WO2009052702A1 - A structure of heat dissipation substrate for power led and a device manufactured by it - Google Patents

A structure of heat dissipation substrate for power led and a device manufactured by it Download PDF

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Publication number
WO2009052702A1
WO2009052702A1 PCT/CN2008/001740 CN2008001740W WO2009052702A1 WO 2009052702 A1 WO2009052702 A1 WO 2009052702A1 CN 2008001740 W CN2008001740 W CN 2008001740W WO 2009052702 A1 WO2009052702 A1 WO 2009052702A1
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WO
WIPO (PCT)
Prior art keywords
counterbore
heat sink
hole
heat dissipation
structure according
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/CN2008/001740
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English (en)
French (fr)
Inventor
Binhai Yu
Junzheng Li
Xunli Xia
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Foshan NationStar Optoelectronics Co Ltd
Original Assignee
Foshan NationStar Optoelectronics Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Foshan NationStar Optoelectronics Co Ltd filed Critical Foshan NationStar Optoelectronics Co Ltd
Priority to US12/527,295 priority Critical patent/US8174832B2/en
Priority to JP2010515340A priority patent/JP2010532925A/ja
Priority to EP08841900A priority patent/EP2202809A4/en
Priority to CN2008800011899A priority patent/CN101663768B/zh
Priority to KR1020097017332A priority patent/KR101303777B1/ko
Publication of WO2009052702A1 publication Critical patent/WO2009052702A1/zh
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10H—INORGANIC LIGHT-EMITTING SEMICONDUCTOR DEVICES HAVING POTENTIAL BARRIERS
    • H10H20/00—Individual inorganic light-emitting semiconductor devices having potential barriers, e.g. light-emitting diodes [LED]
    • H10H20/80—Constructional details
    • H10H20/85—Packages
    • H10H20/858—Means for heat extraction or cooling
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10H—INORGANIC LIGHT-EMITTING SEMICONDUCTOR DEVICES HAVING POTENTIAL BARRIERS
    • H10H20/00—Individual inorganic light-emitting semiconductor devices having potential barriers, e.g. light-emitting diodes [LED]
    • H10H20/80—Constructional details
    • H10H20/85—Packages
    • H10H20/858—Means for heat extraction or cooling
    • H10H20/8582—Means for heat extraction or cooling characterised by their shape
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10H—INORGANIC LIGHT-EMITTING SEMICONDUCTOR DEVICES HAVING POTENTIAL BARRIERS
    • H10H20/00—Individual inorganic light-emitting semiconductor devices having potential barriers, e.g. light-emitting diodes [LED]
    • H10H20/80—Constructional details
    • H10H20/85—Packages
    • H10H20/8506—Containers

Definitions

  • the present invention relates to a power LED heat dissipating substrate structure and a device for manufacturing the heat dissipating substrate structure, and more particularly to a heat dissipating substrate having a counterbore and a heat sink structure and a device for manufacturing the heat dissipating substrate.
  • LED Light Emitting Diode
  • the LED light source generates heat when it is working. Its power value is proportional to its calorific value.
  • Early LED devices were all milliwatt-class low-power LED devices due to manufacturing technology limitations. In recent years, some new improvements have appeared. The technology makes the power of manufacturing LED devices relatively higher, and there are LED devices and products with higher power, that is, power LEDs, whose power has increased to more than 100 mW.
  • power LED light sources are advancing in the field of general illumination, and 1W has appeared. The above high-power LEDs have gradually appeared in every corner of the lighting field.
  • the power LED light source generates heat when it is working, and when the power LED light source works for a long time, the life of the power LED light source is shortened due to the accumulation of heat, and the product characteristics are not stable.
  • the package structure of the current power LED light source is usually complicated.
  • FIG. 1 it is a lead frame type high power LED package structure.
  • a heat-sinking 102 is added, and the main feature of the support structure is
  • the metal holder 103 is molded with a white or black colloid 104 to form a cavity, and the electrode lead 103 and the heat sink block 102 are fixed.
  • the chip 105 and the heat sink 106 are placed in the emitter cup 107 of the heat slug 102, and the optical lens 108 is mounted above the frame.
  • a ceramic substrate type power LED package structure is introduced.
  • the main features are as follows:
  • the chip 201 is directly placed on the ceramic substrate 202 printed with the circuit, and the ceramic substrate 202 and its lines constitute the heat dissipation of the LED.
  • the conductive structure, a metal reflective cavity 203 is mounted over the ceramic substrate 202, supports the lens 204 and forms an optical structure.
  • the ceramic substrate has a complicated processing process, low production efficiency, high cost, and limited heat dissipation of the ceramic substrate, which makes the ceramic substrate
  • the power boosting space of the fabricated LED device is limited.
