WO2012061985A1 - 盖板的制造方法及用于制造封装发光二极管的方法 - Google Patents

盖板的制造方法及用于制造封装发光二极管的方法 Download PDF

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Publication number
WO2012061985A1
WO2012061985A1 PCT/CN2010/078609 CN2010078609W WO2012061985A1 WO 2012061985 A1 WO2012061985 A1 WO 2012061985A1 CN 2010078609 W CN2010078609 W CN 2010078609W WO 2012061985 A1 WO2012061985 A1 WO 2012061985A1
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WIPO (PCT)
Prior art keywords
manufacturing
cover plate
emitting diode
intermediate product
light emitting
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Application number
PCT/CN2010/078609
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English (en)
French (fr)
Inventor
詹国光
Original Assignee
Chang Kuo-Kuang
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Filing date
Publication date
Application filed by Chang Kuo-Kuang filed Critical Chang Kuo-Kuang
Priority to KR1020137013605A priority Critical patent/KR20140075640A/ko
Priority to DE112010005984T priority patent/DE112010005984T5/de
Priority to JP2013538022A priority patent/JP2013546184A/ja
Priority to PCT/CN2010/078609 priority patent/WO2012061985A1/zh
Priority to US13/884,879 priority patent/US20130228276A1/en
Publication of WO2012061985A1 publication Critical patent/WO2012061985A1/zh

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/0001—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor characterised by the choice of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
    • B29C39/02—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C39/10—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. casting around inserts or for coating articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/0013—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor using fillers dispersed in the moulding material, e.g. metal particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/1701—Component parts, details or accessories; Auxiliary operations using a particular environment during moulding, e.g. moisture-free or dust-free
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/26—Moulds
    • B29C45/34—Moulds having venting means
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L33/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides or nitriles thereof; Compositions of derivatives of such polymers
    • C08L33/04—Homopolymers or copolymers of esters
    • C08L33/06—Homopolymers or copolymers of esters of esters containing only carbon, hydrogen and oxygen, which oxygen atoms are present only as part of the carboxyl radical
    • C08L33/08—Homopolymers or copolymers of acrylic acid esters
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L33/00—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B13/00—Conditioning or physical treatment of the material to be shaped
    • B29B2013/005—Degassing undesirable residual components, e.g. gases, unreacted monomers, from material to be moulded
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/0053—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor combined with a final operation, e.g. shaping
    • B29C2045/0075—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor combined with a final operation, e.g. shaping curing or polymerising by irradiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2011/00—Optical elements, e.g. lenses, prisms
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2933/00—Details relating to devices covered by the group H01L33/00 but not provided for in its subgroups
    • H01L2933/0008—Processes
    • H01L2933/0033—Processes relating to semiconductor body packages
    • H01L2933/0041—Processes relating to semiconductor body packages relating to wavelength conversion elements

