TWM660368U - Packaging substrate and light emitting module - Google Patents

Packaging substrate and light emitting module Download PDF

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Publication number
TWM660368U
TWM660368U TW113203795U TW113203795U TWM660368U TW M660368 U TWM660368 U TW M660368U TW 113203795 U TW113203795 U TW 113203795U TW 113203795 U TW113203795 U TW 113203795U TW M660368 U TWM660368 U TW M660368U
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Taiwan
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light
layer
adhesive layer
disposed
circuit board
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TW113203795U
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Chinese (zh)
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楊智峰
林曉龍
趙信傑
陳冠宇
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富鹿貿易股份有限公司
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Publication of TWM660368U publication Critical patent/TWM660368U/en

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Abstract

A packaging substrate, including a metal substrate, which has a microstructure layer with a rough surface; a first adhesive layer, disposed on the microstructure layer; a reflection layer, disposed on the first adhesive layer; and a protective layer, disposed on the reflection layer, wherein a surfaces of the first adhesive layer, the reflection layer, and the protective layer all follow the undulations of the rough surface of the microstructure layer. A lighting emitting module including the packaging substrate is also proposed.

Description

封裝基板以及發光模組 Packaging substrate and light-emitting module

本新型創作是有關於一種基板以及封裝模組,特別是關於一種封裝基板以及發光模組。 This novel invention relates to a substrate and a packaging module, in particular to a packaging substrate and a light-emitting module.

高亮度的發光二極體(Light Emitting Diode,LED)是未來光源趨勢,但LED亮度提升的同時,釋放的熱能造成的溫度升高也會隨之增加,而LED本身在高溫環境下容易失效甚至損毀,故如何設計出高導熱效果的LED的乘載基板,是相關廠商需面對問題。 High-brightness light emitting diodes (LEDs) are the future trend of light sources, but as the brightness of LEDs increases, the temperature rise caused by the heat energy released will also increase. LEDs themselves are prone to failure or even damage in high temperature environments. Therefore, how to design a high thermal conductivity LED carrier substrate is a problem that related manufacturers need to face.

另一方面,現有的LED若採用板上晶片封裝(Chips on Board,COB)具有成本低、製程簡便、利於出光和散熱效果佳的優勢。而COB封裝通常是使用正裝LED進行封裝,即LED的電極皆位於LED中背離承載基板的一側,並利用打線進行LED的電性連接。但是在正裝LED的光場分布中側發光佔LED整體出光的比例極高。造成LED設質密度增加時,LED的側向出光容易被附近的其他LED吸收或遮擋,致使發光裝置的出光效率降低。 On the other hand, if the existing LED adopts Chips on Board (COB) packaging, it has the advantages of low cost, simple process, good light output and heat dissipation. COB packaging is usually packaged using a regular LED, that is, the LED electrodes are all located on the side of the LED away from the carrier substrate, and the LED is electrically connected by wire bonding. However, in the light field distribution of regular LEDs, the side emission accounts for a very high proportion of the overall light output of the LED. As a result, when the LED device density increases, the side emission of the LED is easily absorbed or blocked by other nearby LEDs, resulting in a decrease in the light output efficiency of the light-emitting device.

“先前技術”段落只是用來幫助了解本新型創作內容,因此在“先前技術”段落所揭露的內容可能包含一些沒有構成所屬技術領域中具有通常知識者所知道的習知技術。在“先前技術”段落所揭露的內容,不代表該內容或者本新型創作一個或多個實施例所要解決的問題,在本新型創作申請前已被所屬技術領域中具有通常知識者所知曉或認知。 The "Prior Art" paragraph is only used to help understand the content of this novel creation. Therefore, the content disclosed in the "Prior Art" paragraph may contain some knowledge that does not constitute the common knowledge in the relevant technical field. The content disclosed in the "Prior Art" paragraph does not mean that the content or the problems to be solved by one or more embodiments of this novel creation have been known or recognized by the common knowledge in the relevant technical field before the application of this novel creation.

本新型創作提供一種封裝基板及發光模組,其可以增加發光元件的光能利用率,有效改善光學品質。 This novel invention provides a packaging substrate and a light-emitting module, which can increase the light energy utilization rate of the light-emitting element and effectively improve the optical quality.

本新型創作的其他目的和優點可以從本新型創作所揭露的技術特徵中得到進一步的了解。 Other purposes and advantages of this novel creation can be further understood from the technical features disclosed by this novel creation.

本新型創作的一實施例提出一種封裝基板,包括金屬基板,具有一凹凸表面的微結構層;第一黏著層,設置於微結構層上;反射層,設置於第一黏著層上;以及保護層,設置於反射層上,其中第一黏著層的表面、反射層的表面和保護層的表面皆隨著微結構層的凹凸表面起伏。 An embodiment of the present invention provides a packaging substrate, including a metal substrate having a microstructure layer with a concave-convex surface; a first adhesive layer disposed on the microstructure layer; a reflective layer disposed on the first adhesive layer; and a protective layer disposed on the reflective layer, wherein the surface of the first adhesive layer, the surface of the reflective layer, and the surface of the protective layer all fluctuate along the concave-convex surface of the microstructure layer.

本新型創作的一實施例提出一種發光模組,包括封裝基板以及發光元件。其中封裝基板包括金屬基板、第一黏著層、反射層、保護層。金屬基板具有凹凸表面的微結構層,第一黏著層設置於微結構層上。反射層設置於第一黏著層上,保護層設置於反射層上。第一黏著層的表面、反射層的表面和保護層的表面皆隨著微結 構層的凹凸表面起伏,且發光元件和封裝基板之間還包括一導熱膠層設置在保護層上。 An embodiment of the present invention proposes a light-emitting module, including a packaging substrate and a light-emitting element. The packaging substrate includes a metal substrate, a first adhesive layer, a reflective layer, and a protective layer. The metal substrate has a microstructure layer with a concave-convex surface, and the first adhesive layer is disposed on the microstructure layer. The reflective layer is disposed on the first adhesive layer, and the protective layer is disposed on the reflective layer. The surface of the first adhesive layer, the surface of the reflective layer, and the surface of the protective layer all fluctuate along the concave-convex surface of the microstructure layer, and a heat-conductive adhesive layer is disposed on the protective layer between the light-emitting element and the packaging substrate.

