KR101764344B1 - method for manufacturing substrate for light emitting device mounted driving and power supply circuit together and the substrate thereby - Google Patents

Abstract

The present invention relates to a driver circuit for mounting a plurality of optical elements, a driver circuit, and a power supply circuit on a substrate for a single optical device having a vertical insulating layer so as to reduce the overall size, And an optical device substrate manufacturing method and substrate used therefor.
According to an aspect of the present invention, there is provided an optical device integrated with a drive circuit and a power supply circuit, comprising: a substrate for an optical device having a plurality of transverse vertical insulating layers penetrating the substrate vertically in the vertical direction, A lateral vertical insulating layer, and a lateral vertical insulating layer, wherein the lateral vertical insulating layer includes at least two of the lateral vertical insulating layers and includes a plurality of optical devices; And a driving circuit substrate portion on which the driving circuit element is mounted.
In the above-described configuration, the optical element substrate portion is characterized by having at least one vertical vertical insulating layer penetrating the substrate vertically up and down.
And one or more cavities for the optical device including the vertical insulating layer are formed in the optical device substrate portion to a predetermined depth from the upper surface.
And the at least one drive circuit cavity including the vertical insulating layer is formed in the drive circuit board portion to a predetermined depth from the upper surface.
And a power supply circuit board attached to a lower surface of the drive circuit board portion.
And a heat sink attached to a lower surface of the optical element substrate portion.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to an optical device substrate integrated with a driving circuit and a power supply circuit,

More particularly, the present invention relates to a driving circuit for mounting a plurality of optical elements, a driving circuit thereof, and a power supply circuit on a substrate for a single optical device having a vertical insulating layer, To an optical device substrate integrated with a power circuit.

In general, a light emitting diode (LED), which is a semiconductor light emitting diode, is attracting attention in various fields as an environmentally friendly light source that does not cause pollution. In recent years, as the use range of LEDs has expanded to various fields such as indoor and outdoor lighting, automotive headlights, and back-light units (BLU) of display devices, high efficiency and excellent heat emission characteristics of LEDs have become necessary. In order to obtain a high efficiency LED, the material or structure of the LED must be improved primarily, but the structure of the LED package and the materials used therefor also need to be improved.

Such high-efficiency LEDs generate high temperatures, and if they are not effectively emitted, the temperature of the LEDs becomes high, which deteriorates the characteristics thereof, thereby decreasing the service life. Therefore, efforts are being made to effectively dissipate the heat generated from the LED in a highly efficient LED package.

Hereinafter, various devices including light emitting diodes (LEDs) are collectively referred to as 'optical devices', and various products including one or more thereof are referred to as 'optical devices'.

1A to 1D are perspective views of respective steps for explaining a conventional optical device manufacturing method. First, as shown in FIG. 1A, in order to form a substrate 10 on which a conventional optical device is mounted, a conductive plate 11 made of, for example, copper having a predetermined thickness and an insulating plate 12 Are alternately joined in the planar direction to form the block body 13 (see Fig. 1B). Here, the bonding of the conductive plate member 11 and the insulating plate member 12 may be performed by an adhesive, or by thermocompression bonding.

Subsequently, as shown in Fig. 1B, when the block body 13 manufactured by Fig. 1A is cut in the direction orthogonal to the surface of the conductive plate member 11 by an appropriate width, that is, Shaped conductive portion 10a and the insulating portion 10b are alternately arranged.

Next, as shown in Fig. 1D, the LED chips 2 are arranged in a matrix form at appropriate intervals on the conductive parts 10a-1, 10a-2, 10a-3 of the element substrate 10 and mounted The wires 3 are drawn out from the LED chips 2 in the respective columns of the conductive parts 10a-1, 10a-2, 10a-3 and connected to the conductive parts in the next row. An LED array in the form of a plate-like body is produced by molding.

On the other hand, in the thus manufactured plate array type LED array, each column is electrically connected in parallel, and each row is connected in series. It can be manufactured as it is, separated into appropriate column units or row units, do. Furthermore, if the plate array type LED array is used as it is, it is mounted on a metal PCB or a separate heat sink is attached to the bottom.

2 is a perspective view schematically showing the configuration of a conventional optical device composed of a plurality of optical elements. 2, for driving the LED array 20 in the form of a plate, for example, manufactured by the method of FIG. 1, passive elements 30 such as resistors and capacitors and constant currents And a power supply circuit 60 such as a SMPS or the like including a driving IC 40 that performs a function of supplying a power supply voltage to the power supply circuit 60. Conventionally, And the LED array substrate 10 is connected to the LED array substrate 10 through the power cable 50, thereby increasing the overall size of the optical device, there was.

