The invention relates to a light emitting device and a manufacturing method thereof, and particularly relates to a light emitting device using light emitting diodes as light sources and a manufacturing method thereof.
Since light emitting diode (LED) has advantages of high energy conversion rate, short response time and long service life, etc., it is widely applied in the lighting field. However, when a user connects the LED to an external electronic device, polarities of electrodes in the LED are often unclear and the electrodes are probably reversely connected to the external electronic device (or power supply), which may result in damage of the LED.
The invention is directed to a light emitting device, and a user greatly reduces a chance of reversely connecting electrodes thereof.
The invention is directed to a manufacturing method of a light emitting device, which is adapted to manufacture the aforementioned light emitting device.
An embodiment of the invention provides a light emitting device including a light emitting unit and a phosphor resin layer. The light emitting unit has a top surface and a bottom surface opposite to each other. Each of the light emitting units includes two electrodes. The two electrodes are disposed on the bottom surface. The phosphor resin layer is disposed on the top surface of the light emitting unit. One side of the phosphor resin layer has a mark. One of the two electrodes is closer to the mark with respect to the other one of the two electrodes.
In an embodiment of the invention, the phosphor resin layer further includes a low-concentration phosphor resin layer and a high-concentration phosphor resin layer stacked with each other. The high-concentration phosphor resin layer is located between the light emitting unit and the low-concentration phosphor resin layer.
In an embodiment of the invention, the side of the phosphor resin layer is configured with a groove. The groove penetrates through the high-concentration phosphor resin layer and exposes a part of the low-concentration phosphor resin layer. The groove separates the high-concentration phosphor resin layer into a first portion and a second portion with different sizes. The mark at least includes a smaller one of the first portion and the second portion of the high-concentration phosphor resin layer.
In an embodiment of the invention, the side of the phosphor resin layer is configured with a chamfer, and the chamfer serves as the mark.
In an embodiment of the invention, the side of the phosphor resin layer is configured with a notch, and the notch serves as the mark.
In an embodiment of the invention, the light emitting device further includes a reflection protective member. The reflection protective member covers the light emitting unit and a part of the phosphor resin layer, and at least exposes the two electrodes and the low-concentration phosphor resin layer.
In an embodiment of the invention, the reflection protective member has a concave surface. The concave surface is recessed toward the phosphor resin layer.
In an embodiment of the invention, one side of the concave surface contacts the light emitting unit, and a second side of the concave surface faces the phosphor resin layer and extends toward a direction away from the light emitting unit.
In an embodiment of the invention, the light emitting device further includes a light transmissive resin layer. The light emitting unit further includes a side surface connected to the top surface and the bottom surface. The light transmissive resin layer is configured on the high-concentration phosphor resin layer and extends to the side surface of the light emitting unit.
An embodiment of the invention provides a manufacturing method of a light emitting device, which includes following steps: forming a phosphor resin layer; performing a first cutting procedure to the phosphor resin layer to form a plurality of first grooves in the phosphor resin layer, so as to separate the phosphor resin layer into a plurality of portions, where each of the portions serves as a bonding area; providing a plurality of light emitting units, where each of the light emitting units includes two electrodes; respectively forming a plurality of marks at one side of the portions of the phosphor resin layer; respectively bonding the light emitting units to the bonding areas. Each of the marks is close to one of the two electrodes of the corresponding light emitting unit and is away from the other one of the two electrodes; performing a final cutting procedure along the first grooves to form a plurality of light emitting devices.
In an embodiment of the invention, the step of forming the phosphor resin layer further includes following steps: forming a phosphor resin; statically disposing the phosphor resin to separate the phosphor resin into a high-concentration phosphor resin and a low-concentration phosphor resin stacked with each other; curing the phosphor resin into the phosphor resin layer, where the high-concentration phosphor resin and the low-concentration phosphor resin are respectively cured into the high-concentration phosphor resin layer and the low-concentration phosphor resin layer.
