A kind of high diffuse reflection optics design carrying out of substrate efficient LED chip packaging method that utilizes
Technical field
The present invention relates to a kind of new LED base plate for packaging, referring more particularly to a kind of raising LED light efficiency and reducing light decay increases photochromic inhomogeneity base plate for packaging and method for packing.
Background technology
LED is as a kind of new type light source, owing to have energy-efficient, environmental protection, conventional light source incomparable advantage such as the life-span is long, toggle speed is fast, no stroboscopic height, obtained fast development.
Generally speaking, traditional White-light LED package structure is like Fig. 1; Mainly be provided with the substrate A of a tool groove A1; The interior chip B that combines of this groove A1, this chip B links through a tie line C and another support D again, the last ejection formation that passes through a photic zone E again; Substrate A, chip B, tie line C and sealing photic zone E are combined as a whole, accomplish the encapsulation of LED.
Mostly common LED chip substrate or solid brilliant substrate surface are plating highly reflecting films such as Al film or Ag film etc., to make full use of the light that sends from the led chip bottom.But this high reflectivity film stack can cause reverberation more concentrated; Light more than 80% all concentrates in the narrow reflector space light beam; Be in 60 ° the sector region like the angle of the dotted line F-G-H-I among Fig. 1, thereby it is remarkable to cause dazzling light, especially for the transparent sealing that is mixed with fluorescent material; Less lasing area can cause the area of fluorescent material Stimulated Light-emission gold-tinted very limited, can obviously influence led light source efficient like this.In addition, the high anti-coating of Ag film is easy jaundice variable color in high temperature drying glue process, thereby has reduced the reflectivity of blue wave band, has reduced the light efficiency and the color rendering index of packaged LED.
Based on existing common LED encapsulating structure with and the deficiency of improving one's methods, the present invention has designed " a kind of method of utilizing the encapsulation of the high diffuse reflection optics design carrying out of substrate led chip ".
Summary of the invention
The present invention is intended to solve the foregoing problems of prior art, therefore an object of the present invention is to provide a kind of have high diffuse reflection and the durable high reflectance substrate of high low-temperature stabilization.With the luminous efficiency of obvious raising white light LEDs, reduce the direct light decay that the variable color of Ag reflectance coating causes, improve and dazzle light characteristic.And can guarantee good photochromic consistency.
The object of the invention and solve its technical problem and adopt following technical scheme to realize:
LED encapsulating structure provided by the invention is as shown in Figure 2; It comprises the base plate for packaging 10 with high diffuse reflection film or coating or substrate 102; The one side 101 that said base plate for packaging 10 is used for solid crystalline substance is high diffuse reflector 102, is formed with two electrodes 501 and 502 on it simultaneously; Led chip 20, chip adopt solid crystal type to be fixed on the high diffuse reflector 102 of base plate for packaging; And sealer 40, sealer covers said led chip 20 and said high diffuse reflector 102, to protect said led chip and high diffuse reflector and substrate.
Described high diffuse reflector or substrate are positioned at the below on said led chip plane of living in and in parallel.
Above-mentioned high diffuse reflection baseplate material comprise have the high irreflexive metal of ultraviolet and visible-range, high-molecular organic material such as high whiteness nylon/plastics/Te Fulong etc., high whiteness metallic compound material is like pottery (comprise ceramic body that sintering is crossed and not the ceramic body crossed of sintering) etc.Wherein surperficial high diffuse-reflective material processing mode comprises: 1) powder metallurgy sintered mode or the high pressure mode of colding pressing obtain the homogenous material system of high whiteness or metallic compound such as single-phase or multiphase ceramic, the cermet etc. of heterogeneous material system mixture, and obtain the nonmetallic surfaces such as high polymer have high irreflexive metal surface or have high whiteness; 2) to all surface roughening process of metal surface or nonmetallic surface, surface sand-blasting roughening process etc. for example; 3) realize the composite surface material preparation technology of high diffuse-reflective material coating or coating at the alligatoring substrate surface; Comprise and adopt thermal spraying or modes such as flame-spraying or electric arc plating, the conventional spraying of employing, electrochemistry plating or be coated with ceramic glaze or swabbing mode, form one or more layers at said substrate surface and have film or coating or the glaze layer or the coating of high diffuse effect.Substrate surface can be processed the three-dimensional convex-concave structure with submillimeter level, is beneficial to further strengthen the dispersion effect of chip bottom bright dipping.