SUMMARY OF THE INVENTION The present invention has been conceived to solve the problems described above, and it is an object of the present invention to provide an optical device substrate having a vertical insulating layer by mounting a plurality of optical elements, a driving circuit thereof, And an optical device substrate integrated with a power circuit for facilitating handling and management.

According to an aspect of the present invention, there is provided an optical device integrated with a drive circuit and a power supply circuit, comprising: a substrate for an optical device having a plurality of transverse vertical insulating layers penetrating the substrate vertically in the vertical direction, A lateral vertical insulating layer, and a lateral vertical insulating layer, wherein the lateral vertical insulating layer includes at least two of the lateral vertical insulating layers and includes a plurality of optical devices; And a driving circuit substrate portion on which the driving circuit element is mounted.

In the above-described configuration, the optical element substrate portion is characterized by having at least one vertical vertical insulating layer penetrating the substrate vertically up and down.

And one or more cavities for the optical device including the vertical insulating layer are formed in the optical device substrate portion to a predetermined depth from the upper surface.

And the at least one drive circuit cavity including the vertical insulating layer is formed in the drive circuit board portion to a predetermined depth from the upper surface.

And a power supply circuit board attached to a lower surface of the drive circuit board portion.

And a heat sink attached to a lower surface of the optical element substrate portion.

According to another aspect of the present invention, there is provided a method of manufacturing a driver circuit board, the method comprising: (a) stacking a plurality of metal plate members for a drive circuit board to function as a drive circuit board unit on which a drive circuit is mounted; The two side surfaces of the optical element substrate block, which are formed by laminating a plurality of metal plate members for an optical element substrate to serve as an optical element substrate portion on which the longitudinal length is equal to the longitudinal length of the drive circuit board portion and on which the optical devices are mounted, (B) stacking the uppermost metal plate of the driving circuit board portion with an insulating layer interposed therebetween in a lateral direction while interposing the insulating layer interposed therebetween; (C) stacking a metal plate for connection, which has the same length and the same length as the metal plate for the drive circuit board, on the uppermost metal plate of the optical element substrate through the insulating layer, (D) cutting the intermediate product after the step (c) by a predetermined width in the horizontal direction and the step (d).

According to still another aspect of the present invention, there is provided a method of manufacturing a driver circuit board, comprising: (h) stacking a plurality of metal plate members for a driver circuit board to serve as a drive circuit board unit on which a drive circuit is mounted; Two side surfaces of the metal plate for an optical element substrate to function as an optical element substrate portion having a vertical length equal to the longitudinal length of the drive circuit board portion and to be mounted with an optical element are interposed in the transverse direction with an insulating layer interposed therebetween, (I) depositing a plurality of layers on a metal plate with an insulating layer interposed therebetween; (J) stacking a metal plate for connection, which has the same length and the same length as the metal plate for the drive circuit board, on the uppermost metal plate of the optical element substrate through the insulating layer, And cutting (k) the intermediate product through the step (j) by a predetermined width in the horizontal direction. The present invention also provides a method of manufacturing a substrate for an optical device with an integrated power circuit.

According to the optical device substrate integrated with the drive circuit and the power supply circuit of the present invention, not only the overall size of the optical device can be reduced, but also the handling and management of the optical device can be facilitated.

FIGS. 1A to 1D are perspective views illustrating respective steps of a conventional optical device manufacturing method.
2 is a perspective view schematically showing a configuration of an optical device made up of a plurality of conventional optical elements.
3 is a circuit configuration diagram of an optical device according to an embodiment of the present invention;
4 is a flow chart for explaining a method for manufacturing a substrate for an optical device of the present invention.
5A is a plan view of a substrate for an optical device according to an embodiment of the present invention.
FIG. 5B is a plan view of the state in which the cavity forming process is completed in FIG. 4, and FIG.
FIG. 5C is a plan view of the substrate for an optical device in a state where the plating process is completed in FIG. 4, and FIG.
FIG. 5D is a plan view of a substrate for an optical device in a state where the mounting process of the optical device and the driving circuit device is completed in FIG. 4, and FIG.
Fig. 5E is a plan view of the optical device substrate in a state in which the encapsulating material encapsulating process is completed in Fig. 4, and Fig.
Fig. 5F is a plan view of the substrate for an optical device in a state where the attachment of the power supply circuit board is completed, and Fig.
FIG. 5G is a plan view of the substrate for an optical device in a state where the attachment of the heat sink is completed, and FIG.
FIG. 6 is a photograph showing an actual manufacturing process of a driving circuit and a power circuit integrated optical device having the circuit configuration of FIG. 3; FIG.
7 is a perspective view for explaining another method for manufacturing the circuit board for an optical device shown in Fig. 3 in the present invention. Fig.
8 is a perspective view for explaining another method for manufacturing the circuit board for an optical device shown in Fig. 3 in the present invention. Fig.
9 is a plan view of an optical device according to another embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout.