基於上述,本新型創作的封裝基板和發光模組,除了利用金屬基板具有高導熱效果有效散熱之外,在金屬基板上增加微結構,以及其上再鍍上高反射率的反射層。具有凹凸表面的微結構讓反射層的表面也隨著凹凸表面起伏。因此即使因為LED高密度封裝使LED的間距變小,LED的側向出光照射至反射層的表面時也容易形成漫反射,導致LED的出光被反射層反射後出光角度會變更大,光束越不容易被附近的LED遮擋或吸收影響出光效率,導致出光效率提升,有效提升發光模組的亮度,也增進了發光元件的光能利用率。 Based on the above, the packaging substrate and light-emitting module of this novel invention, in addition to utilizing the high thermal conductivity of the metal substrate to effectively dissipate heat, add microstructures to the metal substrate and coat a reflective layer with high reflectivity on it. The microstructure with a concave and convex surface allows the surface of the reflective layer to fluctuate along with the concave and convex surface. Therefore, even if the spacing of the LEDs is reduced due to the high-density packaging of the LEDs, the side light of the LEDs is easily diffused when it is irradiated on the surface of the reflective layer, resulting in a larger light angle after the LED light is reflected by the reflective layer, and the light beam is less likely to be blocked or absorbed by nearby LEDs to affect the light output efficiency, resulting in improved light output efficiency, effectively improving the brightness of the light-emitting module, and also improving the light energy utilization rate of the light-emitting element.

為讓本新型創作的上述特徵和優點能更明顯易懂,下文特舉實施例,並配合所附圖式作詳細說明如下。 In order to make the above features and advantages of this novel creation more clearly understood, the following is a specific example and a detailed description with the attached diagrams.

10A,10B,10C:封裝基板 10A, 10B, 10C: packaging substrate

20A,20B:發光模組 20A, 20B: Light-emitting module

100:金屬基板 100:Metal substrate

101:微結構層 101: Microstructure layer

101A,111,111A,111B,111C,121,131:表面 101A,111,111A,111B,111C,121,131: Surface

110A:第一黏著層 110A: First adhesive layer

110B:第二黏著層 110B: Second adhesive layer

110C:第三黏著層 110C: The third adhesive layer

120,200:反射層 120,200:Reflection layer

130:保護層 130: Protective layer

140:電路板 140: Circuit board

141:接墊 141:Pad

150:發光元件 150: Light-emitting element

160:導熱膠層 160: Thermal conductive adhesive layer

160S:接觸面 160S: Contact surface

170:遮光層 170: Shading layer

180:光學轉換層 180: Optical conversion layer

CA:凹部 CA: Concave

CX:凸部 CX: convex part

IB:照明光束 IB: Illumination beam

L:導線 L: Conductor

SP:空間 SP: Space

X、Y、Z:方向 X, Y, Z: direction

圖1A是本新型創作的一實施例的一種封裝基板的示意圖。 Figure 1A is a schematic diagram of a packaging substrate of an embodiment of the present invention.

圖1B是圖1A的微結構表面的俯視示意圖。 FIG1B is a schematic top view of the microstructure surface of FIG1A.

圖2是本新型創作的一實施例的一種封裝基板的示意圖。 Figure 2 is a schematic diagram of a packaging substrate of an embodiment of the present invention.

圖3A是本新型創作的一實施例的一種封裝基板的示意圖。 FIG3A is a schematic diagram of a packaging substrate of an embodiment of the present invention.

圖3B是圖3A實施例的封裝基板的製程示意圖。 FIG3B is a schematic diagram of the manufacturing process of the packaging substrate of the embodiment of FIG3A.

圖4是本新型創作的一實施例的一種發光模組的示意圖。 Figure 4 is a schematic diagram of a light-emitting module of an embodiment of the present invention.

圖5是本新型創作的一實施例的一種發光模組的示意圖。 Figure 5 is a schematic diagram of a light-emitting module of an embodiment of the present invention.

圖6A和圖6B是本新型創作的實施例的發光模組原理示意圖。 Figures 6A and 6B are schematic diagrams of the light-emitting module principle of the embodiment of the novel invention.

有關本新型創作之前述及其他技術內容、特點與功效,在以下配合參考圖式之一較佳實施例的詳細說明中,將可清楚的呈現。以下實施例中所提到的方向用語,例如:上、下、左、右、前或後等,僅是參考附加圖式的方向。因此,使用的方向用語是用來說明並非用來限制本新型。 The aforementioned and other technical contents, features and effects of the novel invention will be clearly presented in the detailed description of the preferred embodiment with reference to the following drawings. The directional terms mentioned in the following embodiments, such as up, down, left, right, front or back, etc., are only referenced to the directions of the attached drawings. Therefore, the directional terms used are used to illustrate and not to limit the novel invention.

參照本實施例之圖式以更全面地闡述本新型。然而,本新型亦可以各種不同的形式體現,而不應限於本文中所述之實施例。圖式中的層與區域的厚度會為了清楚起見而放大,不代表實際尺寸之間的比例關係。相同或相似之參考標號表示相同或相似之元件,以下段落將不再一一贅述。 The present invention is described more fully with reference to the drawings of the present embodiment. However, the present invention can also be embodied in various forms and should not be limited to the embodiments described herein. The thickness of the layers and regions in the drawings are exaggerated for clarity and do not represent the proportional relationship between the actual sizes. The same or similar reference numerals represent the same or similar elements, and the following paragraphs will not be repeated one by one.

