CN104124325A - 一种光反射基板、led模组及其制作方法 - Google Patents
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Abstract
本发明公开了一种光反射基板,包括镜面铝基板,镜面铝基板上设有绝缘感光胶层,绝缘感光胶层上设有导电线路层,导电线路层上设有用于连接LED芯片的正电极和负电极的镀锡层和用于保护导电线路层的保护层;还公开了一种LED模组及制作方法。本发明采用在镜面铝基板上设有绝缘感光胶层,绝缘感光胶层上设有导电线路层,导电线路层设有用于连接LED芯片的正电极和负电极的镀锡层和用于保护导电线路层的保护层,由于镜面铝基板具有高反射、高导热的性能,不仅提高了铝基板的光反射率,而且导热性、散热性好,大大提升了LED模组的性能。
Description
技术领域
本发明涉及LED技术,尤其是涉及一种光反射基板、LED模组及其制作方法。
背景技术
目前,LED发光二极管由于具有耗电量低、环保节能等优点而得到社会各界的广泛关注和认可,众多相关的生产厂商积极响应国家提出的节能减排政策,在LED的研发和推广上做出了极大投入,许多公司都开发出了集成式LED模组,但现有的LED模组(如图1所示)存在一些不足之处:LED模组中基板101采用反射率低的普通铝基板,存在光效低下的问题,而且热阻高,散热性能也不好,导致LED模组的可靠性大大降低;LED芯片通过固晶胶102固定在基板101上,固晶胶102导热性很低,不容易将热量散发出去,影响产品的使用寿命;各LED芯片104通过焊线103连接,焊线103容易断掉,失效率很高,降低了产品的稳定性。
发明内容
本发明所要解决的技术问题在于:提供一种光反射基板、LED模组及制作方法,不仅光反射率更高,而且导热性、散热性好,大大提升了LED模组的性能和稳定性。
为解决上述技术问题,本发明提出了一种光反射基板,包括镜面铝基板,所述镜面铝基板上设有绝缘感光胶层,所述绝缘感光胶层上设有导电线路层,所述导电线路层设有用于连接LED芯片的正电极和负电极的镀锡层和用于保护导电线路层的保护层。
进一步地,所述保护层为白油层。
为解决上述技术问题,本发明还提出了一种LED模组,包括上述的光反射基板,还包括LED芯片,所述LED芯片的正电极和负电极通过金属层与镀锡层连接。
进一步地,所述LED芯片的正电极和负电极位于LED芯片的靠近导电线路层的同一侧面上。
进一步地,所述LED芯片上罩设有一封装胶体。
进一步地,所述镜面铝基板上设有围坝装置,所述围坝装置内填充有封装胶体。
进一步地,所述成型封装胶体内设有荧光粉。
优选地,所述金属层为锡膏层。
为解决上述技术问题,本发明还提出了一种LED模组的制作方法,包括以下步骤:
步骤(1),在镜面铝基板上使用绝缘感光胶按照所需线路位置进行印刷,生成绝缘感光胶层;
步骤(2),在绝缘感光胶层上压合或者印刷导电线路层,然后根据线路位置将多余绝缘感光胶层通过曝光去除;
步骤(3),在导电线路层与LED芯片的正电极和负电极的焊接位置进行镀锡,生成镀锡层,在导电线路层上未生成镀锡层的区域采用保护层进行保护;
步骤(4),在镀锡层上点胶形成金属层,将LED芯片的正电极和负电极通过金属层与镀锡层焊接。
进一步地,所述步骤(4)中,通过回流焊或者高温加热的方式将金属层融化,然后将LED芯片的正电极和负电极分别与镀锡层固定连接。
上述技术方案具有如下有益效果:本发明采用在镜面铝基板上设有绝缘感光胶层,绝缘感光胶层上设有导电线路层,导电线路层设有用于连接LED芯片的正电极和负电极的镀锡层和用于保护导电线路层的保护层,由于镜面铝基板具有高反射、高导热的性能,不仅提高了铝基板的光反射率,而且导热性、散热性好,大大提升了LED模组的性能;同时LED芯片的正电极和负电极与导电线路层通过镀锡层连接,提高了了产品的稳定性。
上述说明仅是本发明技术方案的概述,为了能够更清楚了解本发明的技术手段,而可依照说明书的内容予以实施,并且为了让本发明的上述和其他目的、特征和优点能够更明显易懂,以下特举较佳实施例,并配合附图,详细说明如下。
附图说明
图1是现有LED模组结构的正面剖视图;
图2是本发明中LED模组结构的正面剖视图;
图3是本发明中LED模组结构的侧面剖视图;
图4是本发明中LED模组设有成型封装胶体时的正面剖视图;
图5是本发明中LED模组设有围坝装置时的正面剖视图。
具体实施方式
需要说明的是,在不冲突的情况下,本申请中的实施例及实施例中的特征可以相互组合。下面结合附图对本发明做进一步描述。
实施例一
如图2和图3所示,光反射基板包括镜面铝基板1,镜面铝基板1上设有绝缘感光胶层2,绝缘感光胶层2上设有导电线路层3,导电线路层3上设有用于连接LED芯片6的正电极61和负电极62的镀锡层4和用于保护导电线路层3的保护层5,在本实施例中,保护层5采用白油层来保护导电线路层3,由于镜面铝基板1具有高反射、高导热的性能,所以采用光反射基板制作的LED模组,相比传统的铝基板,镜面铝基板1不仅可以提升LED模组的光反射率,而且导热性、散热性好,大大提升了LED模组的性能。
