CN101621110B - 侧面发光二极管封装件 - Google Patents

侧面发光二极管封装件 Download PDF

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CN101621110B
CN101621110B CN2009101600948A CN200910160094A CN101621110B CN 101621110 B CN101621110 B CN 101621110B CN 2009101600948 A CN2009101600948 A CN 2009101600948A CN 200910160094 A CN200910160094 A CN 200910160094A CN 101621110 B CN101621110 B CN 101621110B
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packaging part
emitting diode
chamber
lead
light
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CN101621110A (zh
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金昶煜
韩允锡
宋怜宰
金炳晚
卢在基
洪性在
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Samsung Electronics Co Ltd
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Abstract

一种用于背光单元的侧面发光二极管封装件,包括:封装件本体,其具有腔室,所述腔室具有在底部与顶部之间倾斜的内侧壁;第一和第二引线框架,布置在封装件本体中,每个所述第一和第二引线框架的一部分位于腔室的底部;发光二极管芯片,其安装在所述腔室的底部,以电连接至第一和第二引线框架;以及至少一条导线,用于将所述发光二极管芯片电连接至所述第一和第二引线框架中的至少一个。所述导线布置的方式使得从所述发光二极管芯片的顶表面到所述导线的顶端的高度是100μm或更少,并且发光二极管芯片的安装高度是50μm至200μm,且所述腔室的深度是200μm至480μm。从而改进发射光的光束孔径角特性、增加光通量、并防止侧壁的模塑缺陷。

Description

侧面发光二极管封装件
本申请是分案申请,其原案申请的申请号为200610140337.8,申请日为2006年11月27日,发明名称为“侧面发光二极管封装件”。
相关申请交叉参考
本申请要求2005年11月25日向韩国知识产权局提交的韩国专利申请No.2005-113834的优先权,其公开内容结合于此作为参考。
技术领域
本发明涉及一种大功率发光二极管(LED)封装件,具体地,在该封装件中,侧壁高度被缩短,以改进发射光的光束孔径角特性、增加光通量、并防止侧壁的模塑缺陷。
背景技术
液晶显示器(LCD)不具备自身的光源,因此需要通常被称为背光单元的外部照明。背光单元从后方照亮LCD,并使用冷阴极荧光灯(CCFL)或LED作为光源。
图1和图2示出了LCD常用的背光单元1。参照图1和图2,背光单元1包括多个LED封装件10、光导向板20、反射片24、散射片26、和一对棱镜片28。对于这样的布置,从LED封装件10入射到光导向板20的光射向上方的LCD面板30,为LCD提供背光。
对其进行更详细的描述,LED封装件10包括:LED芯片12;阴极和阳极引线14,用于为置于其上的LED芯片12供电;封装件本体16,其保持引线14;以及透明树脂的密封剂18,其被填充到封装件本体16的腔室C中,以封装LED芯片12,如图3和图4所示。