圖1A是本新型創作的第一實施例的一種封裝基板的示意圖。圖1B是圖1A的微結構表面的俯視示意圖。請參照圖1A以及圖1B,封裝基板10A包括金屬基板100,適於在一安裝側(例如圖1A中的方向Z)設置電子元件(未繪示)。另一方面,金屬基板100具有微結構層101,微結構層101具有凹凸形狀的表面101A。第一黏著層110A設置於微結構層101上。反射層120設置於第一黏著層110A上,以及保護層130設置於反射層120上。 FIG. 1A is a schematic diagram of a packaging substrate of the first embodiment of the present invention. FIG. 1B is a schematic diagram of a top view of the microstructure surface of FIG. 1A. Referring to FIG. 1A and FIG. 1B, the packaging substrate 10A includes a metal substrate 100, which is suitable for arranging electronic components (not shown) on a mounting side (e.g., direction Z in FIG. 1A). On the other hand, the metal substrate 100 has a microstructure layer 101, and the microstructure layer 101 has a concave-convex surface 101A. The first adhesive layer 110A is disposed on the microstructure layer 101. The reflective layer 120 is disposed on the first adhesive layer 110A, and the protective layer 130 is disposed on the reflective layer 120.

金屬基板100例如為具有散熱功能的電路基板、散熱板、 散熱鰭片或其他類型的封裝基板,本新型不以此為限。在本實施例中,金屬基板100的材質例如為金屬材料,包括鋁、銅、鋁合金或任意具良好導熱率的材質,本新型亦不以此為限。 The metal substrate 100 is, for example, a circuit substrate, a heat sink, a heat sink fin or other types of packaging substrates with heat dissipation function, but the present invention is not limited thereto. In the present embodiment, the material of the metal substrate 100 is, for example, a metal material, including aluminum, copper, aluminum alloy or any material with good thermal conductivity, but the present invention is not limited thereto.

微結構層101的表面101A例如可以使用壓合製程,包含平板壓合或是連續滾輪壓金屬基板100的表面形成。換句話說,微結構層101和金屬基板100可以是一體成形的相同材料,然而本新型並不限於此。微結構層101可以是凸、凹或是同時存在等適合設計,在本實施例中微結構層101的表面101A具有多個凹部CA以及多個凸部CX,能夠使照射至封裝基板10A的光束或電磁波產生漫反射,以達成增加發散角度的效果。 The surface 101A of the microstructure layer 101 can be formed by, for example, a pressing process, including flat plate pressing or continuous roller pressing of the surface of the metal substrate 100. In other words, the microstructure layer 101 and the metal substrate 100 can be formed of the same material in one piece, but the present invention is not limited thereto. The microstructure layer 101 can be convex, concave, or have a suitable design such as both. In the present embodiment, the surface 101A of the microstructure layer 101 has a plurality of concave portions CA and a plurality of convex portions CX, which can cause the light beam or electromagnetic wave irradiated to the package substrate 10A to produce diffuse reflection, so as to achieve the effect of increasing the divergence angle.

第一黏著層110A例如是具有高導熱率的金屬材料或是無機材料等適合的材料,例如可以是二氧化鈦(TiO2)、氧化矽(SiO2)、氧化鋁(Al2O3)、鈦金屬(Ti)、鎳金屬(Ni)、鎘金屬(Cr)、銅金屬(Cu)等材料或上述材料的合金等,本新型並不限於此。在一些實施例中,第一黏著層110A可以是單層層別或是多層不同材料結構的設計,本新型也不限於此。第一黏著層110A可以是利用電鍍方式設置在微結構層101上,例如可以包括濕式電鍍的方式或物理氣相沉積(physical vapor deposition,PVD)法,將第一黏著層110A設置於微結構層101上。上述物理氣相沉積的方法包括蒸鍍法、濺鍍法、離子光束輔助蒸鍍(ion beam assisted deposition,IAD)、脈衝雷射沉積或其他合適的方法,以增加後續膜層(如反射層120和保護層130等)的接著性,本新型並不以此為限。 The first adhesive layer 110A is, for example, a metal material or an inorganic material with high thermal conductivity, such as titanium dioxide (TiO 2 ), silicon oxide (SiO 2 ), aluminum oxide (Al 2 O 3 ), titanium (Ti), nickel (Ni), cadmium (Cr), copper (Cu) or alloys thereof, but the present invention is not limited thereto. In some embodiments, the first adhesive layer 110A may be a single layer or a multi-layer structure of different materials, but the present invention is not limited thereto. The first adhesive layer 110A may be disposed on the microstructure layer 101 by electroplating, for example, wet electroplating or physical vapor deposition (PVD) to dispose the first adhesive layer 110A on the microstructure layer 101. The physical vapor deposition method includes evaporation, sputtering, ion beam assisted deposition (IAD), pulsed laser deposition or other suitable methods to increase the adhesion of subsequent film layers (such as the reflective layer 120 and the protective layer 130, etc.), but the present invention is not limited thereto.

反射層120優選具有對欲反射的電磁波波長具有高反射率的材料製作而成。例如在本實施例中,若欲反射可見光波段的電磁波,反射層120的材質可以包括銀或其他合適材料。以下是以反射層120為銀舉例說明。在本實施例中,設置反射層120的方法包括透過物理氣相沉積(physical vapor deposition,PVD)法或濕式電鍍的方式,將金屬材料設置於第一黏著層110A上。上述物理氣相沉積的方法包括蒸鍍法、濺鍍法、離子光束輔助蒸鍍(ion beam assisted deposition,IAD)、脈衝雷射沉積或其他合適的方法,形成銀金屬薄膜於第一黏著層110A上,但本新型不以此為限。在一些實施例中,上述濕式電鍍的方法包括先透過對金屬基板100進行電鍍,以形成第一黏著層110A,再將銀電鍍於第一黏著層110A上,以形成反射層120。在另一實施例中,上述濕式電鍍的方法也可以包括先對鋁製的金屬基板100進行陽極氧化處理,以形成氧化鋁為材質的第一黏著層110A,再將銀電鍍於第一黏著層110A上以形成反射層120,但本新型不以此為限。 The reflective layer 120 is preferably made of a material having a high reflectivity for the wavelength of the electromagnetic wave to be reflected. For example, in this embodiment, if the electromagnetic wave in the visible light band is to be reflected, the material of the reflective layer 120 may include silver or other suitable materials. The following is an example of the reflective layer 120 being silver. In this embodiment, the method of setting the reflective layer 120 includes setting the metal material on the first adhesive layer 110A by physical vapor deposition (PVD) or wet plating. The physical vapor deposition method includes evaporation, sputtering, ion beam assisted deposition (IAD), pulsed laser deposition or other suitable methods to form a silver metal film on the first adhesive layer 110A, but the present invention is not limited thereto. In some embodiments, the wet plating method includes first plating the metal substrate 100 to form the first adhesive layer 110A, and then plating silver on the first adhesive layer 110A to form the reflective layer 120. In another embodiment, the wet electroplating method may also include first performing an anodic oxidation treatment on the aluminum metal substrate 100 to form a first adhesive layer 110A made of aluminum oxide, and then electroplating silver on the first adhesive layer 110A to form a reflective layer 120, but the present invention is not limited thereto.