Definitions

  • the present invention relates to light emitting diodes for packaging, and more particularly to a method of fabricating a cover sheet that can be used to package light emitting diodes. Background technique
  • the well-known packaged light-emitting diode is mixed with a phosphor powder in a silica gel or an epoxy resin, and is coated with a silica gel or an epoxy resin around the light-emitting diode chip, and the light generated by the light-emitting diode can be used to excite the phosphor, thereby emitting various kinds of light. Color or white visible light.
  • the present invention provides a method for manufacturing a cover plate comprising the steps of: preparing, blending, defoaming, injection molding, curing, and demoulding.
  • the preparation material is an acrylic rubber and a phosphor, wherein the acrylic rubber refers to an uncured acrylic material.
  • the injection molding is carried out by pouring the intermediate product after the defoaming step into a molding die, and using a vacuum assisting machine to eliminate bubbles generated by the intermediate product poured into the molding die.
  • the curing is carried out by irradiating the intermediate product of the molding die with ultraviolet rays, and the intermediate product is solidified and formed into a cover plate, and the ultraviolet exposure amount is continuously exposed for 20-40 seconds at a rate of 3000 to 3500 megajoules per square centimeter. .
  • the demolding is such that the cover is separated from the molding die.
  • the present invention also provides a method of fabricating a packaged light emitting diode comprising a method of fabricating a package, the method for fabricating a packaged light emitting diode comprising the steps of:
  • the substrate has a first surface and a second surface
  • the cover plate has a third surface and a fourth surface
  • the second surface and the third surface have a flange
  • the flange has a groove
  • Constructing a circuit fixing an LED circuit on the second surface, the LED circuit comprising at least one LED chip;
  • the cover plate is fixed to the substrate in a vacuum environment, and the recess is closed by the cover plate and the substrate to form a closed space, and the LED circuit is located in the closed space.
  • the present invention can be used to fabricate a cover plate for further manufacturing a packaged light-emitting diode, and the cover plate is disposed on the light-emitting diode or the light-emitting diode chip to avoid or reduce the heat or contact with the phosphor, and improve the phosphor powder.
  • the stability in turn, makes the packaged LED have better service life and stability.
  • FIG. 1 is a partial cross-sectional view of a packaged light emitting diode made in accordance with the present invention
  • FIG. 2 is a flow chart of a method for manufacturing a cover plate provided by the present invention
  • 3 to FIG. 6 are respectively schematic diagrams showing the continuous operation of the packaged light emitting diode in the present invention. Description of the reference numerals
  • the present invention provides a method of fabricating a cover plate that can be used to fabricate a packaged light emitting diode as shown in FIG.
  • the manufacturing method of the cover plate provided by the present invention comprises the following steps: Preparation: Acrylic glue and phosphor are obtained by preparing or preparing in advance, wherein the acrylic glue refers to the pressure of uncured forming.
  • Acrylic material preferably, the above-mentioned acrylic adhesive mixed with phosphor, which comprises methyl methacrylate, methyl methacrylate oligopolymer and photoinitiator, and will be produced after being irradiated by ultraviolet rays.
  • Polymerization the formation of solid acrylic.
  • the phosphor therein refers to a powdery fluorescent substance.
  • Blending Mixing acrylic and phosphor in a predetermined ratio, viscosity
  • the phosphor is a white light excitation effect for the light-emitting diodes of different colors.
  • the above-mentioned phosphors are independent yellow phosphors, mixed RGB (red, green, blue) phosphors of the three primary colors, mixed yellow and red phosphors, mixed Red and green phosphors, or blends of orange and green phosphors.
  • the intermediate product is placed in a vacuum environment and the air mixed in the intermediate product is separated from the intermediate product by means of a vacuum assisting machine.
  • Injection molding The intermediate product after the defoaming step is cast into a molding die.
  • the injection molding step is carried out in a vacuum environment to avoid excessive residual air or bubbles between the intermediate product and the mold.
  • vacuuming the auxiliary machine it is the best solution by vacuuming the auxiliary machine.
  • the intermediate product cast into the molding die is irradiated with ultraviolet rays, and the intermediate product is solidified to form a cover.
  • the exposure energy of the ultraviolet light irradiated is approximately 3,000 to 3,500 megajoules per square centimeter, and the exposure time is between 20 and 40 seconds, and the optimum is 3,000 to 3,000 megajoules per square centimeter of exposure energy. Irradiation for 30 seconds.
  • Demolding The cover is separated from the forming die.
  • the steps before the curing step are carried out in a yellow light chamber to prevent the acrylic rubber from being exposed to ultraviolet rays in the environment before the curing step, and curing occurs early.
  • the cover plate made by the above steps is further incorporated into a method for manufacturing a packaged light emitting diode, which can be used to fabricate a packaged light emitting diode.
  • the method for manufacturing a packaged LED includes the following steps:
  • the substrate 1 has a first surface 11 and a second surface 12, and the cover 2 has a third surface 21 and a fourth surface 22.
  • the second surface 12 is formed with a flange 3, and the flange 3 is surrounded by a concave surface. a groove, wherein the flange 3 may be integrally formed on the substrate 1, or may be assembled or glued to the substrate 1 by other parts, in other possible embodiments of the invention, the protrusion
  • the edge 3 can also be located on the third face 21.
  • the cover plate 2 is a cover plate made by the method for manufacturing the cover plate, and more specifically, the cover plate is mixed and distributed with phosphor powder, and the cover plate 2 is mainly made of acrylic, so that The cover 2 is for transmitting light.
  • the surface of the third surface 21 or the fourth surface 22 of the cover plate 2 is formed with a concave-convex texture, and the concave and convex lines can be used to reflect and refract light.
  • the LED circuit 4 is fixed on the second surface 12, and the LED circuit 4 can include at least one LED chip 41, and can include a wire 42 connected to the LED chip 41, wherein Preferably, the arrangement of the LED circuit 4 can be performed by an SMT (Surface Mount Technology) process.
  • SMT Surface Mount Technology
  • the cover plate 2 is fixed to the substrate 1 in a vacuum environment, and the groove is closed by the cover plate 2 and the substrate 1 to form a closed space, and the closed space is in a vacuum state, and the light is emitted.
  • the diode circuit 4 is then located in the enclosed space.
  • the cover plate 2 and the substrate 1 are fixed by the photo-curing resin 5, and in other possible embodiments of the present invention, the high-frequency heating may be used to locally melt the cover plate 2 or the substrate 1, and further The cover 2 is pressed against the substrate 1.
  • the packaged light emitting diode shown in FIG. 1 can be manufactured, wherein the light emitting diode chip 41 is separated from the cover plate 2, and the closed space is in a vacuum state, so that the heat generated by the light emitting diode chip 41 is not easily transmitted.
  • the fluorescent material in the cover 2 can be prevented from being deteriorated by the high temperature; at the same time, the phosphor in the cover 2 is mixed and covered in the acrylic of the cover 2, so that the fluorescent substance can be prevented from directly outward. Exposure can prevent the fluorescent substance from deteriorating by contact with moisture.
  • the closed space between the cover plate 2 and the substrate 1 is in a vacuum state, which can reduce the loss of light generated by the LED chip 41 and cause loss of light, and can maintain better luminous efficiency.
  • the cover plate 2 can form irregularities. The texture can provide a concentrated effect and maintain better lighting.
  • other protective layers may be additionally provided on the fourth side 22 of the cover 2 to protect the cover 2 from abrasion or other substances.
  • the manufacturing method of the cover provided by the present invention can be used to manufacture a cover plate, and further In the method for manufacturing a packaged light emitting diode, a light emitting diode for manufacturing a package can improve the durability and stability of the packaged light emitting diode.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Organic Chemistry (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
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Description

