, a substrate 30 and a plurality of light emitting diode wafers 40 are first provided. The substrate 30 defines a plurality of units U for respectively setting the LEDs 40. The substrate 30 can be a semiconductor substrate, such as a germanium substrate, a gallium arsenide substrate, or other substrate having excellent thermal conductivity, suitable for batch production, and compatible with semiconductor processes. The upper surface of the substrate 30 may have a plurality of recessed solid crystal regions 32. The depth of the die-bonding region 32 is preferably close to the height of the light-emitting diode wafer subsequently fixed therein, and the depth thereof is between several micrometers and several tens of micrometers, for example, preferably between 10 and 50 micrometers. Between, but not limited to. Since the depth of the solid crystal region 32 is close to the height of the LED wafer 40, the substrate 30 and the upper surface of the LED wafer 40 can be approximately in the same plane.

The present invention can adopt any suitable electrical connection manner to facilitate external electrical connection of the LED chip. However, due to the numerous electrical connections that can be used, The detailed connection method is not clearly shown in the figure. For example, a wire (not shown) connected to the substrate 30 by a bonding wire, a wire connected to the substrate 30 through a solder bump by a flip chip (not shown), a conductive paste, and a eutectic bonding can be used. (eutectic bonding) or other means, and the wires 38 of the substrate 30 are connected to the lower surface of the substrate 30 via the through holes 36 of the substrate 30, but are not limited thereto. In addition, the LED array 40 of the present invention can employ various types of light-emitting diode wafers, for example, a vertical type wafer or a horizontal type wafer.

As shown in FIGS. 3a and 3b, a light transmissive planar structure 50 is then selectively formed on the substrate 30 and the LED substrate 40. The flat structure 50 has a dielectric property and fills a gap between the outer side of the LED substrate 40 and the die bonding region 32, so that the substrate 30 and the upper surface of the LED substrate 40 form a complete flat surface, such that To help the subsequent film layer production. A plurality of contact holes 52 may be further included in the flat structure 50 for electrically connecting the light-emitting diode wafers 40 via the contact holes 52, but are not limited thereto.

As shown in Figs. 4a and 4b, thereafter, the wires 54 are selectively formed on the flat structure 50, and the wires 54 are filled into the contact holes 52, thereby electrically connecting. Then, a fluorescent layer 64 is formed on the substrate 30, the LED substrate 40 and the flat structure 50 by a spin coating process. The phosphor layer 50 comprises a photosensitive adhesive 46 and a phosphor powder 48 mixed with the photosensitive adhesive. In 46, for example, a photosensitive material incorporating the fluorescent powder 48 is contained. It should be noted that the phosphor powder 48 is actually a relatively small particle, and the phosphor powder 48 is not shown in the top view in order to clearly show the distribution position of the phosphor layer 50. Wherein, the photosensitive adhesive 46 may comprise a photosensitive resin or the like which will form a chain after illuminating or cleave after illumination, and preferably has good properties. Translucent, and the phosphor powder may contain a material of a convertible light wavelength such as yttrium aluminum garnet (YAG).

As shown in FIGS. 5a and 5b, the phosphor layer 64 is patterned by an exposure and development process to form the phosphor layer 64 into a plurality of phosphor colloids 56, and each of the phosphor colloids 56 can have a plurality of phosphor colloids 56 at the same time. Light perforations 57. Each of the phosphor colloids 56 is disposed correspondingly above each of the light-emitting diode wafers 40. Each of the light ray perforations 57 can be evenly distributed in each of the phosphor colloids 56 and can vertically penetrate the respective phosphor colloids 56 to expose the flat structure 50 under the phosphor colloid 56 or a portion of the surface of the light emitting diode wafer 40. Since the portion of the light perforation 57 does not have the phosphor powder 48, the presence of the light perforation 57 can reduce the amount of phosphor powder 48 in the region, thereby changing the color temperature exhibited by the LED package structure. The area occupied by the light perforations 57 of each of the phosphor colloids 56 can be adjusted according to the brightness and product requirements of each of the LED chips 40, preferably 5% to 30% of the area of each of the phosphor colloids 56. .