保護層130例如可以是金屬鍍層材質,在保護反射層120避免其氧化或外力刮傷的同時,還可以增進接合的電子元件的導熱效率。保護層130例如包括TiO2、SiO2、Al2O3等適合材料,然而本新型並不以此為限。保護層130的鍍層結構可以是單層或是多層結構,多層結構可以是相同材料或是不同材料的結構,本新型亦不以此為限。 The protective layer 130 can be, for example, a metal coating material, which can protect the reflective layer 120 from oxidation or scratches by external forces, and can also improve the thermal conductivity of the joined electronic components. The protective layer 130 includes, for example, suitable materials such as TiO 2 , SiO 2 , and Al 2 O 3 , but the present invention is not limited thereto. The coating structure of the protective layer 130 can be a single layer or a multi-layer structure, and the multi-layer structure can be a structure of the same material or different materials, but the present invention is not limited thereto.

值得一提的是,在本實施例中由於金屬基板100具有凹 凸的表面101A,因此第一黏著層110A的表面111、反射層120的表面121和保護層130的表面131,皆隨著表面101A凹凸起伏。也可以理解為,表面101A的凹凸形狀可以傳遞至表面111、表面121和表面131,使得上述各表面皆實質上共形設置,進而使表面131也具有對應表面101A的凹部CA與凸部CX(如圖1A和1B所示)。 It is worth mentioning that in this embodiment, since the metal substrate 100 has a concave and convex surface 101A, the surface 111 of the first adhesive layer 110A, the surface 121 of the reflective layer 120, and the surface 131 of the protective layer 130 all follow the concave and convex shape of the surface 101A. It can also be understood that the concave and convex shape of the surface 101A can be transmitted to the surface 111, the surface 121, and the surface 131, so that the above surfaces are substantially conformally arranged, and the surface 131 also has a concave portion CA and a convex portion CX corresponding to the surface 101A (as shown in Figures 1A and 1B).

經由上述配置,封裝基板10A於放置電子元件的表面(例如圖1A中方向Z一側的表面131)具有凹凸的紋路或形狀,應用於需擴大電磁波發射角度、擴大發光元件出光角度或擴大訊號涵蓋範圍的元件或裝置時,可有利於波束的漫反射以達成期望的效果。金屬基板100的高導熱率也有利於電子元件的散熱,應用於高功率電子元件時有助於維持裝置的穩定性和性能,增加產品的使用壽命。 Through the above configuration, the package substrate 10A has a concave-convex pattern or shape on the surface where the electronic components are placed (e.g., the surface 131 on the Z side in FIG. 1A ). When applied to components or devices that need to expand the electromagnetic wave emission angle, expand the light emission angle of the light-emitting component, or expand the signal coverage range, it can be beneficial to diffuse reflection of the beam to achieve the desired effect. The high thermal conductivity of the metal substrate 100 is also beneficial to the heat dissipation of the electronic components. When applied to high-power electronic components, it helps to maintain the stability and performance of the device and increase the service life of the product.

以下將列舉另一些實施例以詳細說明本新型,其中相同的構件將標示相同的符號,並且省略相同技術內容的說明,省略部分請參考前述實施例,以下不再贅述。 The following will list some other embodiments to illustrate the new invention in detail, in which the same components will be marked with the same symbols, and the description of the same technical content will be omitted. For the omitted parts, please refer to the above embodiments, and no further description will be given below.

在一些實施例中,封裝基板還可以進一步設置其他膜層。舉例來說,圖2是本新型創作的一實施例的一種封裝基板的示意圖。在圖2的封裝基板10B的實施方式中,還包括第二黏著層110B,設置在保護層130和反射層120之間。第二黏著層110B可以是電鍍的鍍層,舉例來說可以包括前述之濕式電鍍法或蒸鍍法、濺鍍法、離子光束輔助蒸鍍(ion beam assisted deposition,IAD)、脈衝 雷射沉積或其他合適的方法,將第二黏著層110B設置於反射層120上。如此可用來增加保護層130和反射層120之間的接著性和可靠性,使得保護層130可以充分保護反射層120避免氧化或刮傷。 In some embodiments, the package substrate may be further provided with other film layers. For example, FIG. 2 is a schematic diagram of a package substrate of an embodiment of the present invention. In the embodiment of the package substrate 10B of FIG. 2, a second adhesive layer 110B is further included, which is disposed between the protective layer 130 and the reflective layer 120. The second adhesive layer 110B may be an electroplated layer, for example, the aforementioned wet electroplating method or evaporation method, sputtering method, ion beam assisted deposition (IAD), pulse laser deposition or other suitable methods may be included to arrange the second adhesive layer 110B on the reflective layer 120. This can be used to increase the adhesion and reliability between the protective layer 130 and the reflective layer 120, so that the protective layer 130 can fully protect the reflective layer 120 from oxidation or scratches.

類似地,第二黏著層110B背離金屬基板100的表面111B,也可以沿著第一黏著層110A的表面111A、反射層120的表面121和保護層130的表面131凹凸配置,意即上述各表面之間可以實質上彼此共形設置。第二黏著層110B的材質例如是Ti、Ni、Cr等適合材料或上述材料組成的複合層,本新型並不以此為限。 Similarly, the second adhesive layer 110B is away from the surface 111B of the metal substrate 100, and can also be arranged along the surface 111A of the first adhesive layer 110A, the surface 121 of the reflective layer 120, and the surface 131 of the protective layer 130, which means that the above surfaces can be substantially conformally arranged with each other. The material of the second adhesive layer 110B is, for example, Ti, Ni, Cr or a composite layer composed of the above materials, but the present invention is not limited thereto.