由LED芯片12产生的光束L1至L3被引导到光导向板20内,并在光点图形22处分散之前在光导向板20内传播。当光束L1在光点图形22处向上分散时,其退出光导向板20,从而穿过散射板26和棱镜片28而到达LED面板30。
参照图3和图4更详细地描述LED封装件10,其中LED封装件10的填充有密封剂18的腔室C的深度d通常为600μm至650μm。深度d主要取决于LED芯片12的安装高度t、导线W的环路高度h1、以及从导线W直到密封剂18的顶表面的高度h2。
当深度d具有更大的值时,从LED芯片12顶表面到密封剂18顶表面的高度h1+h2也增加。但是,这将带来以下问题。
首先,这限制了从LED封装件10发射出的光的光束孔径角α。当光束孔径角α更小时,背光单元1将使用更多的LED封装件10。
第二,如从图5所看到的,当由LED芯片12产生的光束L1沿箭头A方向发射时,部分光束L1撞到LED封装件10的侧壁17。当撞到侧壁17时,光束L1由于例如吸收/分散而损失。这减少了从LED封装件10发射出来的总体光通量。当侧壁17越高,即图4中的腔室深度d越大时,光通量减少的越多。
第三,更高的侧壁17可能更容易导致诸如侧壁17的上部或下部中空虚(void)等的模塑缺陷。所述的模塑缺陷尤其可能发生在图3中以附图标记I表示的部分中。由于模塑缺陷,LED封装件10的性能会降低,并且有时将被弃用。
发明内容
已经构思了本发明来解决现有技术中的上述问题,因此,本发明的一方面在于提供一种侧面发光LED封装件,其中侧壁的高度被缩短,以改进发射光的光束孔径角特性、增加光通量、并防止侧壁的模塑缺陷。
根据本发明的一方面,用于背光单元的侧面发光LED封装件包括:封装件本体,其具有腔室,该腔室具有在底部与顶部之间倾斜的内侧壁;第一和第二引线框架,其布置于封装件本体中,封装件本体的腔室使得置于腔室底部的第一和第二引线框架中的至少一个的一部分暴露于外部;发光二极管芯片,其安装在腔室的底部,以电连接至第一和第二引线框架;以及透明密封剂,其布置于围绕发光二极管芯片的腔室中。腔室具有的深度大于发光二极管芯片的安装高度,并且不超过该安装高度的六倍。
发光二极管芯片的安装高度可以是50μm到200μm。这里,腔室的深度优选地是200μm到480μm。
根据本发明的另一方面,提供了一种降低导线高度的方法,因为导线是限制腔室深度的降低的一个因素。根据本发明的这个方面的侧面发光LED封装件包括:封装件本体,其具有腔室,该腔室具有在底部与顶部之间倾斜的内侧壁;第一和第二引线框架,其布置于封装件本体中,封装件本体的腔室使得置于腔室底部的第一和第二引线框架中的至少一个的一部分暴露于外部;发光二极管芯片,其安装在腔室的底部,以电连接至第一和第二引线框架;透明密封剂,其布置于围绕发光二极管芯片的腔室中;以及导线,用于将发光二极管芯片电连接至第一和第二引线框架中的至少一个,该导线的一端连接至发光二极管芯片的隆起焊球(bump ball),而另一端自动点焊至引线框架。这里,腔室的深度是200μm至480μm。
在这种情况下,导线的从LED芯片顶部到导线顶部的高度可以优选地降低至100μm或更少,并且更优选地降低到大约70μm。因此,上述的结合对于将腔室深度设置成较小值是有利的。
根据本发明的再一方面,提供了一种适于设计腔室的方法,该方法考虑到了相对于封装件本体的相对较低的深度和塑模可成形性而言,在透明的密封液态树脂的填充过程中的方便性。此方面的侧面发光LED封装件包括:封装件本体,其具有腔室,该腔室具有在底部与顶部之间倾斜的内侧壁;第一和第二引线框架,其布置于封装件本体中,封装件本体的腔室使得置于腔室底部的第一和第二引线框架中的至少一个的一部分暴露于外部;发光二极管芯片,其安装在腔室的底部,以电连接至第一和第二引线框架;以及透明密封剂,其布置于围绕发光二极管芯片的腔室中。这里,腔室的深度可以是200μm至480μm,腔室可以具有沿短轴方向的第一宽度和沿垂直于短轴方向的长轴方向的第二宽度,并且腔室的第二宽度在腔室的底部处可以是1.5mm至1.7mm。考虑到侧壁的倾斜角度,腔室的第二宽度在腔室的顶端处优选地是2.0mm至2.5mm。