  • a power LED bracket (substrate) fabricated by means of a circuit board assembly heat sink is gradually emerging, but it has the disadvantages of complicated structure, high process requirements, poor reliability, and poor heat dissipation effect, thereby making power LED
  • the production cost of the product is still high, and the reliability is not guaranteed and the service life is shortened.
  • the patent publication WO2006104325 provides a solution for assembling a heat sink, the structure of which is shown in Fig. 3, which is a stack of four layers (301, 302, 303, 304) having a through-hole structure. Together, they form a cavity for assembling the heat sink 305.
  • Fig. 3 which is a stack of four layers (301, 302, 303, 304) having a through-hole structure. Together, they form a cavity for assembling the heat sink 305.
  • Fig. 3 is a stack of four layers (301, 302, 303, 304) having a through-hole structure. Together, they form a cavity for assembling the heat sink 305.
  • the requirements for positioning in the manufacturing process are very high, and the welding of superimposed circuit boards is prone to problems such as soldering and uneven welding, and the manufacturing cost and process difficulty are obviously improved. Production efficiency is not high.
  • the patent publication CN1977399A provides a solution for an LED substrate fabricated by mounting a heat sink 404 on a circuit board 403. As shown in FIG. 4, the circuit board via structure 401 is combined with the heat sink 402. At the same time, it is proposed that the circuit board has a push surface or a heat sink having a push surface 403.
  • the technical solution has a thin design and a small heat dissipation, and is not suitable for a large-power LED device.
  • the through-hole structure is equipped with a heat sink, and the bonding force is weak, and the heat sink is easy. Falling off, difficult to locate, poor reliability, and poor heat dissipation.
  • the process of processing the printed circuit board is difficult to obtain good control, and the quality of the product is difficult to guarantee.
  • the object of the present invention is to overcome the above drawbacks in the prior art, that is, the structure of the power LED heat dissipating substrate is complicated, the process requirement is high, the manufacturability is poor, the heat dissipation effect of the substrate is not good, and the manufacturing efficiency of the power LED device is not high.
  • Technical defects with poor product consistency and reliability, high cost providing a heat sink substrate structure for assembling a heat sink of a circuit substrate, and utilizing the dispersion
  • the power LED device manufactured by the thermal substrate has the structure of the heat dissipating substrate, is easy to manufacture, reduces the production process requirements of the prior art, and can effectively solve the heat dissipation problem of the power LED device, in particular, can effectively solve the power of the larger power.
  • the heat dissipation problem of the LED device the device manufactured by using the heat dissipation substrate of the invention has good consistency, high reliability, good heat dissipation effect, and the production efficiency of the invention is high, the structure is simple, the production cost is low, and the device can be largely Increasing the power of power LED devices provides a guarantee for power LED products to meet growing market demands.
  • the present invention provides a heat dissipating substrate structure for manufacturing a power LED, the heat dissipating substrate structure comprising: a circuit substrate, wherein the circuit substrate is an integrated structure, and the counterbore and the metal line are disposed thereon
  • the sinking structure is a combination of two holes of different sizes, the small holes are through holes, and the large holes are blind holes, the through holes are in the same axial direction as the blind holes;
  • the heat sink structure of the present invention is upper step and lower a stepped column-like integrated structure composed of steps, the diameter of the upper step is close to the aperture of the through hole, the diameter of the lower step is close to the aperture of the blind hole, and the height of the lower step of the heat sink is equal to or greater than the depth of the blind hole
  • the upper step is the same as the axial direction of the lower step; the heat sink structure is matched with the counterbore structure, and the heat sink can be inserted into the counterbore to form a firm fit.
  • the heat dissipating substrate structure has a multi-layered complex structure of the circuit board of the prior art due to the integrated structure of the circuit board, thereby effectively ensuring the processing quality of the heat dissipating substrate; the above-mentioned structural design of the heat sink and the circuit substrate, so that the heat dissipating substrate is in heat
  • the assembly method of the sinking and countersinking is very simple, the heat sink is firmly assembled, the positioning is reliable, and it is not easy to slip off, which effectively ensures the assembly quality of the heat-dissipating substrate; and the column-integrated structure of the heat sink is due to the volume of the lower step relative to the upper step.
  • the heat transfer medium contacts the heat to dissipate heat, thereby producing a good heat dissipation effect, and greatly increasing the power of the manufactured power LED device, making the design of the present invention particularly suitable for the manufacture of larger power LED devices.
  • the heat dissipating substrate has a single structure, is easy to manufacture, and greatly reduces the production cost of the power LED heat dissipating substrate.
