The present invention is related to a packaging method for light emitting diode (LED), especially a packaging method for ultraviolet LED (UV LED).
A light emitting diode (LED) is a semiconductor light source and has benefits of energy conservation, low electrical power consumption, higher efficiency, shorter activation time, longer service life, mercury free, environmental protection, and etc. And thus, LED has been widely used in lighting. In order to increase service life of LED, LED is packaged for better protection. Not only materials of a LED package structure are limited (i.e. transparent material is required for light emitting), but also structures and packaging methods are essential.
In a conventional packaging technique, a LED chip is fixed on a patterned non-transparent substrate and electrically connected to the substrate via metal wires. Transparent material is then disposed and covers the entire chip, the metal wires, and the substrate; and afterward, a curing process is performed to finish packaging process. Transparent materials are required for light emitting in a LED package, and thus choices of materials used in the LED package are very limited. Conventionally, it uses transparent polymer materials, such as epoxy resin and/or benzene-containing pure siloxane, in packaging; however, it faces problems of degradation
Epoxy resin, which is of a lower cost and easily processing material and can provide good protection to a LED chip after curing, is widely used in LED packaging. However, it is not a suitable material for high power LED chip packaging because its thermal stability is not sufficient enough and its characteristic stress is too high after curing. On the other hand, although benzene-containing pure siloxane is easy to process and has good light transparency and thermal stability and good protection after packaging, it will degrade after being exposed under ultraviolet light (wavelength less than 420 nm). Benzene rings of pure siloxane that have been exposed under light having short wavelength can lead to material degradation and embrittlement. Thus, benzene-containing pure siloxane cannot be used in packages of light source having shorter wavelength, especially for LED having wavelength less than 365 nm, or packages is going to loss protection to LED chips after a certain period of time. Therefore, service life of a lighting device or element is reduced due to the loss of protection to the LED chip leading to damages of the LED chip.
How to improve packaging method for a UV LED chip in order to improve protection and avoid material degradation becomes the subject of the present invention.
The present invention provides a packaging method of ultraviolet light emitting diode, comprising: (S1) providing a carrier, connected to an electrode; (S2) fixing a UV LED chip onto the carrier and electrically connecting the UV LED chip to the electrodes; (S3) covering the UV LED chip with transparent silicon-and-oxygen-containing solution; and (S4) performing a thermal curing process.
In one embodiment of the present invention, wherein the transparent silicon-and-oxygen-containing solution is made of spin-on glass (SOG).
In one embodiment of the present invention, wherein the step (S3) comprises: (S3A) dispensing the transparent silicon-and-oxygen-containing solution onto the carrier to cover the UV LED chip; and (S3B) spinning the carrier to make the transparent silicon-and-oxygen-containing solution completely covering the carrier, the UV LED chip, and the electrode. And then the step (S4) is performed under a temperature condition in a range of 300˜600° C. in order to cure the transparent silicon-and-oxygen-containing solution.
In one embodiment of the present invention, after the step (S1) and before the (S2), further comprising: forming a dielectric layer covering a portion of the electrode and exposing a portion of the electrode.
In one embodiment of the present invention, wherein the step (S3) comprises: (53A′) dispensing the transparent silicon-and-oxygen-containing solution onto the carrier to cover the UV LED chip; and (S3B′) spinning the carrier to make the transparent silicon-and-oxygen-containing solution completely covering the carrier, the UV LED chip, and the exposed portion of the electrode. And then the step (S4) is performed under a temperature condition in a range of 300˜600° C. in order to cure the transparent silicon-and-oxygen-containing solution.
In one embodiment of the present invention, wherein the step (S3) comprises: (S3a) dispensing the transparent silicon-and-oxygen-containing solution onto the carrier to cover the UV LED chip; and (S3b) spinning the carrier to make the transparent silicon-and-oxygen-containing solution completely covering the UV LED chip and the exposed portion of the electrode.
In one embodiment of the present invention, wherein the UV LED chip is a flip chip comprises a chip electrode electrically connected to the electrode by direct contact.
In one embodiment of the present invention, wherein the silicon-and-oxygen-containing solution conformally covers the UV LED chip and the exposed portion of the electrode and exposes a portion of the dielectric layer.
In one embodiment of the present invention, wherein the silicon-and-oxygen-containing solution is flattened and completely covers the dielectric layer.
In one embodiment of the present invention, wherein the UV LED chip is electrically connected to the electrode by a metal wire and the silicon-and-oxygen-containing solution is flattened and completely covers the metal wire after the sub-step (S3b).
In one embodiment of the present invention, wherein the step (S3) comprises: (S3a′) dispensing the transparent silicon-and-oxygen-containing solution onto the carrier to cover the UV LED chip; and (S3b′) performing a molding process to flatten the transparent thermosetting silicon-and-oxygen-containing solution and make the transparent thermosetting silicon-and-oxygen-containing solution completely covering the carrier, the UV LED chip and the electrode.
In one embodiment of the present invention, wherein the UV LED chip is a flip chip.
In one embodiment of the present invention, wherein the UV LED chip is electrically connected to the electrode by a metal wire and the silicon-and-oxygen-containing solution is completely covering the metal wire after the sub-step (S3b′).
In one embodiment of the present invention, wherein in the step (S1), a cavity structure is disposed on the carrier exposing a portion of the electrode.