Finish materials can select to have the material system of surperficial high diffuse reflective characteristics, like a kind of in the high whiteness materials such as nitride, oxide, sulfide, phosphide, boride, aluminate, silicate, borate, carbonate, chloride and high white clay such as high purity aluminium oxide, magnesia, titanium oxide, zirconia, barium monoxide, calcium phosphate, barium phosphate, barium sulfate, calcium silicates, calcium carbonate, boron nitride, zirconium silicate, (oxygen) zirconium chloride, quartz or several.But be not limited only to above-mentioned several types of materials.
Said substrate comprises printed circuit board (PCB), pottery or the metal substrate that is formed with electrode above that.
Said sealer can be by mixing within it and evenly disperseing the transparent epoxy resin glue or the silica gel moulding of fluorophor to process.
The object of the present invention is to provide a kind of New LED chip package base plate; Its effectively diffuse reflection bright dipping bottom led chip; Make the full and uniform covering of the fan (radian is near 170 degree, and the FGHJ covering of the fan among Fig. 1 is seen in traditional being merely about 60 degree) that expands into wide-angle of reflective cylinder, obtain the more large-area face (seeing the JKLMNO covering of the fan among Fig. 2) that excites; Thereby significantly improve the stimulated emission area of fluorescent material, finally significantly improve the light characteristic of dazzling of light efficiency, reduction LED lamp.Simultaneously since substrate not the color rendering index stability of the LED of making easy to change be enhanced, directly light decay also obviously reduces.
Other characteristics of the present invention and specific embodiment can further be understood in the detailed description of following conjunction with figs..
Description of drawings
Below in conjunction with accompanying drawing and embodiment the present invention is further specified.
Fig. 1 is the encapsulating structure of existing common LED chip, and the fan-shaped angle of usable reflection cylinder of direct reflection optics design wherein is about 60 degree;
Fig. 2 is the overall package structure side view of the embodiment of the invention, and the fan-shaped angle of usable reflection cylinder of diffuse reflection optics design wherein is about 170 degree;
Fig. 3 is the overall structure vertical view of the embodiment of the invention;
Embodiment
Embodiment 1:
With reference to Fig. 2 and Fig. 3, the present invention implements like this:
On the upper surface 101 of aluminium or copper or iron or made LED base plate for packaging 10 such as pottery or circuit board, carry out surface diffuse reflectance layer 102 and handle, make its have diffuse reflectance greater than 80%, direct reflection and transmitance be lower than 20% surface.Can adopt ceramic membrane, ceramic glaze, surface inorganic or organic coating, Te Fulong film etc. even high whiteness ceramic body to make to have high irreflexive upper surface layer 102 with high diffuse reflection such as high whiteness.In embodiment 1, the ultrawhite glaze that adopts diffuse reflection in the 200nm-760nm wave-length coverage can reach 98% (promptly whiteness also can reach 98 simultaneously) is coated on the high diffuse reflector 102 of formation on the Cu substrate.
Pre-designed electrode 501 and 502 is installed on the relevant position of substrate 10, and fixes with AB glue.
Utilize transparent crystal-bonding adhesive 201 that blue-light LED chip 20 is fixing on it on the high diffuse reflector 102 having, and baking 2 hours in 150 ℃-180 ℃ baking oven, crystal-bonding adhesive is solidified.
Two electrodes that utilize gold thread or aluminum steel 30 will accomplish the led chip of solid crystalline substance are drawn respectively and are welded in respectively on two electrodes 501 and 502 on the substrate.
Transparent silica gel and fluorescent material are evenly mixed and vacuum defoamation, evenly disperseed to utilize behind the silica gel of fluorescent material point gum machine with led chip 20 and high diffuse reflector 102 embeddings in silica gel 40.Packaged LED was toasted 1 hour down at 130 ℃, toasted 3 hours down at 150 ℃ then.