  • the present invention further provides a heat dissipating substrate structure comprising a plurality of counterbore and heat sinks, which are composed of a counterbore and a heat sink structure of the heat dissipating substrate, and a heat sink substrate.
  • the circuit substrate is an integrated structure, and a cutting positioning line is disposed at an end of the circuit substrate, and a slot and/or a hole is disposed in the circuit substrate; and the M substrate is composed of a plurality of counterbore
  • the array of holes, M and N are integers equal to or greater than 1, respectively, and M and N are not equal to 1 at the same time, and each heat sink and the counterbore of the counterbore array are firmly matched.
  • the above-mentioned arrangement of the heat dissipating substrate structure solves the defects in the manufacturing of the power LED manufacturing, the manufacturing of the power LED is a single device, the defect of the product consistency is poor, and the design of the heat dissipating substrate through the single tube is realized. It is now possible to manufacture a plurality of power LEDs simultaneously on the same heat sink substrate.
  • the LED substrate is produced by using the heat dissipating substrate, after the encapsulant is performed, the packaged LED product can be divided into independent LED devices by cutting the substrate along the cutting positioning line, which enables the production of the power LED device. Large cylinderization increases production efficiency, reduces production costs, and ensures consistent product quality.
  • the present invention also provides a power LED device manufactured by using the heat dissipation substrate structure of the above power LED, the device comprising: a heat sink, a circuit substrate having a counterbore structure, an LED chip, a lead wire, The encapsulant colloid, wherein the heat sink is firmly matched with the counterbore of the circuit substrate; the LED chip is placed on the heat sink; the circuit substrate is composed of an internal lead connection portion and an external electrode, and the lead wire is connected to the LED chip electrode and the line An internal lead connection portion on the substrate; then the encapsulant covers a side of the circuit substrate on which the chip is mounted, and the external electrode portion is retained, the encapsulant is a sealing layer material, and the chip and the lead are sealed to be insulated from external moisture and air.
  • the above-mentioned power LED device manufactured by using the heat dissipation substrate has a good heat dissipation effect, and can greatly improve the power of the manufactured power LED device; since the device has the structure of the heat dissipation substrate and the package of the device package, the batch can be realized once.
  • the production of multiple devices is high in productivity, and the power LED device of the present invention has good consistency; importantly, the encapsulant is a one-shot optical lens, which is a lens-mounted device on the encapsulant used in the prior art.
  • the light-emitting characteristics of the power LED device are better improved, and the power LED device of the invention has a compact structure, high reliability and low cost; and the heat-dissipating substrate structure has good heat dissipation performance, and the heat-dissipating substrate of the invention is used for manufacturing power.
  • the LED device has a large power boosting space, and is particularly suitable for manufacturing a high-power LED device. Due to the intricate design of the counterbore and the heat sink of the above-mentioned heat sink substrate, the complicated power LED manufacturing process is completed, and the power LED is made. The production efficiency of the device is greatly improved, so that the power LED The device has a longer life.
  • Figure 1 shows a prior art lead frame type power LED package structure
  • Figure 2 shows a conventional ceramic substrate type power LED package structure
  • Figure 3 shows the prior art A structure diagram of a power LED bracket fabricated by assembling a heat sink on a circuit board;
  • FIG. 4 is a structural view showing a heat dissipating substrate of a prior art circuit board assembly heat sink;
  • FIG. 5 is a schematic view showing a first embodiment of the heat dissipating substrate of the present invention;
  • Figure 6 is a schematic view showing the assembly of a counterbore and a heat sink structure according to a first embodiment of the present invention;
  • Figure 7 is a schematic view showing the structure of a preferred embodiment of the first embodiment of the present invention
  • Figure 8 is a schematic view showing a preferred embodiment of the first embodiment of the present invention
  • Figure 9 is a view showing the structure of the present invention.
  • FIG. 10 is a schematic view showing a preferred embodiment of the second embodiment of the heat dissipating substrate of the present invention
  • Figure 11 is a schematic view showing the second embodiment of the heat dissipating substrate of the present invention after chip mounting;
  • Figure 12 is a cross-sectional view showing the structure of the power LED device of the present invention;
  • Figure 13 is a perspective view of the power LED device of the present invention.
  • a preferred embodiment 1 of a heat dissipating substrate for manufacturing a power LED of the present invention will be described with reference to the above-mentioned Figs. 5 and 6.
  • FIG. 5 and FIG. 6 show the basic configuration of the circuit substrate 1 and the heat sink 4 constituting the heat dissipation substrate of the present invention.