盖板的制造方法及用于制造封装发光二极管的方法
技术领域
本发明是有关于封装的发光二极管， 特别是关于一种可用于封装发光 二极管的盖板的制造方法。 背景技术
公知的封装发光二极管， 是以荧光粉混合于硅胶或环氧树脂中， 并以 硅胶或环氧树脂包覆于发光二极管芯片周围， 可利用发光二极管产生的光 激发荧光粉， 进而可发出各种颜色或白色的可见光。
然而， 这种封装发光二极管却容易产生不稳定与寿命不长的问题。 硅 胶与环氧树脂外表可能受到水分侵蚀， 使荧光粉与水分接触， 而造成荧光 粉变质， 耗损封装发光二极管的寿命； 此外， 发光二极管芯片于使用时将 会使周遭温度上升， 尤其， 在不断提高发光二极管照明功率的同时， 发光 二极管芯片将产生更多的热， 使周围的硅胶、 环氧树脂与荧光粉发生变质， 影响封装发光二极管的稳定度与使用寿命。 发明内容
有鉴于此， 本发明的主要目的在于提供一种具有较佳寿命与稳定度的 封装的发光二极管及制造该封装发光二极管的方法。
为达到上述目的， 本发明提供一种盖板的制造方法， 包括以下步骤： 备料、 调合、 脱泡、 注模、 固化、 脱模。
其中的备料是取备压克力胶与荧光粉， 其中， 该压克力胶是指未固化 成型的压克力材料。
其中的调合是将该压克力胶与该荧光粉依比例混合制成中间产物， 该 荧光粉的重量百分比介于百分之五至百分之五十之间。 其中的脱泡是将该中间产物置于真空环境， 并通过抽真空辅助机器， 使该中间产物内混合的空气自该中间产物分离。
其中的注模是将经过脱泡步骤后的中间产物浇注于一成型模具， 并利 用抽真空辅助机器， 将浇注至成型模具的中间产物产生的气泡消除。
其中的固化是以紫外线照射浇注于该成型模具的中间产物， 使该中间 产物固化成型制成盖板， 该紫外线曝光量以每平方厘米 3000至 3500 兆焦 条件下持续曝光 20-40秒之间。
其中的脱模是令该盖板与该成型模具分离。
本发明还提供一种制造封装发光二极管的方法， 其包含盖板的制造方 法， 该用于制造封装发光二极管的方法包含下列步骤：
取材： 取一基板与该盖板， 该基板具有第一面与第二面， 该盖板具有 第三面与第四面， 该第二面与该第三面其中之一具有凸缘， 该凸缘围构有 一凹槽；
建置电路： 在所述第二面固设一发光二极管电路， 该发光二极管电路 包含至少一个发光二极管芯片；
固定： 在真空环境下将所述盖板固设于该基板， 使所述凹槽被所述盖 板及所述基板所封闭形成一封闭空间， 所述发光二极管电路位于该封闭空 间中。
借此， 本发明可利用上述方法制作一盖板， 用以进一步制作封装发光 二极管， 以盖板盖设于发光二极管或发光二极管芯片上， 避免或减少荧光 粉受热或接触水分， 提高荧光粉的稳定度， 进而使封装发光二极管具有较 佳的使用寿命与稳定度。 附图说明
图 1为本发明所制成的封装发光二极管局部剖视图；
图 2为本发明所提供盖板的制造方法流程图； 图 3至图 6分别为本发明中封装发光二极管的生产连续动作示意图。 附图标记说明
1 基板
11 第一面
12 第二面
2 盖板
21 第三面
22 第四面
3 凸缘
4 发光二极管电路
41 发光二极管芯片
42 导线
5 光硬化树脂 具体实施方式
以下仅以实施例说明本发明较佳的实施例， 然而并非用以限制本发明 所欲保护的范畴。
本发明提供一种盖板的制造方法， 所制造的盖板可供用于制造如图 1 所示的封装发光二极管。
如图 2所示， 本发明所提供盖板的制造方法包括有以下步骤： 备料： 预先准备或制备而取得压克力胶与荧光粉， 其中， 该压克力胶 是指未固化成形的压克力材料， 较佳者， 前述与荧光粉混拌的压克力胶， 是包含甲基丙烯酸甲酯、 甲基丙烯酸甲酯寡聚合体与光起始剂， 且在受到 紫外线照射后将产生聚合反应， 形成固体的压克力。 其中的荧光粉， 是指 粉末状的荧光物质。