3 is a circuit block diagram of an optical device according to an embodiment of the present invention. As shown in FIG. 3, an optical device according to an exemplary embodiment of the present invention includes a total of 10 optical devices (D1 to D10), for example, a total of 10 LEDs each having a power consumption of 1 W connected in series. A DC power source VDDH of a predetermined size is connected to the anode electrode of the optical device serial connection pair made up of the above-mentioned ten optical devices D1 to D10, and a driving IC And the output terminal OUT of the transistor U1 is connected.

On the other hand, an external resistor R is connected to the external resistor terminal R _ext of the driving IC U1, and a ground terminal GND thereof is grounded. A capacitor C is connected to the power supply terminal VDD, (VDD) is applied. The driving IC U1 may further include an OEB terminal receiving an external illumination control command. The circuit configuration of the optical device shown in FIG. 3 is only an example, and it can be modified in any amount depending on the type of the driving IC, the number of optical devices, or the connection relation.

4 is a flowchart for explaining a method of manufacturing a substrate for an optical device according to the present invention. 4, in step S10, a plurality of optical elements are connected at least in series, and further, a substrate having at least two vertical insulating layers is mounted on a substrate Such a substrate can be manufactured by the manufacturing process shown in, for example, Figs. 1A to 1D. On the other hand, the substrate for optical devices may be made of aluminum, copper, or one or more metal plates having good thermal conductivity and electrical conductivity. Particularly, when the substrate for optical devices is implemented by a metal plate made of aluminum, It is preferable to perform the substrate manufacturing process shown in Figs. 1A to 1D after the entire surface is anodized.

5A is a plan view of a substrate for an optical device according to an embodiment of the present invention. In FIG. 5A, five optical devices are arranged on the optical device substrate corresponding to the optical device circuit of FIG. 3, for example, the left column and the right column, A substrate for an optical device is illustrated. Accordingly, a total of five vertical insulating layers and driving circuits, for example, passive elements such as a resistor R and a capacitor C, for electrically insulating the electrodes of the upper and lower optical devices, A total of four vertical insulating layers (hereinafter, a total of nine vertical insulating layers are referred to as a 'transverse vertical insulating layer' 110) for electrically insulating the terminals of the driving IC U1 are formed. Hereinafter, a substrate region in which an optical device is arranged is referred to as an 'optical device substrate portion A', and a substrate region in which a driving circuit is disposed is referred to as a 'driving circuit substrate portion'.

In the meantime, the optical elements of the left column and the right column are electrically insulated except for the uppermost optical element. To this end, a vertical insulating layer (hereinafter referred to as a vertical vertical insulating layer) (Not shown). The vertical vertical insulating layer 120 may be formed of a slit-shaped gap cut in accordance with laser processing, or may be formed such that a separate insulating material is filled in the gap. Other methods of forming the vertical vertical insulating layer 120 will be described later.

5A, the vertical length between the transverse vertical insulating layers 110 of the drive circuit board portion B is larger than that of the passive element or the driving IC mounted on the optical element substrate portion A But may be formed differently from the vertical length between the respective transverse vertical insulating layers 100. Reference numeral 125 in FIG. 5A denotes an optical device that electrically connects the optical device disposed on the upper surface of the optical device substrate 100 and the driving IC to the terminal pin of the power supply circuit board attached to the lower surface of the optical device substrate 100 Pin hole.

Next, in step S15, a white paint 130 (for example, white soldering paste) is applied to the upper surface of the optical device substrate 100 in order to improve the light distribution effect. FIG. 5B shows a state in which the white paint application process is completed Fig. 2 is a plan view of the substrate for an optical device of Fig. This white paint layer 130 also contributes to the reduction of the plating material in the plating process described later.