The function of the phosphor colloid 56 is to convert part of the light generated by the LED chip 40 into light of another color. For example, the LED chip 40 of the embodiment may be a blue light emitting diode chip, and thus the phosphor colloid 56 can use a yellow phosphor that produces yellow light, and then white light is obtained by mixing blue light with yellow light. Alternatively, an ultraviolet light emitting diode chip is used to excite blue, green, and red phosphors. It should be noted that the material and formation manner of the phosphor colloid 56 are not limited to the embodiment.

It should be noted that the shape, size, total area occupied, density and position of the light perforations 57 of each phosphor colloid 56 can be adjusted according to the distribution density of the phosphor powder 48 and the product requirements. Taking the package structure of the blue light emitting diode as an example, for the phosphor layer 64 formed by the spin coating process, when the phosphor colloid 56 does not have When the light is perforated 57, the density of the yellow fluorescent powder 48 located in the central portion of the substrate 30 is generally higher than the density of the yellow fluorescent powder 48 located in the edge region of the substrate 30, so that the light emitting diode package structure is located in the central portion of the substrate 30. The yellow hue of the present invention may be stronger than the yellow hue of the LED package structure located in the edge region of the substrate 30, resulting in different degrees of color temperature for the same batch of LED packages. Therefore, the present invention can measure the color temperature or brightness exhibited on any of the substrates 30 after forming the phosphor layer 64, and then compare the measurement results with the product specifications required to be presented, and then use the comparison. The result is to design the layout of the light perforations 57, using the settings of the light perforations 57 to make adjustments. As shown in FIG. 5c, for example, the ratio of the opening of the light perforation 57 in the central portion of the substrate 30 can be made higher than the ratio of the opening of the light perforation 57 in the edge region of the substrate 30. Alternatively, when the surface of the substrate 30, the light-emitting diode wafer 40 and/or the flat structure 50 has a recess, the density of the phosphor powder 48 in the recess is generally higher than that at the flat portion or the protrusion, and thus the present invention A light opening 75 having a higher opening ratio can be provided in the depression to balance.

In addition, the present invention can form a plurality of closed loop patterns 58 on the flat structure 50 to surround the respective die attach regions 32. The closed loop pattern 58 has a height, such as a few microns, which serves to maintain the surface tension of the subsequently formed colloid, maintaining it in a hemispherical shape and functioning as an optical lens. In this embodiment, the closed loop pattern 58 and the phosphor colloid 56 can use the same photosensitive material and are formed by the same exposure and development process to simplify the process, but the method of the present invention is not limited thereto. .

As shown in Figures 6a and 6b, a glue process is then performed to form a colloid 62 on the phosphor colloid 56 of each unit U, and the colloid 62 is closed by a ring pattern. Case 58 is present to maintain its surface tension to form a hemispherical shape. The colloid 62 forms an optical lens after curing, and finally a plurality of light emitting diode packages can be fabricated by using a cutting process.

In the foregoing embodiment, the phosphor layer 64 is spin-coated on the surface of the flat structure 50. Due to the flat nature of the flat structure 50, the photosensitive paste 46 and the phosphor powder 48 can be smoothly formed by the spin coating process. Fluorescent layer 64. In other embodiments, the present invention may also not include the flat structure 50, but the photosensitive adhesive 46 and the phosphor powder 48 may be spin-coated on a flat surface by other means. Please refer to Figure 7 and Figure 8. FIG. 7 and FIG. 8 are schematic diagrams showing a method for fabricating a light-emitting diode package structure according to another preferred embodiment of the present invention, wherein FIG. 7 is a top view and FIG. 8 is a cross-sectional view. As shown in FIGS. 7 and 8, after the LED substrate 66 is placed in the die bonding region 32, the top surface of the LED substrate 66 is approximately the same as the top surface of the substrate 30, and the spin coating process is utilized. The patterning process forms a phosphor colloid 56 having light perforations 57. Wherein, the LED array 66 can be formed into an external electrical connection by various means, and the LED package structure can further comprise other components or layers that can improve product reliability or optical efficiency, but the detailed electrical connection status thereof. Other elements or layers are omitted here and are not shown in the drawings.