In an embodiment of the invention, the step of respectively forming the marks at the side, of the portions of the phosphor resin layer further includes: performing a second cutting procedure on the portions of the phosphor resin layer, so as to respectively form a plurality of second grooves in the portions of the phosphor resin layer, where in each portion of the phosphor resin layer, the second groove penetrates through the high-concentration phosphor resin layer and exposes a part of the low-concentration phosphor resin layer, and the second groove separates the high-concentration phosphor resin layer into a first portion and a second portion with different sizes. The mark at least includes a smaller one of the first portion and the second portion of the high-concentration phosphor resin layer.
In an embodiment of the invention, the step of respectively forming the marks at the side of the portions of the phosphor resin layer further includes: performing a second cutting procedure on the portions of the phosphor resin layer, so as to respectively form a plurality of second grooves in the portions of the phosphor resin layer. The second grooves cut out a plurality of chamfers in the portions of the phosphor resin layer. A cutting direction of the second cutting procedure is different to a cutting direction of the first cutting procedure. The chamfers serve as the marks.
In an embodiment of the invention, the step of respectively forming the marks at the side of the portions of the phosphor resin layer further includes: irradiating laser light to the portions of the phosphor resin layer, such that the low-concentration phosphor resin layer in each of the portions has a notch, and the notch serves as the mark.
In an embodiment of the invention, the step of respectively bonding the light emitting units to the bonding areas further includes: respectively forming a plurality of light transmissive resin layers on the high-concentration phosphor resin layers in the bonding areas; and respectively bonding the light emitting units to the high-concentration phosphor resin layers through the light transmissive resin layers.
In an embodiment of the invention, the method further includes: forming a reflection protective member on the phosphor resin layer and between the light emitting units to fill the first grooves, where the reflection protective member exposes the electrodes.
In an embodiment of the invention, the step of forming the reflection protective member further includes: statically disposing the reflection protective member, such that the reflection protective member forms a concave surface recessed toward the phosphor resin layer; and curing the reflection protective member.
Based on the above description, in the light emitting device and the manufacturing method thereof of the embodiments of the invention, since the distances between the mark on the phosphor resin layer and the two electrodes are different, the user may accordingly determine the polarities of the electrodes, so as to greatly reduce the chance of reversely connecting the electrodes.
To make the aforementioned more comprehensible, several embodiments accompanied with drawings are described in detail as follows.
The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
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In detail, in the embodiment, one side of the phosphor resin layer PL is configured with the second groove C2. The second groove C2 penetrates through the high-concentration phosphor resin layer HPL and exposes a part of the low-concentration phosphor resin layer LPL′. The second groove C2 separates the high-concentration phosphor resin layer HPL into a first portion HPL1 and a second portion HPL2 with different sizes. The mark M includes the exposed part of the low-concentration phosphor resin layer LPL′, or at least one of the exposed part of the low-concentration phosphor resin layer LPL′, the first portion HPL1 and the second portion HPL2. In detail, since the low-concentration phosphor resin layer LPL and the high-concentration phosphor resin layer HPL have different colors due to different concentrations thereof, viewing along a direction D, it is learned that the phosphor resin layer PL has a varied color distribution, for example, a deep color (corresponding to the first portion HPL1 of the high-concentration phosphor resin layer HPL), a light color (corresponding to the exposed low-concentration phosphor resin layer LPL) and a deep color (corresponding to the second portion HPL2 of the high-concentration phosphor resin layer HPL) to cause a gradation of color, and such gradation of color may be regarded as a type of the mark M, i.e. the mark M includes the first portion HPL1, the exposed part of the low-concentration phosphor resin layer LPL′ and the second portion HPL2.