调合： 将压克力胶与荧光粉依一预定的比例混拌成， 粘度介于 1000-3000CPS (厘泊） 的中间产物， 较佳者， 预定的比例中， 荧光粉的重 量百分比介于百分之五至百分之五十之间。 且荧光粉为配合不同颜色的发 光二极管产生白光的激发效果， 上述的荧光粉为独立的黄色荧光粉、 混合 R.G.B (红、 绿、 蓝） 三原色的荧光粉、 混合黄色与红色的荧光粉、 混合红 色与绿色的荧光粉， 或者混合橘色与绿色的荧光粉。
脱泡： 将中间产物置于真空环境中， 并通过抽真空辅助机器， 将中间 产物内混合的空气自该中间产物分离。
注模： 将经过脱泡步骤后的中间产物浇注于一成型模具， 较佳者， 在 真空环境中进行注模步骤， 尽可能避免中间产物与模具之间残留过量空气 或气泡。 当然为完全消除中间产物浇注至成型模具产生的气泡， 通过抽真 空辅助机器为最佳的方案。
固化： 以紫外线照射浇注于成型模具的中间产物， 使中间产物固化成 型制成盖板。其中，所照射的紫外线曝光能量约略为每平方厘米 3000至 3500 兆焦， 曝光时间则介于 20-40 秒之间， 最佳者为以曝光能量每平方厘米 3000-3500 兆焦条件下， 持续照射 30秒。
脱模： 令该盖板与该成型模具分离。
其中较佳者， 固化步骤之前的各步骤是在一黄光室中进行， 可避免压 克力胶于固化步骤前受到环境中的紫外线照射， 而提早发生固化的现象。
借此， 利用上述步骤所制成的盖板， 进一步投入用于制造封装发光二 极管的方法中， 可用以制作封装发光二极管。请参考图 3至图 6， 该用于制 造封装发光二极管的方法包括有以下步骤：
取材： 取基板 1与该盖板 2。 其中， 该基板 1具有第一面 11与第二面 12， 该盖板 2具有第三面 21与第四面 22， 该第二面 12形成有凸缘 3， 该 凸缘 3围构有一凹槽， 其中该凸缘 3可能为一体成型于该基板 1， 或可利用 其它零件组装或胶合于基板 1 形成， 在本发明其它可能的实施例中， 该凸 缘 3也可位于该第三面 21。 该盖板 2为前述盖板的制造方法所制作而成的 盖板， 更明确地说， 该盖板中混合分布有荧光粉， 且该盖板 2主要是由压 克力所制成， 使该盖板 2可供光线透射。 较佳者， 该盖板 2的第三面 21或 第四面 22表面可形成有凹凸紋路， 可利用凹凸紋路对光进行反射与折射。
建置电路： 如图 4所示， 在第二面 12固设发光二极管电路 4， 该发光 二极管电路 4可包括至少一个发光二极管芯片 41， 并可包括连接于发光二 极管芯片 41 的导线 42， 其中较佳者， 该发光二极管电路 4的设置可采用 SMT (Surface Mount Technology, 表面粘着技术） 工艺进行。
固定： 在真空环境下将该盖板 2固设于该基板 1， 使该凹槽被该盖板 2 与该基板 1 所封闭， 形成一封闭空间， 且该封闭空间内为真空状态， 该发 光二极管电路 4则位于该封闭空间中。 其中， 该盖板 2与该基板 1之间是 利用光硬化树脂 5 加以固定， 在本发明其它可能的实施例中， 也可利用高 周波加热， 使盖板 2或基板 1发生局部熔化， 再进一步将该盖板 2与该基 板 1压合。
利用上述步骤， 即可用以制造如图 1 所示的封装发光二极管， 其中， 发光二极管芯片 41与该盖板 2分离， 且封闭空间中为真空状态， 使发光二 极管芯片 41所产生的热不易传递至盖板 2， 可避免盖板 2中的荧光物质受 到高温影响而变质； 同时， 盖板 2中的荧光粉被混合包覆于盖板 2的压克 力中， 可避免荧光物质直接向外暴露， 而可避免荧光物质接触水分而变质。
又， 盖板 2与基板 1之间的封闭空间为真空状态， 可减少发光二极管 芯片 41所产生的光接触空气而产生损耗， 可维持较佳的发光效率； 同时， 该盖板 2可形成凹凸紋路， 可提供聚光的效果， 维持较佳的照明能力。 较 佳者， 也可在盖板 2的第四面 22额外设置其它保护层， 避免盖板 2遭受磨 耗或其它物质的侵蚀。
综上所述， 本发明所提供盖板的制造方法可用以制造盖板， 进一步供 用于制造封装发光二极管的方法中， 用以制造封装的发光二极管， 可提高 封装发光二极管的耐用度与稳定度。
以上所述， 仅为本发明的较佳实施例而已， 并非用于限定本发明的保 护范围。