圖3A是本新型創作的一實施例的一種封裝基板的示意圖。請參照圖3A,封裝基板10C與圖2的封裝基板10B相似,其差異在於:封裝基板10C還可以進一步包括設置於保護層130上的電路板140、配置於電路板140上用於電性連接電子元件的接墊141、以及用於黏合電路板140與保護層130的第三黏著層110C。電路板140例如可以是印刷電路板(printed circuit board,PCB)、金屬芯印刷電路板(metal core printed circuit board,MCPCB)、可撓式印刷電路板(flexible PCB)、或其他合適種類的電路板。接墊141可以為合適的導電材料(如鋁、銀、銅等),並適於以打線封裝、例如電路板140可以利用接墊141以及導線L,電性連接至所需的電子元件。第三黏著層110C的材料包括光學透明膠(Optical Clear Adhesive,OCA)、感壓膠(Pressure Sensitive Adhesive,PSA)、熱固膠(例如Epoxy resin)、矽膠(silicone adhesive)、聚氨酯活性 (Polyurethane reactive,PUR)膠、聚氨酯(Polyurethane,PU)膠、或其他合適的膠材。導線L的材料可以是銅、鋁或是金,本新型並不以此為限。 FIG3A is a schematic diagram of a package substrate of an embodiment of the present invention. Referring to FIG3A , a package substrate 10C is similar to the package substrate 10B of FIG2 , except that the package substrate 10C may further include a circuit board 140 disposed on the protective layer 130, a pad 141 disposed on the circuit board 140 for electrically connecting electronic components, and a third adhesive layer 110C for bonding the circuit board 140 to the protective layer 130. The circuit board 140 may be, for example, a printed circuit board (PCB), a metal core printed circuit board (MCPCB), a flexible printed circuit board (flexible PCB), or other suitable types of circuit boards. The pad 141 can be a suitable conductive material (such as aluminum, silver, copper, etc.) and is suitable for wire bonding packaging. For example, the circuit board 140 can be electrically connected to the required electronic components using the pad 141 and the wire L. The material of the third adhesive layer 110C includes optical clear adhesive (OCA), pressure sensitive adhesive (PSA), thermosetting adhesive (such as epoxy resin), silicone adhesive, polyurethane reactive (PUR) glue, polyurethane (PU) glue, or other suitable adhesive materials. The material of the wire L can be copper, aluminum or gold, but the present invention is not limited thereto.

值得一提的是,第三黏著層110C與電路板140接觸的表面111C可以與電路板140貼合,而實質上呈現一平面,可有利於確保電路板140接合的可靠性。換句話說,表面101A、表面111A、表面121、表面111B、表面131的凹凸形狀可以不傳遞至表面111C。 It is worth mentioning that the surface 111C of the third adhesive layer 110C in contact with the circuit board 140 can be attached to the circuit board 140 and substantially present a plane, which is conducive to ensuring the reliability of the connection of the circuit board 140. In other words, the concave and convex shapes of the surface 101A, the surface 111A, the surface 121, the surface 111B, and the surface 131 can not be transmitted to the surface 111C.

圖3B是圖3A實施例的封裝基板的製程示意圖。請參照圖3B,封裝基板10C的製作過程可以是先分別製作電路板140及製作封裝基板10A或封裝基板10B完成後,再將電路板140與封裝基板10B之間使用第三黏著層110C結合在一起。第三黏著層110C可以先設置在電路板140面向封裝基板10B的一側,再與封裝基板10B貼合。或第三黏著層110C先設置在封裝基板10B的保護層130上,再與電路板140貼合,本新型並不限於此。 FIG3B is a schematic diagram of the manufacturing process of the package substrate of the embodiment of FIG3A. Referring to FIG3B, the manufacturing process of the package substrate 10C can be to first manufacture the circuit board 140 and the package substrate 10A or the package substrate 10B separately, and then use the third adhesive layer 110C to combine the circuit board 140 and the package substrate 10B. The third adhesive layer 110C can be first arranged on the side of the circuit board 140 facing the package substrate 10B, and then bonded to the package substrate 10B. Or the third adhesive layer 110C is first arranged on the protective layer 130 of the package substrate 10B, and then bonded to the circuit board 140, and the present invention is not limited to this.

圖4是本新型創作的一實施例的一種發光模組的示意圖。請參照圖4,在本新型的各實施例中,封裝基板可以應用於各種封裝元件的載板。舉例來說,圖4的發光模組20A可以包括前述的封裝基板10C以及設置在其上的發光元件150。值得一提的是,在圖4中是以封裝基板10C乘載多個發光元件150作為示範性說明,然而本新型並不限於此。在其他實施例中,發光模組20A中的封裝基板可以不包括第二黏著層110B。另一方面,發光元件150的數量可以是多個,且在方向X和方向Y所組成的平面上排列成陣 列,再以導熱膠層160貼合至保護層130。在一些實施例中,導熱膠層160和發光元件150之間可以直接接觸而不具有其他膜層,然而本新型並不限於此。在圖4中導熱膠層160的數量可以是多個並且分別和發光元件150對應設置,然而本新型也不限於此。在其他實施例中,導熱膠層160可以是整面設置於保護層130上,並且多個發光元件150可以利用表面貼合技術(Surface-mount technology,SMT)或固晶機(Die Bonder)設備,將發光元件150轉置於封裝基板10C上。 FIG4 is a schematic diagram of a light-emitting module of an embodiment of the present invention. Referring to FIG4, in each embodiment of the present invention, the packaging substrate can be applied to a carrier of various packaging components. For example, the light-emitting module 20A of FIG4 may include the aforementioned packaging substrate 10C and the light-emitting element 150 disposed thereon. It is worth mentioning that FIG4 is an exemplary illustration of the packaging substrate 10C carrying a plurality of light-emitting elements 150, but the present invention is not limited thereto. In other embodiments, the packaging substrate in the light-emitting module 20A may not include the second adhesive layer 110B. On the other hand, the number of light-emitting elements 150 may be multiple, and they are arranged in an array on a plane formed by the direction X and the direction Y, and then attached to the protective layer 130 by a thermal conductive adhesive layer 160. In some embodiments, the thermal conductive adhesive layer 160 and the light emitting element 150 may be in direct contact without other film layers, but the present invention is not limited thereto. In FIG. 4 , the number of thermal conductive adhesive layers 160 may be multiple and they may be arranged corresponding to the light emitting elements 150, but the present invention is not limited thereto. In other embodiments, the thermal conductive adhesive layer 160 may be arranged on the protective layer 130 in its entirety, and the multiple light emitting elements 150 may be transferred to the packaging substrate 10C using surface-mount technology (SMT) or die bonder equipment.