Based on another point of view, since colors of the first portion HPL1 and the second portion IIPL2 of the high-concentration phosphor resin layer IIPL located adjacent to both sides of the exposed low-concentration phosphor resin layer LPL′ are all lower than the color of the low-concentration phosphor resin layer LPL′, the exposed low-concentration phosphor resin layer LPL′ may also be regarded as one type of the mark M, i.e. the mark M includes the exposed low-concentration phosphor resin layer LPL′. Alternatively, since the low-concentration phosphor resin layer LPL′ is configured between the smaller second portion HPL2 of the high-concentration phosphor resin layer HPL located at one side of the phosphor resin layer PL and the first portion HPL1 of the high-concentration phosphor resin layer HPL, a combination of one of the first portion HPL1 and the second portion HPL2 of the high-concentration phosphor resin layer HPL and the low-concentration phosphor resin layer LPL′ may also be regarded as one type of the mark M, i.e. the mark M includes the first portion HPL1 of the high-concentration phosphor resin layer HPL and the low-concentration phosphor resin layer LPL′, or the mark M includes the second portion HPL2 of the high-concentration phosphor resin layer HPL and the low-concentration phosphor resin layer LPL′, which is not limited by the invention.
In the embodiment, the reflection protective member RP covers the light emitting unit EU and a part of the phosphor resin layer PL, and at least exposes the two electrodes E1 and E2 and the low-concentration phosphor resin layer LPL. The reflection protective member RP has a concave surface RPS facing external. The concave surface RPS is recessed toward the phosphor resin layer PL. A first side of the concave surface RPS contacts the light emitting unit EU, and a second side of the concave surface faces the phosphor resin layer PL and extends a long a direction away from the light emitting unit EU. When the light emitting device EA1 of the embodiment is to be connected to an external substrate (for example, a back plate, a printed circuit board or other types of substrate in a display panel) later, through the design that the surface of the reflection protective member RP exposed to external is the concave surface RPS, a gap spaced between the light emitting device EA and the external substrate due to protrusion of the reflection protective member RP between the reflection protective member RP and the external substrate is avoided, and generation of such gap may result in a fact that the electrodes E1 and E2 of the light emitting unit EU cannot be perfectly bounded to the external substrate.
In the embodiment, the light transmissive resin layer C is disposed on the high-concentration phosphor resin layer HPL and extends to the side surface SS of the light emitting unit EU.
Based on the above description, in the light emitting device and the manufacturing method thereof of the embodiment of the invention, since the phosphor resin layer PL is configured with the mark M, and average distances respectively between the mark M and the two electrodes E1 and E2 are different, when manufacturing of the light emitting devices EA is completed, the user may be informed that the electrode E2 closer to the mark M is, for example, a P-type electrode, and the user may clearly know that the electrode E2 is the P-type electrode, and the electrode E1 is an N-type electrode with an opposite electrical property. In brief, the user simply determines polarities of the electrodes according to the distances between the mark M and the electrodes E1 and E2, which may greatly reduce the chance of reversely connecting the electrodes.
Some steps of the manufacturing flow of the light emitting device EA2 of the second embodiment are similar to that of the manufacturing flow of the light emitting device EA of the first embodiment, and only differences there between are described below.
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Some steps of the manufacturing flow of the light emitting device EA3 of the third embodiment are similar to that of the manufacturing flow of the light emitting device EA of the first embodiment, and only differences there between are described below.
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It should be noted that in the embodiments of the invention, the pattern of the marks M is, for example, a notch, a chamfer, a gradation of color formed between the high-concentration and low-concentration phosphor resin layers, and in other embodiments, the pattern of the marks M may also be a round breach, a triangular breach or other polygon breach or other marks that may be obviously identified by naked eyes, which is not limited by the invention.
In summary, in the light emitting device and the manufacturing method thereof of the embodiments of the invention, since the marks spaced by different distances with the two electrodes are configured on the phosphor resin layer, the user may accordingly determine the polarities of the electrodes according to the relative positions of the marks and the two electrodes, so as to greatly reduce the chance of reversely connecting the electrodes.
It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosed embodiments without departing from the scope or spirit of the invention. In view of the foregoing, it is intended that the invention covers modifications and variations provided they fall within the scope of the following claims and their equivalents.
This application claims the priority benefit of U.S. provisional application Ser. No. 62/581,763, filed on Nov. 5, 2017. The entirety of the above-mentioned patent application is hereby incorporated by reference herein and made a part of this specification.
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