Claims

权利要求书
1.一种盖板的制造方法， 其特征在于， 其包含下列步骤：
备料： 取压克力胶与荧光粉， 其中， 该压克力胶是指未固化成型的压 克力材料；
调合： 将该压克力胶与该荧光粉依比例混合制成粘度介于 1000-3000 厘泊的中间产物， 该荧光粉的重量百分比介于百分之五至百分之五十之间； 脱泡： 将该中间产物置于真空环境， 并通过抽真空辅助机器， 使该中 间产物内混合的空气自该中间产物分离；
注模： 将经过脱泡步骤后的中间产物浇注于成型模具， 并利用抽真空 辅助机器， 将浇注至成型模具的中间产物产生的气泡消除；
固化： 以紫外线照射浇注于该成型模具的中间产物， 使该中间产物固 化成型制成盖板； 该紫外线曝光量以每平方厘米 3000至 3500 兆焦条件下 持续曝光 20-40秒之间；
脱模： 令该盖板与该成型模具分离。
2.如权利要求 1 所述的盖板的制造方法， 其特征在于， 所述固化步骤 中， 所述紫外线曝光量以每平方厘米 3000至 3500 兆焦持续曝光 30秒。
3.如权利要求 1 所述的盖板的制造方法， 其特征在于， 所述注模步骤 是在真空环境中进行。
4.如权利要求 1 所述的盖板的制造方法， 其特征在于， 所述固化步骤 之前的各步骤是在黄光室中进行。
5.如权利要求 1所述的盖板的制造方法， 其特征在于， 所述压克力胶 包含甲基丙烯酸甲酯、 甲基丙烯酸甲酯寡聚合体与光起始剂。
6.一种用于制造封装发光二极管的方法， 其特征在于，包含权利要求 1 至 5 中任一项所述的盖板的制造方法， 该用于制造封装发光二极管的方法 包含下列步骤： 取材： 取一基板与该盖板， 该基板具有第一面与第二面， 该盖板具有 第三面与第四面， 该第二面与该第三面其中之一具有凸缘， 该凸缘围构有 一凹槽；
建置电路： 在所述第二面固设一发光二极管电路， 该发光二极管电路 包含至少一个发光二极管芯片；
固定： 在真空环境下将所述盖板固设于该基板， 使所述凹槽被所述盖 板及所述基板所封闭形成一封闭空间， 所述发光二极管电路位于该封闭空 间中。
7.如权利要求 6所述的用于制造封装发光二极管的方法， 其特征在于， 所述固定步骤中， 是以光硬化树脂将所述盖板与所述基板相互固定。
8.如权利要求 6所述的用于制造封装发光二极管的方法， 其特征在于， 所述第三面形成有凹凸紋路。
9.如权利要求 6所述的用于制造封装发光二极管的方法， 其特征在于， 所述第四面形成有凹凸紋路。
PCT/CN2010/078609 2010-11-10 2010-11-10 盖板的制造方法及用于制造封装发光二极管的方法 WO2012061985A1 (zh)

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