  • 5A is a schematic view of the upper surface of the heat dissipation substrate
  • FIG. 5-5B is a schematic view of the lower surface of the heat dissipation substrate
  • FIG. 5C shows a heat dissipation of the counterbore equipped with a heat sink.
  • 5E and 5E in FIG. 5 are a perspective view and a cross-sectional view of the heat sink.
  • the circuit substrate 1 is an integral structure, and the counterbore 2, the metal line 3, and the metal line are disposed thereon.
  • the counterbore structure is a combination of two holes of different sizes, the small hole is a through hole 2a, and the large hole is a blind hole 2b, The axial direction of the same is perpendicular to the upper and lower surfaces of the circuit substrate;
  • the structure of the heat sink 4 is a stepped column-like integrated structure composed of an upper step 4a and a lower step 4b, and the diameter of the upper step 4a is close to the aperture of the through hole 2a.
  • the diameter of the lower step 4b is similar to the diameter of the blind hole 2b, and the axial direction of the upper step 4a and the lower step 4b are the same; the heat sink structure is matched with the counterbore structure, and the heat sink can be fitted into the counterbore to form a firm fit. , preferably the interference is firm Adhesively bonded or firmly fitted.
  • Fig. 6 is a schematic view showing the assembly of the counterbore 2 and the heat sink 4 of the circuit substrate 1 constituting the heat dissipating substrate of the present invention, and shows a preferred embodiment of the present invention.
  • the height of the lower step 4b of the heat sink is equal to or greater than the depth of the blind hole 2b, so that the bottom of the heat sink is assembled flush with or protrudes from the lower surface of the circuit substrate after assembly.
  • the purpose of making the heat sink easy to contact with the heat transfer medium to dissipate heat is achieved;
  • the height of the upper step 2a of the heat sink is equal to or greater than the depth of the through hole, so that the heat sink is mounted on the top of the assembly after the assembly
  • the upper surface of the circuit substrate is flush or convex, so that the LED chip has a good light-emitting effect when assembled on the top of the heat sink.
  • the cross-section of the blind hole 2b and the cross-section of the through-hole 2a may be any circular shape or any polygonal shape.
  • any circular shape means: A circle, an ellipse, or an irregular circle; an arbitrary polygon is a polygon consisting of an arc, a line, or an arc combined with a line.
  • the blind hole 2b is circular in cross section; the through hole 2a is transversely arbitrarily circular or arbitrary polygonal, and the upper step 4a is a circular or arbitrary polygon corresponding to the transverse plane of the through hole 2a; The diameter of the step 4a is close to the aperture of the through hole 2a, and the diameter of the lower step 4b is close to the aperture of the blind hole 2b, so that the heat sink can be fitted into the counterbore to form a firm fit.
  • a preferred solution is: the top of the column of the upper step 4a of the heat sink is a flat surface or a concave reflecting cup; the axis of the through hole 2a as shown by 8A in FIG.
  • the blind hole 2B has the same axial axis direction and may be coaxial or non-coaxial.
  • the through hole 2a and the blind hole 2b are not coaxial; correspondingly, the axis of the upper step 4a and the axis of the lower step 4b Similarly, it may be coaxial or non-coaxial; a preferred solution is that the upper step 4a and the lower step 4b are not coaxial, so that the heat sink is easily positioned and assembled into the counterbore; further, as shown in FIG.
  • the top cross section of the upper step 4a of the heat sink is slightly smaller than the bottom cross section thereof, so that the upper step is tapered;
  • the top cross section of the lower step 4b of the heat sink is slightly smaller than the bottom cross section thereof, so that the lower step is tapered;
  • the column height of the lower step 4b of the heat sink is equal to or larger than the depth of the blind hole 2b, making it easy to achieve an interference and firm assembly. It is also possible to firmly bond the heat sink and the counterbore through the adhesive.
  • a preferred embodiment 2 of the heat dissipation substrate of the LED is explained below.
  • the heat dissipation substrate of the previous embodiment is composed of a basic unit structure. a counterbore heat dissipating substrate, the circuit substrate of the heat dissipating substrate is an integral structure, and the cutting positioning line 5 and the groove 6 and/or the hole 7 (not shown) are disposed thereon; wherein the circuit board is provided with M columns of XN rows of countersinks Array, M, N are integers equal to or greater than 1, respectively, and ⁇ 1, N are not equal to 1 at the same time; the cutting positioning lines are multiple, and each cutting positioning line corresponds to each counterbore column and/or each counterbore row a plurality of slots and/or holes are disposed in each of the counterbore rows or sides of each of the counterbore rows; the cutting positioning lines 5 are plurality of strips, and each cutting positioning line 5 corresponds to each counterbore row and/or Or the side of the counterbore row; the plurality of grooves 6 and/or holes 7 are provided at each of the counterbore rows
  • Each of the counterbore is equipped with a heat sink, and is firmly combined in an interference fit manner or the heat sink is firmly bonded to the counterbore, preferably in a interference fit manner.