Since the light emitting diode package structure of the present invention can form a fluorescent colloid using a photosensitive material, the batch manufacturing and patterning step of the fluorescent colloid can be performed by using a semiconductor process, thereby greatly shortening the processing time of the light emitting diode package structure, thereby making Process efficiency has increased significantly. Moreover, since the present invention can utilize the patterning step of the phosphor colloid to form the light perforation, the phosphor powder distribution density of the phosphor colloid can be precisely and simply adjusted to improve the optical effect of the LED package structure and can be controlled. Illuminated dipole The body package structure can emit the same or similar color temperature, or can adjust different color temperatures especially for the LED package structure produced in the same batch.

In addition to the use of a spin coating process and a patterning process to batch produce a uniform phosphor layer, the present invention can also utilize a laser printing method to batch produce a uniform phosphor layer. Please refer to Figure 9 to Figure 11. 9 to 11 are schematic views showing a method of fabricating a light emitting diode package structure according to still another preferred embodiment of the present invention, wherein FIGS. 9a to 11a are top views of the phosphor film, and FIG. 9b is a view Figure 11b is a schematic cross-sectional view of a fluorescent film. As shown in FIG. 9a and FIG. 9b, a substrate 30 and a plurality of light emitting diode wafers 40 are first provided. The substrate 30 defines a plurality of cells U for respectively arranging the LEDs 40. The upper surface of the substrate 30 may have a plurality of recessed solid crystal regions 32. The depth of the solid crystal region 32 is preferably close to the height of the light-emitting diode wafer subsequently fixed therein, but is not limited thereto. A light transmissive flat structure 50 is selectively included on the substrate 30 and the LED array 40. The planar structure 50 has dielectric properties and fills a gap between the outer side of the LED substrate 40 and the die bonding region 32 such that the substrate 30 forms a complete flat surface with the upper surface of the LED substrate 40. Thereafter, a wire 54 is selectively formed on the flat structure 50, and the wire 54 is filled into the contact hole 52, thereby electrically connecting.

As shown in FIG. 10a and FIG. 10b, a phosphor film 70 is formed by at least one laser printing process, wherein the phosphor film 70 contains the phosphor powder 72. For example, the fluorescent film 70 can be formed by firstly using the main charging shaft to project static electricity onto the photosensitive drum or the photosensitive belt, and then electrostatically adsorbing the fluorescent powder 72 according to a predetermined pattern to be formed, and then presenting the predetermined color. The patterned phosphor powder 72 is transferred onto a photosensitive dry film 74 to form the desired phosphor film 70.

Due to the characteristics of the laser printing, the fluorescent powder 72 of the single fluorescent film 70 is arranged in a single layer without vertical stacking in a cross-sectional view; the resolution of the laser printing process can reach 50 in a plan view. It is about micrometers or even smaller, so that the distribution of the phosphor powder 72 can be controlled to form any predetermined pattern without being limited by Fig. 10b, and the density of the phosphor powder 72 in any region can be controlled. For example, the phosphor powder 72 may be evenly distributed over the entire phosphor film 70 or only on the die attach region 32 of the substrate 30. In other embodiments, in the case of a single light-emitting diode package structure, the light-emitting intensity directly above the light-emitting diode wafer 40 is generally greater than that around the light-emitting diode wafer 40, and thus the phosphor film 70 is The density of the phosphor powder 72 corresponding to directly above the light-emitting diode wafer 40 can be large, and the density of the phosphor powder 72 corresponding to the periphery of the light-emitting diode wafer 40 can be slightly smaller.

As shown in Fig. 11a and Fig. 11b, the phosphor powder 72 of the phosphor film 70 is transferred onto the LED wafer 40 by a thermal pressing process to form a phosphor layer 76. Accordingly, the phosphors 72 of the single phosphor layer 76 are also arranged in a single layer without being vertically stacked, and the density of the phosphor powder 72 in any region on the LED array 40 can be accurately controlled.

In other embodiments of the present invention, the laser printing process and the transfer step may be performed in reverse to form a plurality of phosphor layers 76 on the LED wafer 40. The laser printing process helps to precisely configure the configuration of the tiny phosphors 72 in adjacent or overlapping locations, and combines them with extremely fine patterns and density arrangements to create a color temperature that is fairly uniform to the naked eye.

In summary, since the light emitting diode package structure of the present invention can form a phosphor colloid or a fluorescent layer using a photosensitive material, the semiconductor process can be used for the fluorescent colloid or The batch manufacturing of the phosphor layer effectively improves the process efficiency of the LED package structure. In addition, since the present invention can accurately and easily adjust the phosphor powder distribution density of the phosphor colloid or the phosphor layer by using the exposure and development process or the laser printing process, the optical effect of the LED package structure can be accurately adjusted. .