实施例二
基于实施例一中所述的优点,在实施例一的基础上进一步提出一种LED模组,如图2和图3所示,LED模组包括实施例一中的光反射基板,还包括LED芯片6,LED芯片6的正电极61和负电极62通过金属层7与镀锡层4连接,具体地,金属层7为锡膏层,锡膏层主要是为了将LED芯片6的正电极61和负电极62分别与镀锡层4固定连接,并起到导电导热的作用,降低产品的热阻,而且LED芯片6的正电极61和负电极62位于LED芯片6靠近导电线路层3的同一侧面上,即正电极61和负电极62位于LED芯片6的底部,通过金属层7直接将正电极61和负电极62与镀锡层4焊接,防止了正电极61和负电极62与导电线路层3之间地断开,增加了产品的可靠性,并通过高导热金属层7将LED芯片6发出的热量直接传导到镜面铝基板1上进行散热,降低了产品热阻。
如图4所示,为了保护LED芯片6,在LED芯片6上罩设有一成型封装胶体8,为了提升发光效果,在成型封装胶体8内填充有荧光粉,组成封装胶体8与荧光粉的混合体,发光效果更好;作为另一种实施方式,如图5所示,还可以在镜面铝基板1上设有围坝装置9,封装胶体8与荧光粉的混合体填充在围坝装置9内,围坝装置9可以在每一颗LED芯片6上形成统一规格的成型封装胶体8,提高产品的质量。
实施例三
如图2至5所示,本实施例提出了一种LED模组的制作方法,包括以下步骤:
步骤(1),在镜面铝基板1上使用绝缘感光胶按照所需线路位置进行印刷,生成绝缘感光胶层2;
步骤(2),在绝缘感光胶层2上压合或者印刷导电线路层3,然后根据线路位置将多余绝缘感光胶层2通过曝光去除;
步骤(3),在导电线路层3与芯片的正电极61和负电极62的焊接位置进行镀锡,生成镀锡层4,在导电线路层3上未生成镀锡层4的区域采用白油层进行保护;
步骤(4),在镀锡层4上点胶形成金属层7,将LED芯片6的正电极61和负电极62通过金属层7与镀锡层4焊接,具体地,通过回流焊或者高温加热的方式将金属层7融化,然后将LED芯片6的正电极61和负电极62分别与镀锡层4固定连接。
LED芯片6的正电极61和负电极62通过金属层7、镀锡层4与线路层连接,提高了产品可靠性,与现有产品中的各LED芯片的正电极和负电极采用焊线连接相比,可以避免焊线断开或断裂而出现的失效问题;本发明采用金属层7将LED芯片6与镀锡层4焊接,而金属层7具有导热性高的优点,因此降低了产品热阻;本发明中的镜面铝基板具有很高的反射率,其反射率达到98%以上,增加COB的光效。
本发明LED模组采用高反射、高导热镜面铝材料,反射率达到98%以上,不仅能有助于LED芯片6的散热,而且提高了产品可靠性,由于使用了高反射率、高导热的基板材料,提高了白光LED芯片的出光效率。
以上所述是本发明的具体实施方式,应当指出,对于本技术领域的普通技术人员来说,在不脱离本发明原理的前提下,还可以做出若干改进和润饰,这些改进和润饰也视为本发明的保护范围。
Claims (10)
1.一种光反射基板,其特征在于,包括镜面铝基板,所述镜面铝基板上设有绝缘感光胶层,所述绝缘感光胶层上设有导电线路层,所述导电线路层上设有用于连接LED芯片的正电极和负电极的镀锡层和用于保护导电线路层的保护层。
2.如权利要求1所述的LED模组,其特征在于,所述保护层为白油层。
3.一种LED模组,其特征在于,包括如权利要求1或2所述的光反射基板,还包括LED芯片和设于镀锡表面的金属层,所述LED芯片的正电极和负电极通过金属层与镀锡层连接。
4.如权利要求3所述的LED模组,其特征在于,所述LED芯片的正电极和负电极位于LED芯片靠近导电线路层的同一侧面上。
5.如权利要求3所述的LED模组,其特征在于,所述LED芯片上罩设有一封装胶体。
6.如权利要求3所述的LED模组,其特征在于,所述镜面铝基板上设有围坝装置,所述围坝装置内填充有封装胶体。
7.如权利要求5或6所述的LED模组,其特征在于,所述成型封装胶体内设有荧光粉。
8.如权利要求3所述的LED模组,其特征在于,所述金属层为锡膏层。
9.一种LED模组的制作方法,其特征在于,包括以下步骤:
步骤(1),在镜面铝基板上使用绝缘感光胶按照所需线路位置进行印刷,生成绝缘感光胶层;
步骤(2),在绝缘感光胶层上压合或者印刷导电线路层,然后根据线路位置将多余绝缘感光胶层通过曝光去除;
步骤(3),在导电线路层与LED芯片的正电极和负电极的焊接位置处进行镀锡,生成镀锡层,在导电线路层上未生成镀锡层的区域采用保护层进行保护;
步骤(4),在镀锡层上点胶形成金属层,将LED芯片的正电极和负电极通过金属层与镀锡层焊接。
10.如权利要求9所述的LED模组的制作方法,其特征在于,所述步骤(4)中,通过回流焊或者高温加热的方式将金属层融化,然后将LED芯片的正电极和负电极分别与镀锡层固定连接。
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