  • a preferred solution is as follows: As shown in FIG. 9, a cutting positioning line 5 is disposed at two ends of the corresponding counterbore row of the circuit substrate, and the number of the cutting positioning lines 5 is M+1, and each cutting positioning line 5 corresponds to The intermediate position between each of the counterbore rows; the groove 6 is a through groove penetrating the side of each of the counterbore rows, and the number of the grooves 6 is N+1, and each groove is located at an intermediate position between the rows of the counterbore. As shown in Fig. 9, the array of counterbore consisting of 5 rows and 4 rows has 6 strips of the positioning line 5 and 5 slots 6.
  • the device electrodes 3 are disposed on the upper surface, the lower surface, and the side surfaces of the wiring substrate on both sides of the through-groove.
  • a cutting positioning line 5a is disposed on both ends of the corresponding counterbore row on the circuit substrate, and the number of the cutting positioning lines 5a is N +1 (As shown in FIG. 10, there are 5 rows of 4 rows of counterbore arrays, 5 cutting positioning lines 5a), and each cutting positioning line 5a corresponds to an intermediate position between the rows of countersinks;
  • a cutting positioning line 5b is disposed at both ends of the corresponding counterbore column, and the number of the cutting positioning lines 5b is M+1 (as shown by the cutting positioning line 5b shown in FIG.
  • each cutting positioning line 5b Corresponding to an intermediate position between each of the counterbore rows; the plurality of slots 6 (not shown) and/or the holes 7 arranged in alignment are collinear with the cutting positioning lines provided at the opposite ends of each of the counterbore rows or the counterbore rows
  • the slot is provided with a slot 6 or a hole 7 on the line
  • the device electrodes 3 are disposed on the circuit substrate 1 along the plurality of slots and/or holes arranged on the circuit board corresponding to the respective counterbore, and corresponding to each The counterbore is provided with an inner lead connecting portion 3a.
  • the device electrodes 3 are disposed on the upper surface, the lower surface, and the side surfaces of the wiring substrate on both sides of the groove 6 or the hole 7.
  • a plurality of holes 7 arranged in a line are arranged on the sides of each of the counterbore rows, and a side of each of the counterbore rows corresponds to a hole 7 according to
  • the illustrated hole 7 can also be provided as the groove 6.
  • Figure 11 is a view showing a heat dissipation substrate of a preferred embodiment of the above embodiment of the present invention.
  • FIG. 12 is a schematic structural view of a power LED device manufactured by using the heat dissipation substrate of the present invention, the device comprising: a heat sink 4, a circuit substrate 1 having a counterbore structure, an LED chip 8, a lead 9, an encapsulant 10,
  • the device electrode 3 wherein: the heat sink 4 is firmly matched with the counterbore 2 of the circuit substrate 1; the LED chip 8 is placed on the heat sink 4; the metal line 3 of the circuit substrate 1 is connected by the inner lead connecting portion 3a and the outside a device electrode 3 composed of an electrode 3b, the lead 9 connecting the LED chip electrode and an internal lead connection portion on the circuit substrate; the encapsulant 10 covering one side of the circuit substrate on which the chip is mounted, and retaining the external electrode 3b portion,
  • the encapsulant 10 is both a sealing layer, which seals the chip and the lead, and is an optical lens in which the device is integrally formed.
  • the optical lens in which the device is integrally formed may be a convex lens,
  • the power LED device of the present invention is compact compared to the existing power LED device, and the power LED device using the heat dissipation substrate of the present invention has a large power boosting space, and is particularly suitable for manufacturing a LED device with high power, thereby achieving low cost. High-efficiency manufacturing of high-performance, high-quality power LED devices.