在本實施例中,發光元件150包括發光二極體(light emitting diode,LED)、微型發光二極體(micro-LED)、次毫米發光二極體(mini-LED)以及量子點發光二極體(quantum dot)。並且在發光模組20A的投影方向上(例如圖4中的方向Z),發光元件150的設置位置不重疊電路板140。並且發光元件150可以利用接墊141和多條導線L,以打線封裝將多個發光元件150和電路板140的接墊141彼此電性連接。 In this embodiment, the light emitting element 150 includes a light emitting diode (LED), a micro-LED, a sub-millimeter light emitting diode (mini-LED), and a quantum dot light emitting diode (quantum dot). In addition, in the projection direction of the light emitting module 20A (e.g., direction Z in FIG. 4 ), the light emitting element 150 is disposed so as not to overlap the circuit board 140. In addition, the light emitting element 150 can utilize the pad 141 and a plurality of wires L to electrically connect a plurality of light emitting elements 150 and the pad 141 of the circuit board 140 to each other by wire bonding packaging.

另一方面,導熱膠層160包括錫膏、銀膠、銅膠或其他合適的材料,但本新型不以此為限。在一些實施例中,導熱膠層160的材質還包括非金屬系導電導熱膠。上述非金屬系導電導熱膠例如為包括導電粒子的膠層。舉例而言,上述的導電粒子可為鍍銀的銅球粒子或鍍銀的塑膠粒子,本新型不以此為限。導熱膠層160可以提供發光元件150與保護層130之間良好的接合力,以將發光元件150固定至封裝基板10C上。 On the other hand, the thermally conductive adhesive layer 160 includes solder paste, silver glue, copper glue or other suitable materials, but the present invention is not limited thereto. In some embodiments, the material of the thermally conductive adhesive layer 160 also includes a non-metallic conductive thermally conductive adhesive. The non-metallic conductive thermally conductive adhesive is, for example, an adhesive layer including conductive particles. For example, the conductive particles may be silver-plated copper ball particles or silver-plated plastic particles, but the present invention is not limited thereto. The thermally conductive adhesive layer 160 can provide a good bonding force between the light-emitting element 150 and the protective layer 130 to fix the light-emitting element 150 to the packaging substrate 10C.

值得一提的是,導熱膠層160和發光元件150的接觸面160S可以實質上為平面。換句話說,表面101A、表面111A、表面121、表面111B、表面131的凹凸形狀可以不傳遞至接觸面160S。以確保平整的接觸面160S可以有效貼合各發光元件150,增加發光元件150和封裝基板10C之間的黏著可靠性。 It is worth mentioning that the contact surface 160S between the thermally conductive adhesive layer 160 and the light-emitting element 150 can be substantially flat. In other words, the concave and convex shapes of the surface 101A, the surface 111A, the surface 121, the surface 111B, and the surface 131 can not be transmitted to the contact surface 160S. This ensures that the flat contact surface 160S can effectively fit each light-emitting element 150, and increases the adhesion reliability between the light-emitting element 150 and the packaging substrate 10C.

另一方面,儘管未繪示,然而發光模組20A在其出光方向上(例如方向Z)還可以包括其餘封裝層。封裝層的材料例如可以是光學透明膠或其他光學級膠材,以用於封裝導線L、發光元件150、接墊141以及電路板140上其他可能的電子元件(如電容、二極體或開關元件等),本新型並不限於此。 On the other hand, although not shown, the light-emitting module 20A may also include other packaging layers in its light-emitting direction (e.g., direction Z). The material of the packaging layer may be, for example, optically transparent glue or other optical grade glue to package the wire L, the light-emitting element 150, the pad 141, and other possible electronic components on the circuit board 140 (e.g., capacitors, diodes, or switch components, etc.), but the present invention is not limited thereto.

圖5是本新型創作的一實施例的一種發光模組的示意圖。請參照圖5,發光模組20B和圖4的發光模組20A相似,其差異在於:發光模組20B還進一步包括遮光層170以及光學轉換層180,以利用光學轉換層180封裝多個發光元件150。 FIG5 is a schematic diagram of a light-emitting module of an embodiment of the present invention. Referring to FIG5 , the light-emitting module 20B is similar to the light-emitting module 20A of FIG4 , and the difference is that the light-emitting module 20B further includes a light-shielding layer 170 and an optical conversion layer 180, so as to utilize the optical conversion layer 180 to encapsulate multiple light-emitting elements 150.

詳細來說,遮光層170可以直接設置在電路板140上,並且和電路板140共同形成一空間SP,而多個發光元件150可以進一步設置在空間SP中。並且光學轉換層180可以填充於空間SP中以覆蓋多個發光元件150、導線L、接墊141以及部分的電路板140。因此空間SP也可以定義為發光模組20B的發光區域。 Specifically, the light shielding layer 170 can be directly disposed on the circuit board 140, and together with the circuit board 140, form a space SP, and a plurality of light-emitting elements 150 can be further disposed in the space SP. In addition, the optical conversion layer 180 can be filled in the space SP to cover the plurality of light-emitting elements 150, the wire L, the pad 141, and part of the circuit board 140. Therefore, the space SP can also be defined as the light-emitting area of the light-emitting module 20B.