4, a cavity in which an optical device and a driver circuit are mounted on the upper surface of the optical device substrate 100 prepared in this way is formed by, for example, cutting or etching, and FIG. 5C is a cross- And FIG. 11 is a cross-sectional view taken along line II thereof. As shown in FIG. 5C, the cavity 140 for an optical device contains the transverse vertical insulating layer 110, and it is preferable that the cavity 140 for the optical device is formed of a round groove having a shape of a superimposed light to improve the reflection performance of light Do. Further, a portion where the optical element is to be mounted with respect to the transverse vertical insulating layer 110 is a relatively large area (hereinafter referred to as a " relative small surface area portion 142 " Relatively facing surface portion 144 ').

The cavity for the driving circuit may also be formed with one or more grooves extending over part or all of the length of the driving circuit board portion B so as to include the transverse vertical insulating layer 110. In this embodiment, And the cavity 160 for the driving IC on which the driving IC is to be mounted are separately formed.

Next, in step S30, metal plating, for example, silver (Ag) plating is performed on the bottom surface and the main wall surface of the optical device cavity 140 in order to improve the reflection performance and bonding performance of the light generated in the optical device. The metal plating layer 170 may be formed by an electrolytic plating method or the like. In this case, the horizontal vertical insulating layer 110 is not formed with the metal plating layer 170 as shown in the figure, so that the relative small surface area 142 and the relatively large surface area 144 are formed around the vertical vertical insulating layer 110, Is electrically insulated. A metal plating layer may be formed on the bottom surface of the passive element cavity 150 and the driving IC cavity 160 to improve the bonding performance. FIG. 5D is a plan view of the substrate for an optical device in a state where the plating process is completed, and FIG.

4, in step S40, an optical element 180 (D1 - D10), a passive element (150), and a passive element cavity (150) are formed in the optical device cavity 140, the passive cavity 150, The optical device 180 is mounted on the relatively opposite surface 144 of the optical device cavity 140 and the optical device 180 is mounted on the surface of the optical device 180. [ One of the electrodes, that is, one of the cathode and anode electrodes, for example, the anode electrode, is connected to the relative facing portion 144 via a wire 182 and the cathode electrode is connected to the relative small surface portion 142 via a wire 182 do. Of course, the anode electrode (or the cathode electrode) of the optical element 180 is formed so as to be exposed on the lower surface of the optical element 180, and the optical element 180 is bonded to the optical element 180 by a bonding method that maintains conductivity, In the case of mounting the mounting portion 144, only one wire, for example, a wire connecting the cathode portion of the optical element 180 and the relatively small surface portion 142, will be required. The passive element resistance R, the capacitor C and the driver IC U1 may also be electrically connected to the substrate by direct chip bonding or wire bonding. FIG. 5E is a plan view and a cross-sectional view taken along the line I-I of the optical device substrate in a state where the mounting process of the optical device and the driving circuit device is completed.

Next, in step S50, the encapsulants 190 and 192 are sealed in the cavities 140, 150 and 160, and in particular, the encapsulant 190, which is sealed in the cavity 140 for the optical device, Materials may also be included. Fig. 5F is a plan view of the substrate for an optical device in a state in which the encapsulating material encapsulating process is completed, and Fig.

Next, in step S60, the power supply circuit board 200 on which the power supply circuit element of the lower surface of the drive circuit board portion B of the optical device substrate 100 is mounted is attached. In this case, It may be soldered directly to the substrate 100 and attached. 5G is a plan view of the substrate for an optical device in a state where the attachment of the power supply circuit board is completed and a cross-sectional view thereof taken along the line II, and FIG. Fig. 5H is a plan view of the substrate for an optical device in a state in which the attachment of the heat sink is completed, and Fig.

6 is a photograph showing an actual manufacturing process of a driving circuit and a power circuit integrated optical device having the circuit configuration of FIG.

Fig. 7 is a perspective view for explaining another method for manufacturing the circuit board for an optical device shown in Fig. 3 in the present invention. As shown in Fig. 7, in forming the vertical vertical insulating layer provided on the optical element substrate portion, the laminated block body constituting the optical element substrate portion shown in Fig. 5A is manufactured by the method shown in Fig. Or after a laminated block body having a width of 1/2 of the transverse length of the optical element substrate portion from the beginning is manufactured, the laminated block bodies for the two optical element substrate units thus prepared are laminated by a driving circuit The longitudinal vertical insulating layer may be formed in such a manner as to face each other on the upper portion of the substrate portion. Next, the substrate for optical devices shown in Fig. 5A can be made by cutting the stacked block body thus formed with a predetermined width from top to bottom.