附图说明
通过以下结合附图对实施例的详细描述,本发明的上述和其它目的、特征和优点将变得更易于理解,附图中:
图1是示出了结合侧面发光LED封装件的普通背光单元的透视图;
图2是图1所示的背光单元的透视平面图;
图3是传统侧面发光LED封装件的正视图;
图4是沿图3中的线4-4截取的横截面视图;
图5是示出了由图4所示LED封装件中的侧壁吸收光的横截面视图;
图6是示出了本发明的LED封装件的横截面视图;
图7是示出了本发明的LED封装件内的典型引线接合的横截面视图;
图8是示出了本发明的LED封装件内的另一典型引线接合的横截面视图;
图9是示出了从本发明的LED封装件发射光的横截面视图;
图10是示出了根据本发明LED封装件的几个变型的亮度水平的示图;
图11是示出了本发明LED封装件的光束孔径角特性的示图;
图12是示出了传统LED封装件的光束孔径角特性的示图;
图13至图15是示出了根据本发明LED封装件的几个变型的光束孔径角特性的示图;
图16是示出了依照LED封装件中的凹部宽度而注射模塑封装件本体时的缺陷百分率的曲线图。
具体实施方式
下文将参照附图对本发明进行更全面的描述,附图中示出了本发明的优选实施例。
图6是示出了根据本发明实施例的LED封装件100的横截面视图。
参照图6,本发明的侧面发光LED封装件100适用于图1所示的背光单元1。LED封装件100包括:LED芯片102;第一和第二引线框架104,用于为置于其上的LED芯片102供电;封装件本体106,其被注射塑模以保持第一和第二引线框架104;以及透明树脂的密封剂108,其填充在封装件本体106的腔室C中,以封装LED芯片102。
根据本发明此实施例的LED封装件100在腔室C方面具有改进,以便改进光通量和光束孔径角。LED封装件100的侧壁的高度,即腔室C的深度,被设置为大于LED芯片102的高度t,但不会超过高度t的六倍。考虑到普通LED芯片的安装高度(例如,在50μm到200μm范围内),腔室C的深度d被设定为200μm至480μm。这明显地小于前述的传统LED封装件10的腔室深度(600μm至650μm)(见图4)。
因此,从LED封装件100发射出的光的光束孔径角可以被改进成有利地适用于背光单元。对其进行更详细的描述,在用于背光单元的情况下,具有较大光束孔径角的LED封装件相对于具有较小光束孔径角的LED封装件来说在数量上可以减少。
这种结构还降低了从LED芯片102产生的光撞到侧壁107的可能性,从而可以降低通过侧壁107的光吸收/分散,以提高LED封装件100发射出的光通量。
图9示出了由本实施例的LED封装件100发射的光。如图9所示,当光束L从LED芯片102的焦点F发射时,大多数的光束L沿箭头A的方向前进,而不会撞到侧壁107。这可以大大地减少光损失,从而大大地提高了光强度。
而且,随着腔室C深度d的降低,侧壁107的高度也降低。这可以有利地防止由图3中的附图标记I表示的模塑缺陷,否则的话,该模塑缺陷在封装件本体的注射塑模时很容易发生。
由于本实施例的LED封装件100在腔室C的深度d方面被调节,可以改进作为光源的LED封装件100的性能,并且减少注射塑模中的任何缺陷。
通常,如图6所示,侧面发光LED封装件100具有LED芯片102与第一和第二LED框架104的电连接,该电连接可以通过导线W实现。
在这种情况下,需要腔室深度大于导线高度h11+t,从而作为电连接件而设置的导线W可以布置在透明密封剂内部。这样,导线W变成限制腔室C的深度d降低的一个因素。为了克服这个问题,本发明的一方面提供了一种降低导线高度的方法。
现在,将参照图7和图8描述LED封装件内部的引线接合。
图7和图8中的每个均示出了借助于粘合层103安装在引线框架104上的LED芯片102。
参照图7,导线W的一端利用隆起焊球连接至LED芯片102。在另一端,导线W端接于连接至引线框架104的接缝(stitch)S。