In one embodiment of the present invention, wherein after the step (S1) and before the (S2), further comprising: forming a dielectric layer covering a top surface and an inner surface of the wall structure.
In one embodiment of the present invention, wherein the step (S3) is performed by only dispensing the transparent silicon-and-oxygen-containing solution onto the UV LED chip to form a convex or dome-like structure of the transparent silicon-and-oxygen-containing solution covering the UV LED chip, the exposed portion of the electrode and the cavity structure.
In one embodiment of the present invention, wherein the step (S3) comprises: (S3a″) dispensing the transparent silicon-and-oxygen-containing solution onto the carrier to cover the UV LED chip and the cavity structure; and (S3b″) spinning the carrier to flatten the transparent thermosetting silicon-and-oxygen-containing solution and make the transparent silicon-and-oxygen-containing solution completely covering the carrier, the UV LED chip, the electrode, and the cavity structure.
In one embodiment of the present invention, wherein the UV LED chip is a flip chip.
In one embodiment of the present invention, wherein the UV LED chip is electrically connected to the electrode by a metal wire and the silicon-and-oxygen-containing solution is completely covers the metal wire after the sub-step (S3b″).
In one embodiment of the present invention, wherein the step (S3) comprises: (S3a′″) dispensing the transparent silicon-and-oxygen-containing solution onto the carrier to cover the UV LED chip and the wall structure; and (S3b′″) performing a molding process to flatten the transparent silicon-and-oxygen-containing solution and make the transparent silicon-and-oxygen-containing solution completely covering the carrier, the UV LED chip, the electrode, and the cavity structure.
In one embodiment of the present invention, wherein the UV LED chip is a flip chip.
In one embodiment of the present invention, wherein the UV LED chip is electrically connected to the electrode by a metal wire and the silicon-and-oxygen-containing solution is completely covering the metal wire after the sub-step (S3b′″).
In one embodiment of the present invention, wherein the step (S4) is performed under a temperature condition in a range of 300˜600° C.
Accordingly, the present invention provides a packaging method for UV LED, which is suitable for any conventional LED chip with common ranges of wavelengths, especially for UV LED chip with wavelength less than 365 nm. The present invention provides the packaging method is able to avoid degradation problems resulted by the conventional packaging method and thus improve service life of a UV LED chip.
The present invention will become more readily apparent to those ordinarily skilled in the art after reviewing the following detailed description and accompanying drawings, in which:
The present invention provides a packaging method for UV LED to avoid degradation problems resulted by the conventional packaging method in order to improve long-term protection to a UV LED chip, especially to a UV LED chip emitting light with wavelength less than 365 nm, and thus improve operation life of a UV LED chip. It is to be noted that the following descriptions of preferred embodiments of this invention are presented herein for purpose of illustration and description only but not intended to be exhaustive or to be limited to the precise form disclosed.
In the following illustration, the element arranged repeatedly is described in word “one”, “a” or “an” for simpler explanation; and an arrange of number represented by “˜” includes both ends of the numbers as minimum and maximum values. However, one skilled in the art should understand the practical structure and arrangement of each element based on the following illustration and figures provided in the present application. In addition, in the following description, the word “solution” means a mixture of solvent and solute and is in liquid state if there is no other special limitation. The solute can be gas, liquid, or solid, and solvent has to be liquid.
As shown in
According to the above method, different embodiments of the present invention are provided in the following description for illustration only but not intend to limit the present invention. The packaging method provided by the present invention can be applied to a conventional wire-bonding chip and a flip chip without wire-bonding and is suitable with or without a lead frame structure/a ceramic wall structure.
In some embodiments of the present invention which are applying the similar process; however, an amount of the transparent silicon-and-oxygen-containing solution dispensed in the step (S3) is less than sufficient and not enough to evenly cover the entire carrier but only cover the entire UV LED chip and the exposed portion of the electrodes. As shown in
In other embodiments of the present invention after applying the method as illustrated in
In another embodiment of the present invention, it uses conventional wire-bonding chips applying the packaging method provided above. As shown in
In the above mentioned embodiment, the packaging structure has the cavity structure 7 applied to a flip chip, as shown in
In other embodiments (also with cavity structure 7 on the carrier 1) of the present invention following similar process, after the dispensing process to form the (convex-shaped) transparent silicon-and-oxygen-containing solution 5 as shown in
In another embodiment of the present invention, it applies similar process as illustrated in
In another embodiment of the present invention, a wire-bonding chip and a cavity structure 7 are applied to the method provided by the present invention. As shown in
Therefore, the present invention provides a packaging method for UV LED, which is suitable for any conventional LED chip with common ranges of wavelength, especially for UV LED chip with wavelength less than 365 nm. The above embodiments are for illustration only but not intending to limit the present invention. The present invention provides the packaging method is able to avoid degradation problems resulted by the conventional packaging method and thus improve service life of a UV LED chip.
While the invention has been described in terms of what is presently considered to be the most practical and preferred embodiments, it is to be understood that the invention needs not be limited to the disclosed embodiment. On the contrary, it is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims which are to be accorded with the broadest interpretation so as to encompass all such modifications and similar structures.
Number | Date | Country | Kind |
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105104503 | Feb 2016 | TW | national |