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Description

功率 LED散热基板结构及由其制造的器件
技术领域
本发明专利申请涉及一种功率 LED散热基板结构以及该散热基板结 构制造的器件， 特别是涉及一种具有沉孔和热沉结构的散热基板及该散热 基板制造的器件。 背景技术
发光二极管 ( Light Emitting Diode, LED ) 因其具有体积小、 寿命长、 驱动电压低、 耗电量低、 反应速度快、 耐震性佳等优点， 为日常生活中各 种应用设备中常见的元件， LED光源在工作时会产生发热现象， 其功率值 与其发热量成正比， 早期的 LED 器件由于受制造技术的限制， 均为毫瓦 级的小功率 LED器件，近年来， 出现了一些新的改进技术，使得制造 LED 器件的功率相对提高， 出现了具有较大功率的 LED 器件和产品， 即功率 LED,其功率增加到了 100毫瓦以上， 目前功率 LED光源正向普通照明领 域推进， 出现了 1W以上的大功率 LED, 已逐渐出现在照明领域的各个角 落。 功率 LED光源在工作时会产生发热现象， 且当功率 LED光源长时间 工作时， 由于热量的积蓄会导致功率 LED 光源的寿命缩短， 产品特性不 稳定。 为了解决功率 LED芯片在工作时的散热问题， 目前的功率 LED光 源的封装结构通常较为复杂。
常见的大功率 LED支架有引线框架、 陶瓷基板等。 如图 1所示， 是 一种引线框架式的大功率 LED封装结构， 在原来普通 PLCC型 LED塑封 框架 101 的基础上， 加入散热块（heat-sinking ) 102, 该支架结构的主要 特点是在金属支架 103上塑封白色或黑色胶体 104, 形成腔体， 固定电极 引线 103与散热块 102, 芯片 105与热沉 106安放在散热块 102的发射杯 107内， 框架上方安装光学透镜 108。
又如图 2所示， 介绍了一种陶瓷基板式的功率 LED封装结构， 其主 要特点在于： 芯片 201直接安放在印刷有线路的陶瓷基板 202上， 陶瓷基 板 202及其线路组成 LED的散热和导电结构， 陶瓷基板 202上方安装一 个金属反射腔 203 , 支撑透镜 204并形成光学结构。 陶瓷基板加工工艺复 杂， 生产效率低、 成本高， 而且陶瓷基板的散热有限， 使得用陶瓷基板制 造的 LED器件的功率提升空间受到限制。
随着功率发光二极管生产规模的扩大， 应用领域的进一步推广， 以上 产品结构生产制造工艺复杂， 生产效率低。
为了节约生产成本， 逐渐出现一种以线路板装配热沉的方式制作的功 率 LED支架（基板）， 但其存在结构复杂， 工艺要求高， 可靠性差， 散热 效果不佳的缺点， 从而使得功率 LED产品的生产成本高仍然较高， 并且 可靠性没有保障， 使用寿命缩短。
例如公开号为 WO2006104325 的专利提供了一种装配热沉的解决方 案，其结构如附图 3所示， 由具有通孔结构的多层线路板（301、 302、 303、 304共四层） 叠在一起， 组成一个装配热沉 305的腔体。 这种方式需要实 现多层线路板的叠加装配并需要焊接， 制造工艺中对定位的要求非常高， 而且叠加线路板焊接易出现虚焊、 焊接不平整等问题， 制作成本、 工艺难 度明显提高， 生产效率不高。
关于解决 LED 器件的散热问题， 已有在散热板中开孔， 将散热片装 入孔中的技术方案。 例如公开号为 CN1977399A的专利， 提供了一种以线 路板 403装配热沉 404的方式制作的 LED基板的解决方案， 如附图 4所 示， 其线路板通孔结构 401与散热片 402相结合， 同时提出了线路板具有 推面或散热片具有推面 403的特征。 该技术方案由于装入的散热片设计较 薄， 散热量较小， 不适用于较大功率 LED 器件； 而且该方案在实际生产 中， 通孔结构装配散热片的方式结合力弱， 热沉易脱落， 难定位， 可靠性 差， 而且散热效果不佳。 另外， 线路板加工推面的工艺， 一致性很难得到 良好控制， 产品质量难于保证。
此外， 现有技术还存在在批量生产功率 LED产品时， 由于功率 LED 的散热基板结构相对复杂， 生产效率低、 成本高的问题。 因此需要开发一 种生产效率高、 结构筒单、 生产成本低的新型产品， 以满足日益发展的市 场需求。 发明内容