对于这种类型的引线接合,导线W的从LED芯片102到导线环路顶部的高度h′11可以被降低至150μm。但是,进一步降低导线W的高度h′11是有困难的。这是因为导线在结合到LED芯片102之后应该在LED芯片102上方形成环路。
相反,参照图8,导线W在一端利用隆起焊球B被结合到引线框架104,而在另一端端接于LED芯片102上的接缝S,以将LED芯片102与引线框架104电连接。
在这种布置中,导线在LED芯片102之上的高度h″11可以进一步从如图7所示的高度降低。这是因为,当导线W从引线框架104(导线W利用隆起焊球B结合于此)向上形成环路至总高度(=h″11+t)时,LED芯片的安装高度t被包含在导线环路的总高度之内。
即,当利用相同设备和方法进行图7和图8所示的引线接合过程时,图8所示的导线W的总高度h″11+t可以与图7所示的导线在LED芯片102之上的高度h′11基本相同。因此,图8的腔室深度d可以被设定为显著地小于图7的腔室深度。
在图8的引线接合中,导线W在LED芯片102之上的高度h″11可以降低至大约100μm或更小,优选地,降低至大约70μm。
对于上述的引线接合,可以相对于现有技术显著地降低引线接合所需的高度,从而显著地降低腔室深度d。
因此,对于如图8所示的引线接合结构,可以容易地制造具有200μm至480μm范围内的腔室深度的侧面发光LED封装件。
考虑到在不采用引线接合结构的情况下,导线W的总高度h″11+t或LED芯片的最大安装高度时,腔室深度d优选地可以是200μm或更大,以确保将封装LED芯片和/或导线的透明树脂的适宜厚度,而不会暴露于外部环境。
考虑到随后的透明树脂填充过程,为了进一步提高由于腔室方面的改进而产生的效果,腔室深度更优选地是250μm至400μm,并且进一步优选地是大约300μm。
在另一方面,本发明提供了一种适当控制腔室宽度的方法,该方法考虑到了用于透明密封剂的树脂填充过程以及封装件本体的注射塑模时的缺陷百分率。
参照图6所示的侧面发光LED封装件100,还可以期望腔室深度d更小。但是,具有的缺点是,更小的腔室深度d导致树脂填充过程出现困难。因此需要精准的程序将诸如硅树脂的透明树脂填充到腔室C内,以形成透明密封剂108。具体地说,由于当腔室深度d减小时整个腔室C变得更小,所以需要精准地将少量树脂注射到腔室内。
通常,腔室具有沿最短宽度方向的第一宽度(即横向宽度)和沿垂直于横向的最长宽度方向的第二宽度(即纵向宽度)。在这种情况下,树脂填充过程可以有效地执行。
但是,当腔室的纵向宽度过度增加时,注射塑模可能容易导致对于封装件本体107的缺陷,如参照图3所示和所描述的。因此,腔室的纵向宽度优选地被限制在预定范围内。
在其它因素保持不变的情况下,通过将腔室纵向宽度从2.0mm增加至3.0mm,本发明对所得到的封装件进行注射塑模时的缺陷百分率进行了研究。结果,发现,当腔室的纵向宽度P1超过2.5mm时,注射塑模时的缺陷百分率急剧上升,如图16所示的曲线图。
鉴于这样的结果,腔室C的顶部处的纵向宽度P1优选地设定为2.0mm至2.5mm。考虑到内侧壁为了反射而倾斜的角度,腔室C的底部处的纵向宽度P2优选地设定为1.5mm至1.7mm。
这样,当腔室纵向宽度P(P1、P2)与腔室深度d一起被控制时,可以提供更好的侧面发光LED封装件。
图10是示出了根据本发明LED封装件的几个变型的亮度水平的示图。用于此实施例中的LED封装件具有如下结构:大约80μm的LED安装高度;以及大约170μm至180μm的导线高度(直到包含LED安装高度的导线的顶部)。
图10中,A表示具有300μm的腔室深度以及1.5mm(底部)和2.0mm(顶部)的腔室纵向宽度的LED封装件;B表示具有300μm的腔室深度以及1.5mm(底部)和2.2mm(顶部)的腔室纵向宽度的LED封装件;C表示具有300μm的腔室深度以及1.7mm(底部)和2.2mm(顶部)的腔室纵向宽度的LED封装件;D表示具有400μm的腔室深度以及1.5mm(底部)和2.0mm(顶部)的腔室纵向宽度的LED封装件;以及E表示具有400μm的腔室深度以及1.7mm(底部)和2.2mm(顶部)的腔室纵向宽度的LED封装件。这里,各封装件使用具有18mW输出功率的LED芯片。