Embodiment 1 compares with the silver-plated substrate of light water under similarity condition, and the diffuse reflection of inorganic compound substrate surface 102 is 98%, and the silver-plated specular reflectivity of copper base surface water as a comparison is for being similarly 98%; Under this situation; Adopt same chip and same technology and material to encapsulate, the test result under similarity condition finds that the photoelectric conversion efficiency of present embodiment has improved more than 30%; Highly significant, light decay was lower than 5% in 3000 hours.Concrete data are seen table 1.
Embodiment 2:
Embodiments of the invention 2 are similar with above enforcement row 1; Just the high diffuse reflection glaze layer 102 with above embodiment 1 is changed to barium sulfate coating or aluminium oxide or the magnesium oxide coating that utilizes thermal spraying; Adjusting process makes in the 300nm-600nm wave-length coverage diffuse reflection can reach 92% (promptly whiteness also can reach 92 simultaneously), and all the other steps and embodiment 1 are identical.Concrete data are seen table 1.
Embodiment 3:
Embodiments of the invention 2 are similar with above enforcement row 1; Just the high diffuse reflection glaze layer 102 of above embodiment 1 and Cu substrate are changed to the pottery that has behind in 400nm-620nm wave-length coverage diffuse reflection can reach 98% sintering of (i.e. while whiteness also can reach 98) together, all the other steps and embodiment 1 are identical.Concrete data are seen table 1.
Embodiment 4:
Embodiments of the invention 2 are similar with above enforcement row 1; Just the high diffuse reflection glaze layer 102 of above embodiment 1 and Cu substrate are changed to the pottery that has after in 400nm-620nm wave-length coverage diffuse reflection can reach 98% superhigh pressure of (i.e. while whiteness also can reach 98) is colded pressing together, all the other steps and embodiment 1 are identical.Concrete data are seen table 1.
Embodiment 5:
Embodiments of the invention 2 are similar with above enforcement row 1; Just the Cu substrate with above embodiment 1 is changed to whiteware (diffuse reflection can reach 92%), and high diffuse reflection glaze layer 102 changes the high diffuse reflector that utilizes spraying ultrawhite quartz sand (whiteness 99) or titanium white powder (whiteness 99) to obtain into.The diffuse reflection in the 400nm-620nm wave-length coverage of this diffuse reflector 102 can reach 99% (promptly whiteness also can reach 99 simultaneously).All the other steps and embodiment 1 are identical.Concrete data are seen table 1.
Embodiment 6:
Embodiments of the invention 2 are similar with above enforcement row 1, and just the Cu substrate with above embodiment 1 is changed to aluminium base, and high diffuse reflection glaze layer 102 changes the high diffuse reflector that utilizes spraying ultrawhite quartz sand (whiteness 99) or titanium white powder (whiteness 99) to obtain into.The diffuse reflection in the 400nm-620nm wave-length coverage of this diffuse reflector 102 can reach 99% (promptly whiteness also can reach 99 simultaneously).All the other steps and embodiment 1 are identical.Concrete data are seen table 1.
Embodiment 7:
Embodiments of the invention 2 are similar with above enforcement row 1, and just the blue light GaN chip with above embodiment 1 changes red light chips into, in sealing, does not add fluorescent material.All the other steps and embodiment 1 are identical.Can light efficiency be improved 3%, can improve and dazzle optical phenomenon.
Embodiment 8:
Embodiments of the invention 2 are similar with above enforcement row 1, and just the blue light GaN chip with above embodiment 1 changes the ultraviolet light chip into, in sealing, adds the fluorescent material of ultraviolet stimulated emission.All the other steps and embodiment 1 are identical.Can light efficiency be improved 20%.
The above implements several preferred embodiments that row only are LED encapsulation of the present invention; Be not that technical scope of the present invention is done any restriction; Every foundation technical spirit of the present invention all still belongs to technology contents of the present invention and scope to top any trickle modification, equivalent variations and modification that embodiment did.
The high diffuse reflection substrate LED encapsulation among all embodiment of table 1 the present invention and the substrate water of standard plate luminous efficiency of source and the light decay situation after the high direct reflection Ag film LED encapsulation.
Annotate: contrast standard appearance is meant the led chip encapsulation of behind the high reflection of water plating Ag layer on the red copper substrate, carrying out.