本发明的目的是为了克服上述现有技术中的缺陷， 即功率 LED散热 基板的结构复杂、 工艺要求高、 可制造性差、 基板散热效果不佳的缺陷， 以及功率 LED 器件的制造生产效率不高、 产品一致性和可靠性差、 成本 高的技术缺陷， 提供一种线路基板装配热沉的散热基板结构以及利用该散 热基板制造的功率 LED 器件， 本发明的散热基板结构筒单、 易于制造， 降低了现有技术的生产工艺要求， 能有效解决功率 LED器件的散热问题， 尤其是能够有效解决较大功率的功率 LED 器件的散热问题， 利用本发明 的散热基板制造的器件具有很好的一致性， 可靠性高， 散热效果好， 本发 明的生产效率高、 结构筒单、 生产成本低， 能够较大程度地提升功率 LED 器件的功率， 为功率 LED产品能够满足日益发展的市场需求提供了保障。
为了实现本发明的上述发明目的，本发明提供一种用于制造功率 LED 的散热基板结构， 该散热基板结构包括： 线路基板， 所述线路基板为一体 结构， 其上设置有沉孔、 金属线路； 沉孔结构为大小不等的两个孔组合连 通， 小孔为通孔， 大孔为盲孔， 所述通孔与盲孔的轴方向相同； 本发明的 热沉结构为上台阶和下台阶组成的梯台柱状一体结构， 上台阶的直径与所 述通孔的孔径接近， 下台阶的直径与所述盲孔的孔径接近， 热沉的下台阶 的柱高等于或大于盲孔的深度， 上台阶与下台阶的轴方向相同； 热沉结构 与沉孔结构相对应匹配， 热沉可装入沉孔中形成牢固配合。 上述散热基板 结构由于线路基板为一体结构， 筒化了现有技术的线路基板的多层复杂结 构， 有效保证了散热基板的加工质量； 热沉和线路基板的上述结构设计， 使得散热基板在热沉与沉孔的装配方式上十分筒单， 热沉装配牢固、 定位 可靠、 不易滑脱， 有效保证了散热基板的装配质量； 而且热沉的梯台柱状 一体结构由于下台阶相对于上台阶的体积大， 一是使得热沉具有大的热容 量和散热面积， 二是使得热沉装配入沉孔后热沉的底部与线路基板下表面 平齐或凸出于线路基板外， 可以使热沉与其它传热介质相接触散除热量， 因此能够产生很好的散热效果， 较大的提升了所制造的功率 LED 器件的 功率， 使得本发明的设计尤其适用于较大功率 LED 器件的制造。 该散热 基板结构筒单， 易于制造， 大大降低了功率 LED散热基板的生产成本。
为了实现本发明的上述发明目的， 本发明还提供了一种以上述散热基 板的沉孔和热沉结构为基本单元结构组成的多个沉孔、 热沉组成的散热基 板结构， 该散热基板的线路基板为一体结构， 在线路基板的端部设置有切 割定位线， 在线路基板中设置有槽和 /或孔； 所述线路基板上设置由多个沉 孔组成的 M列 x N行的沉孔阵列， M、 N分别为等于或大于 1的整数， 且 M、 N不同时等于 1 , 各热沉与沉孔阵列的各沉孔相牢固配合。 上述散热 基板结构的设置， 解决了在生产功率 LED制造中加工繁杂、 功率 LED多 为单一器件的制造， 产品一致性差的缺陷， 通过筒单的散热基板设计， 实 现了在同一散热基板上同时进行多个功率 LED 的制造。 当使用该散热基 板生产 LED 器件时， 在进行封装胶体后， 只要沿切割定位线对基板进行 切割，即可将封装后的 LED产品分割为独立的 LED器件，这使得功率 LED 器件的生产得到了很大的筒化， 提高了生产效率， 降低了生产成本， 并且 使产品质量的一致性得到了保证。
为了实现本发明的上述发明目的， 本发明还提供了一种利用上述功率 LED的散热基板结构制造的功率 LED器件， 该器件包括： 热沉， 具有沉 孔结构的线路基板， LED芯片， 引线， 封装胶体， 其中， 热沉与线路基板 的沉孔牢固配合； 将 LED 芯片安放在热沉上； 线路基板的线路为由内部 引线连接部和外部电极组成器件电极， 将引线连接 LED 芯片电极与线路 基板上的内部引线连接部； 然后封装胶体覆盖在装有芯片的线路基板一 面， 并保留外部电极部分， 所述封装胶体既是密封层材料， 将芯片、 引线 密封使其与外部湿气、 空气隔绝， 又是器件的一体成型的光学透镜。 上述 利用散热基板制造的功率 LED 器件具有很好的散热效果， 能够较大程度 提高制造的功率 LED 器件的功率； 由于器件具有的散热基板的结构和器 件的封装的制造筒单， 能够实现一次批量的多个器件生产， 生产效率高， 本发明的功率 LED 器件有良好的一致性； 重要的是， 封装胶体是一次成 型的光学透镜， 相对于现有技术所使用的封装胶体上装配透镜的器件， 较 好的改善了功率 LED器件出光特性， 本发明的功率 LED器件结构筒单紧 凑， 产品的可靠性高， 成本低； 由于散热基板结构具有良好的散热性能， 利用本发明的散热基板制造功率 LED 器件的功率提升空间大， 尤其适于 制造功率较大的 LED 器件， 由于利用上述的散热基板的沉孔和热沉筒单 结构巧妙设计， 筒化了繁杂的功率 LED制造工艺， 使得功率 LED器件的 生产效率大大提高， 使功率 LED器件的使用寿命更长。 附图说明