如图10所示,当腔室深度越大时,亮度越大。当然,侧壁的角度,即底部处的腔室纵向宽度与顶部处的腔室纵向宽度的比值也影响亮度。但是,宽度比值相对于腔室深度来说比较不重要。
图11是示出了本发明LED封装件的光束孔径角特性的示图,而图12是示出了传统LED封装件的光束孔径角特性的示图。图11和12中所使用的LED封装件具有类似于图10所示的芯片安装高度和导线高度。
不同之处在于,本发明的侧面发光LED封装件具有300μm的腔室深度,而传统侧面发光LED封装件具有650μm的腔室深度。
观察LED封装件的光束孔径角特性,本发明的LED封装件具有沿X轴(LED封装件的宽度方向)的114.2°的光束孔径角以及沿Y轴(LED封装件的垂直于宽度方向的厚度方向)的115.3°的光束孔径角。另一方面,传统LED封装件具有沿X轴的111.5°的光束孔径角以及沿Y轴的91.7°的光束孔径角。从这些数值中可以明显地看到,本发明中改进了光束孔径角特性。
图13至图15是示出了根据本发明LED封装件的几个变型的光束孔径角特性的示图。
制造出了本发明LED封装件的三个变型,并观察了根据各LED封装件变型的光束孔径角。
图13中的LED封装件具有500μm的腔室深度,其中透明树脂是可从日本的Otsuka公司获得的NMW114WA,并且荧光材料是G3,它们以12∶1的比例混合。从图13中观察到的LED封装件的光束孔径角A,沿较长轴线(即LED封装件的宽度方向)是119.6°,而沿较短轴线是105.8°。
图14中的LED封装件具有400μm的腔室深度,其中荧光材料透明树脂是可从日本Otsuka公司获得的NMW114WA,并且荧光材料是G3,它们以12∶1的比例混合。图14中观察到的LED封装件的光束孔径角A沿较长轴线(即LED封装件的宽度方向)是121.6°,而沿较短轴线是114.8°。
图15中的LED封装件具有400μm的腔室深度,其中透明树脂是可从日本Otsuka公司获得的NMW114WA,并且荧光材料是TAG,它们以12∶1的比例混合。图15中观察到的LED封装件的光束孔径角A沿较长轴线(即LED封装件的宽度方向)是120.7°,而沿较短轴线是118.7°。
在上文所描述的本发明的侧面发光LED封装件中,侧壁的高度被缩短了,以改进发射光的光束孔径角特性,增加光通量、并防止侧壁的模塑缺陷。
虽然参照具体示例性实施例以及附图已经描述了本发明,但本发明并不仅限于此,所附权利要求将对本发明做出限定。应该理解,在不背离本发明的范围和精神的前提下,本领域技术人员可以将实施例替换、改变、或改进成各种形式。

Claims (4)

1.一种侧面发光二极管封装件,包括:
封装件本体,其具有腔室,所述腔室具有在底部与顶部之间倾斜的内侧壁;
第一和第二引线框架,布置在所述封装件本体中,每个所述第一和第二引线框架的一部分位于所述腔室的底部;
发光二极管芯片,其安装在所述腔室的底部,以电连接至所述第一和第二引线框架;以及
至少一条导线,用于将所述发光二极管芯片电连接至所述第一和第二引线框架中的至少一个,
其中,所述导线布置的方式使得从所述发光二极管芯片的顶表面到所述导线的顶端的高度是100μm或更少,并且
所述发光二极管芯片的安装高度是50μm至200μm,且所述腔室的深度是200μm至480μm。
2.根据权利要求1所述的侧面发光二极管封装件,其中,所述导线的一端连接至所述引线框架的隆起焊球,而另一端自动点焊至所述发光二极管芯片。
3.根据权利要求1所述的侧面发光二极管封装件,其中,在围绕所述发光二极管芯片的所述腔室中形成有透明密封剂,且所述透明密封剂包含硅树脂。
4.一种液晶显示器,其中所述液晶显示器包括根据权利要求1至3中任一项所述的侧面发光二极管封装件。
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