在一些實施例中,遮光層170例如可以是聚合物摻雜碳黑的吸光材料以製作形成框膠,或者是以淺色或白色的聚合物(white bank)所組成的擋牆材料,並在方向X和方向Y上圍繞多個 發光元件150設置,本新型並不限於此。發光元件150例如是藍光或紫外光發光二極體,則光學轉換層180可以具有將藍光或紫外光轉換成其他所需色光(例如綠光、黃光或紅光)或非可見光波段(例如紅外光)的波長轉換材料,本新型也並不限於此。在一些實施例中,光學轉換層180可以是封裝樹酯、環氧樹酯等封裝基材,摻雜習知的波長轉換材料(如螢光粉材料、濾光層材料或是量子點結構)製作而成,本新型並不以此為限。 In some embodiments, the light shielding layer 170 may be a light absorbing material doped with carbon black to form a frame, or a barrier material composed of a light-colored or white polymer (white bank), and is arranged around a plurality of light emitting elements 150 in directions X and Y, but the present invention is not limited thereto. The light emitting element 150 may be a blue light or ultraviolet light emitting diode, and the optical conversion layer 180 may have a wavelength conversion material that converts blue light or ultraviolet light into other desired color light (e.g., green light, yellow light, or red light) or non-visible light bands (e.g., infrared light), but the present invention is not limited thereto. In some embodiments, the optical conversion layer 180 can be a packaging substrate such as a packaging resin or epoxy resin, doped with a known wavelength conversion material (such as a fluorescent powder material, a filter layer material, or a quantum dot structure), but the present invention is not limited to this.

圖6A和圖6B是本新型創作的實施例的發光模組原理示意圖。圖6A為相關技術中,平坦面的反射層200反射發光元件150的側向光束的示意圖,圖6B為本新型實施例的反射層120,反射發光元件150的側向光束的示意圖。為方便說明在圖6B中僅示意性地繪製出保護層130、第二黏著層110B以及反射層120而省略其餘元件的繪製。請先參照圖6A,一般的反射層200由於相對平坦,因此當發光元件150的照明光束IB照射至反射層200時大多會產生鏡面反射。因此當側向出光的照明光束IB於反射層200發生反射時,與反射層200的反射角通常也較大,使得照明光束IB容易傳遞至鄰近的其他發光元件150而被吸收或遮擋,使得多個發光元件150的整體出光效率降低。 FIG6A and FIG6B are schematic diagrams of the principle of the light-emitting module of the embodiment of the present invention. FIG6A is a schematic diagram of a flat reflective layer 200 reflecting a lateral light beam of the light-emitting element 150 in the related art, and FIG6B is a schematic diagram of a reflective layer 120 of the present invention reflecting a lateral light beam of the light-emitting element 150. For the convenience of explanation, FIG6B only schematically depicts the protective layer 130, the second adhesive layer 110B and the reflective layer 120, and omits the drawing of other components. Please refer to FIG6A first. Since the general reflective layer 200 is relatively flat, when the illumination light beam IB of the light-emitting element 150 irradiates the reflective layer 200, mirror reflection will mostly be generated. Therefore, when the side-emitting illumination beam IB is reflected by the reflective layer 200, the reflection angle with the reflective layer 200 is usually larger, so that the illumination beam IB is easily transmitted to other adjacent light-emitting elements 150 and absorbed or blocked, thereby reducing the overall light-emitting efficiency of multiple light-emitting elements 150.

再參照圖6B,反觀來說,由於反射層120的表面凹凸設置,使得發光元件150側向出光的照明光束IB在相同角度下,依序照射至保護層130、第二黏著層110B和反射層120後,容易以漫反射(diffuse reflection)的形式離開反射層120,除了反射光容易 具有一較大視場角(如圖中以光錐形狀示意)導致出光角度更大之外,也較不易被鄰近的其他發光元件150所遮擋。因此於高密度設置的LED封裝時,採用本新型的各封裝基板的發光模組可以有效提升光束的出光效率,提升光能利用率。 Referring to FIG. 6B , on the other hand, due to the concave-convex surface of the reflective layer 120, the illumination beam IB emitted from the light-emitting element 150 is easily diffusely reflected after being sequentially irradiated to the protective layer 130, the second adhesive layer 110B and the reflective layer 120 at the same angle. In addition to the reflected light having a larger viewing angle (as shown in the cone shape in the figure), it is also less likely to be blocked by other adjacent light-emitting elements 150. Therefore, when LED packaging is arranged in a high density, the light-emitting module using each packaging substrate of the present invention can effectively improve the light output efficiency of the light beam and improve the utilization rate of light energy.

綜上所述,本新型創作的封裝基板和發光模組,除了利用金屬基板具有高導熱效果有效散熱之外,在金屬基板上增加微結構,以及其上再鍍上高反射率的反射層。具有凹凸表面的微結構讓反射層的表面也隨著凹凸表面起伏。因此即使因為LED高密度封裝使LED的間距變小,LED的側向出光照射至反射層的表面時也容易形成漫反射,導致LED的出光被反射層反射後出光角度會變更大,光束越不容易被附近的LED遮擋或吸收影響出光效率,導致出光效率提升,有效提升發光模組的亮度,也增進了發光元件的光能利用率。 In summary, the packaging substrate and light-emitting module of this novel invention not only utilize the high thermal conductivity of the metal substrate to effectively dissipate heat, but also add microstructures on the metal substrate and coat a reflective layer with high reflectivity on it. The microstructure with a concave and convex surface allows the surface of the reflective layer to fluctuate along with the concave and convex surface. Therefore, even if the spacing of LEDs becomes smaller due to the high-density packaging of LEDs, the side light of the LED is easily diffused when it irradiates the surface of the reflective layer, resulting in a larger light angle after the light of the LED is reflected by the reflective layer, and the light beam is less likely to be blocked or absorbed by nearby LEDs to affect the light output efficiency, resulting in improved light output efficiency, effectively improving the brightness of the light-emitting module, and also improving the light energy utilization rate of the light-emitting element.