8 is a perspective view for explaining another method for manufacturing the circuit board for an optical device shown in Fig. 3 in the present invention. As shown in Fig. 8, another method of forming the vertical vertical insulating layer is to form two sheets of metal plate having a width of 1/2 the width of the optical element substrate portion in the lamination process of Fig. A longitudinal insulating layer may be formed on the optical element substrate portion by a method of mutually inserting and bonding an insulating film or an insulating adhesive.

9 is a top view of an optical device according to another embodiment of the present invention. The optical device of FIG. 9 is composed of 10 optical elements in total, but since the vertical vertical insulating layer is not formed on the optical device substrate 100 ', the five optical elements vertically arranged are arranged in a mutually in- While the optical elements arranged on the left and right sides of each column are connected in parallel. In this case, the output terminal OUT of the driving IC may be electrically connected to the uppermost row of the optical element substrate portion by the cables.

On the other hand, in the above-described embodiments, the transverse vertical insulating layer and the vertical vertical insulating layer may be made of an anodizing layer and an adhesive or an insulating film and an adhesive or an anodizing layer, an insulating film, and an adhesive when the substrate is an aluminum substrate.

The driving circuit and the power circuit integrated optical device of the present invention, and the optical device substrate manufacturing method and substrate used therefor are not limited to the above-described embodiments, and various modifications can be made within the scope of the technical idea of the present invention have. For example, the structure may be modified to accommodate a total of five optical elements vertically arranged in Fig. 5B by a cavity formed by one rectangular groove.

100, 100 ': substrate for an optical device, 110: transverse vertical insulating layer,
120: longitudinally oriented vertical laminated layer, 130: white colored layer,
140: Cavity for optical device, 142: Relatively small surface area,
144: Relative specific surface area, 150: Cavity for passive element,
160: Cavity for driving IC, 170: Metal plating layer,
180, 190: 50 2: groove,
180, D1 - D10: optical element, 182: wire,
190, 192: sealing material, R: resistance,
C: Capacitor, U1: Drive IC

Claims (8)

The substrate is divided into an optical element substrate portion and a driving circuit substrate portion by a transverse vertical insulating layer penetrating from the upper surface to the lower surface of the substrate,
Wherein the optical device substrate region further includes at least one transverse vertical insulating layer penetrating from the upper surface to the lower surface of the substrate to electrically isolate the photodevice electrodes disposed adjacent to the substrate in the longitudinal direction within the region,
Wherein at least one lateral vertical insulating layer penetrating from the upper surface to the lower surface of the substrate for electrically isolating the terminals of the driving circuit necessary for driving the optical elements is further formed in the driving circuit substrate region,
Wherein the optical device substrate region and the driving circuit substrate region are further provided with pin holes for electrically connecting to the terminal pins of the power supply circuit board attached to the lower surface of the substrate. Device substrate. [2] The apparatus of claim 1, further comprising: at least one vertical vertical insulation layer penetrating from the upper surface to the lower surface of the substrate to electrically isolate the photodevice electrodes disposed adjacent to the substrate laterally of the substrate And an optical device substrate integrated with the power circuit. 3. The method according to claim 1 or 2,
Further comprising a power supply circuit board attached to a lower surface of the drive circuit board area. The method of claim 3,
Further comprising a heat sink attached to a lower surface of the optical device substrate portion region. 4. The driving circuit according to claim 3, wherein at least one cavity for at least one optical device is formed in the optical device substrate region, the cavity for each of the vertical insulating layers being formed in the optical device substrate region, Power circuit integrated optical device substrate. The driving circuit according to claim 3, wherein a cavity for at least one driving circuit enclosing a vertical insulating layer formed in the area of the driving circuit substrate is formed in a region of the driving circuit substrate, Power circuit integrated optical device substrate. The optical device substrate according to any one of claims 1 to 3, wherein at least one cavity for the optical device, each containing a vertical insulating layer formed in the region of the optical device substrate, An optical device substrate integrated with a driving circuit and a power circuit. The driving circuit board of claim 1 or 2, wherein a cavity for at least one driving circuit enclosing a vertical insulating layer formed in the region of the driving circuit substrate is formed to a predetermined depth from the upper surface of the substrate, An optical device substrate integrated with a driving circuit and a power circuit.

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