The above are only the preferred embodiments of the present invention, and all changes and modifications made to the scope of the present invention should be within the scope of the present invention.

1‧‧‧Light emitting diode chip package structure

2‧‧‧Base

3‧‧‧ lead frame

4‧‧‧Package substrate

5‧‧‧Light Emitter Wafer

6‧‧‧Package

7‧‧‧welding line

8‧‧‧ Dispensing equipment

30‧‧‧Substrate

32‧‧‧ Gujing District

36‧‧‧through holes

38‧‧‧Wire

40‧‧‧Light Diode Wafer

46‧‧‧Photosensitive adhesive

48‧‧‧Fluorescent powder

50‧‧‧flat structure

52‧‧‧Contact hole

54‧‧‧Wire

56‧‧‧Fluorescent colloid

57‧‧‧Light perforation

58‧‧‧Closed ring pattern

62‧‧‧colloid

64‧‧‧Fluorescent layer

66‧‧‧Light Emitting Diode Wafer

70‧‧‧Fluorescent film

72‧‧‧Fluorescent powder

74‧‧‧Photosensitive dry film

76‧‧‧Fluorescent layer

Unit U‧‧‧

FIG. 1 is a schematic view showing a dispensing process for forming a light emitting diode package structure.

2 to 6 are schematic views of a preferred embodiment of a method for fabricating a light emitting diode package structure according to the present invention.

7 and 8 are schematic views showing a method of fabricating a light emitting diode package structure according to another preferred embodiment of the present invention.

9 to 11 are schematic views showing a method of fabricating a light emitting diode package structure according to still another preferred embodiment of the present invention.

30‧‧‧Substrate

36‧‧‧through holes

38‧‧‧Wire

40‧‧‧Light Diode Wafer

50‧‧‧flat structure

52‧‧‧Contact hole

54‧‧‧Wire

56‧‧‧Fluorescent colloid

57‧‧‧Light perforation

58‧‧‧Closed ring pattern

Unit U‧‧‧

Claims (12)

A method for fabricating a light emitting diode package structure, comprising: providing a substrate and a plurality of light emitting diode chips, and respectively crystallizing the light emitting diode chips on the substrate; and the substrate and the Forming a phosphor layer on the LED chip; and patterning the phosphor layer such that the phosphor layer is a plurality of phosphor colloids respectively located above the LED wafers, and each of the phosphor colloids has A plurality of light perforations are perforated, and each of the light perforations extends vertically through each of the phosphor colloids. The method of claim 1, wherein the fluorescent layer comprises a photosensitive adhesive mixed with the fluorescent powder in the photosensitive adhesive. The method of claim 1, wherein the phosphor layer is formed using a spin coating process. The method of claim 1, wherein the step of patterning the phosphor layer is performed using an exposure and development process. The method of claim 1, wherein the area of the light perforations of each of the phosphor colloids is 5% to 30% of the area of each of the phosphor colloids. The method of claim 1, wherein an upper surface of the substrate comprises a plurality of recessed solid crystal regions, and the light emitting diode chips are disposed in the solid crystal regions. The method of claim 1, wherein before the forming the phosphor layer, further comprising the step of providing a planar structure overlying the substrate and the surface of the light emitting diode wafer. The method of claim 7, wherein the phosphor layer is formed on a surface of the planar structure. The method of claim 1, wherein the light perforations are uniformly distributed in each of the phosphor colloids, and a portion of the light perforations expose the photodiode wafers. A method for fabricating a light emitting diode package structure, comprising: providing a substrate and a plurality of light emitting diode chips, and respectively crystallizing the light emitting diode chips on the substrate; performing at least one laser column The printing process is to form at least one fluorescent film, the fluorescent film comprises a phosphor powder; and the phosphor powder of the fluorescent film is transferred onto the LED chips to form at least one phosphor layer. The method of claim 10, wherein the transferring step transfers the phosphors onto the light emitting diode wafers using a thermal press process. The method of claim 10, wherein the laser printing process and the transferring step are repeated to form a plurality of layers of phosphor layers on the light emitting diode wafers.