惟以上所述者,僅為本新型創作之較佳實施例而已,當不能以此限定本新型創作實施之範圍,即大凡依本新型創作申請專利範圍及新型創作說明內容所作之簡單的等效變化與修飾,皆仍屬本新型創作專利涵蓋之範圍內。另外本新型創作的任一實施例或申請專利範圍不須達成本新型創作所揭露之全部目的或優點或特點。此外,摘要部分和標題僅是用來輔助專利文件搜尋之用,並非用來限制本新型創作之權利範圍。此外,本說明書或申請專利範圍中提及的“第一”、“第二”等用語僅用以命名元件(element)的名稱或區別不同實施例或範圍,而並非用來限制元件數量上的上限 或下限。 However, the above is only the preferred embodiment of the present invention, and it cannot be used to limit the scope of the implementation of the present invention. That is, all simple equivalent changes and modifications made according to the scope of the patent application of the present invention and the description of the present invention are still within the scope of the patent of the present invention. In addition, any embodiment or patent application of the present invention does not need to achieve all the purposes, advantages or features disclosed by the present invention. In addition, the abstract and title are only used to assist in searching for patent documents, and are not used to limit the scope of rights of the present invention. In addition, the terms "first" and "second" mentioned in this specification or patent application are only used to name the element or distinguish different embodiments or scopes, and are not used to limit the upper or lower limit of the number of elements.

10A:封裝基板 10A:Packaging substrate

100:金屬基板 100:Metal substrate

101:微結構層 101: Microstructure layer

101A,111,121,131:表面 101A,111,121,131: Surface

110A:第一黏著層 110A: First adhesive layer

120:反射層 120: Reflective layer

130:保護層 130: Protective layer

CA:凹部 CA: Concave

CX:凸部 CX: convex part

X、Y、Z:方向 X, Y, Z: direction

Claims (12)

一種封裝基板,包括:一金屬基板,具有一凹凸表面的微結構層;一第一黏著層,設置於該微結構層上;一反射層,設置於該第一黏著層上;以及一保護層,設置於該反射層上,其中該第一黏著層的表面、該反射層的表面和該保護層的表面皆隨著該微結構層的該凹凸表面起伏。 A packaging substrate comprises: a metal substrate having a microstructure layer with a concave-convex surface; a first adhesive layer disposed on the microstructure layer; a reflective layer disposed on the first adhesive layer; and a protective layer disposed on the reflective layer, wherein the surface of the first adhesive layer, the surface of the reflective layer and the surface of the protective layer all fluctuate along the concave-convex surface of the microstructure layer. 如請求項1所述的封裝基板,其中該金屬基板的材料包括鋁。 A packaging substrate as described in claim 1, wherein the material of the metal substrate includes aluminum. 如請求項1所述的封裝基板,其中該反射層的材料包括銀。 A packaging substrate as described in claim 1, wherein the material of the reflective layer includes silver. 如請求項1所述的封裝基板,還包括一第二黏著層,設置在該保護層和該反射層之間。 The packaging substrate as described in claim 1 further includes a second adhesive layer disposed between the protective layer and the reflective layer. 如請求項1所述的封裝基板,還包括:一電路板,設置在該保護層上;以及一第三黏著層,設置在該保護層和該電路板之間,其中該電路板還具有一接墊,適於以打線電性連接至一電子元件。 The package substrate as described in claim 1 further comprises: a circuit board disposed on the protective layer; and a third adhesive layer disposed between the protective layer and the circuit board, wherein the circuit board also has a pad suitable for being electrically connected to an electronic component by wire bonding. 一種發光模組,包括:一封裝基板以及發光元件,其中該封裝基板包括:一金屬基板,具有一凹凸表面的微結構層; 一第一黏著層,設置於該微結構層上;一反射層,設置於該第一黏著層上;以及一保護層,設置於該反射層上;其中該第一黏著層的表面、該反射層的表面和該保護層的表面皆隨著該微結構層的該凹凸表面起伏,其中該發光元件和該封裝基板之間還包括一導熱膠層設置在該保護層上。 A light-emitting module includes: a packaging substrate and a light-emitting element, wherein the packaging substrate includes: a metal substrate having a microstructure layer with a concave-convex surface; a first adhesive layer disposed on the microstructure layer; a reflective layer disposed on the first adhesive layer; and a protective layer disposed on the reflective layer; wherein the surface of the first adhesive layer, the surface of the reflective layer and the surface of the protective layer all fluctuate along the concave-convex surface of the microstructure layer, wherein a heat-conductive adhesive layer disposed on the protective layer is further included between the light-emitting element and the packaging substrate. 如請求項6所述的發光模組,其中該金屬基板的材料包括鋁。 The light-emitting module as described in claim 6, wherein the material of the metal substrate includes aluminum. 如請求項6所述的發光模組,其中該反射層的材料包括銀。 The light-emitting module as described in claim 6, wherein the material of the reflective layer includes silver. 如請求項6所述的發光模組,還包括一第二黏著層,設置在該保護層和該反射層之間。 The light-emitting module as described in claim 6 further includes a second adhesive layer disposed between the protective layer and the reflective layer. 如請求項6所述的發光模組,其中該發光元件和該導熱膠層直接接觸而具有一接觸面,且該接觸面實質上為平面。 As described in claim 6, the light-emitting module, wherein the light-emitting element and the thermally conductive adhesive layer are in direct contact and have a contact surface, and the contact surface is substantially flat. 如請求項6所述的發光模組,還包括:一電路板,設置在該保護層上,在該發光模組的投影方向上,該電路板不重疊該發光元件;以及一第三黏著層,設置在該保護層和該電路板之間,其中該電路板還具有一接墊,該發光元件打線電性連接至該接墊。 The light-emitting module as described in claim 6 further comprises: a circuit board disposed on the protective layer, and in the projection direction of the light-emitting module, the circuit board does not overlap the light-emitting element; and a third adhesive layer disposed between the protective layer and the circuit board, wherein the circuit board also has a pad, and the light-emitting element is electrically connected to the pad by wire bonding. 如請求項11所述的發光模組,還包括: 遮光層,設置在該電路板上,其中該電路板和該遮光層共同形成一空間,該發光元件設置在該空間中;以及光學轉換層,填充於該空間中並進一步覆蓋該發光元件。 The light-emitting module as described in claim 11 further comprises: A light-shielding layer disposed on the circuit board, wherein the circuit board and the light-shielding layer together form a space, and the light-emitting element is disposed in the space; and an optical conversion layer filled in the space and further covering the light-emitting element.
TW113203795U 2024-04-16 2024-04-16 Packaging substrate and light emitting module TWM660368U (en)

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