图 1 : 所示是现有的一种引线框架式的功率 LED封装结构； 图 2: 所示是现有的一种陶瓷基板式的功率 LED封装结构； 图 3:所示是现有技术的线路板装配热沉的方式制作的功率 LED支架 结构图；
图 4: 所示是说明现有技术的线路板装配热沉的散热基板结构图； 图 5: 所示是本发明的散热基板第一实施例的示意图； 图 6: 所示是本发明的第一实施例的沉孔、 热沉结构装配示意图和剖 视图；
图 7: 所示是本发明的第一实施例的优选方案的结构示意图； 图 8:所示是本发明的示意图第一实施例的一个优选方案结构示意图； 图 9:所示是本发明的散热基板第二实施例的一个优选方案的示意图； 图 10: 所示是本发明的散热基板第二实施例的一个优选方案的示意 图；
图 11 : 所示是本发明的散热基板第二实施例在芯片封装后的示意图； 图 12: 所示是本发明的功率 LED器件结构剖视图；
图 13: 所示是本发明的功率 LED器件的立体图。
附图标记：
1 线路基板； 2 沉孔:通孔 2a,盲孔 2b ； 3 金属线路、器件电极： 内部引线连接部 3a、 外部电极 3b; 4 热沉:上台阶 4a和下台阶 4b; 5 切 割定位线； 6槽 ； 7 孔； 8 LED芯片； 9 引线； 10 封装胶体。 具体实施方式
实施例一
根据上述附图 5、 附图 6, 对本发明的一个用于制造功率 LED的散热 基板的优选实施例一进行说明。
在本实施例中， 附图 5、 附图 6所示的是组成本发明散热基板的线路 基板 1和热沉 4的基本结构图。 附图 5中 5A所示的是散热基板的上表面 示意图， 附图 5-5B所示的是散热基板的下表面示意图， 附图 5中 5C所示 的是沉孔中装配有热沉的散热基板剖视图， 附图 5 中 5D和附图 5 中 5E 是热沉的立体示意图和剖视图， 在该实施例中， 线路基板 1为一体结构， 其上设置有沉孔 2、 金属线路 3 , 金属线路 3为器件的电极， 是由内部引 线连接部 3a和外部电极 3b组成； 所述的沉孔结构为大小不等的两个孔组 合连通， 小孔为通孔 2a, 大孔为盲孔 2b, 它们的轴方向相同， 并且垂直 于线路基板的上下表面； 热沉 4的结构为上台阶 4a和下台阶 4b组成的梯 台柱状一体结构， 上台阶 4a的直径与所述通孔 2a的孔径相近， 下台阶 4b 的直径与所述盲孔 2b的孔径相近， 上台阶 4a与下台阶 4b的轴方向相同； 热沉结构与沉孔结构相对应匹配， 热沉能够装入沉孔中形成牢固配合， 优 选的是过盈方式牢固配合或胶粘方式牢固配合。 附图 6所示的是组成本发明散热基板的线路基板 1的沉孔 2和热沉 4 的装配后的示意图，所示的是本发明的优选技术方案。关于热沉 4的高度， 一个优选方案是： 热沉的下台阶 4b的柱高等于或大于盲孔 2b的深度， 使 得热沉装在装配后其底部与线路基板下表面平齐或凸出， 达到使热沉易于 与传热介质接触散除热量的目的； 另一个优选的方案是： 热沉的上台阶 2a 的柱高等于或大于通孔的深度， 使得热沉装在装配后其顶部与线路基板上 表面平齐或凸出， 使得 LED 芯片装配在该热沉顶部时， 具有好的出光效 果。
根据附图 7、 附图 8 , 对本发明的用于制造功率 LED的散热基板的优 选方案， 进行说明如下。
如附图 7、 附图 8所示， 在本实施例中， 盲孔 2b的横切面和通孔 2a 横切面可为任意圓形或者为任意多边形， 在本发明中， 任意圓形是指： 圓 形、 橢圓形、 不规则圓形； 任意多边形是指： 由弧线、 直线或弧线与直线 结合构成的多边形。 其中优选的是盲孔 2b横切面圓形； 通孔 2a横切面圓 的任意圓形或任意多边形， 所述上台阶 4a横切面为与通孔 2a横切面对应 的任意圓形或任意多边形； 上台阶 4a的直径与所述通孔 2a的孔径接近， 下台阶 4b的直径与所述盲孔 2b的孔径接近， 使得热沉能够装入沉孔中形 成牢固配合。 如附图 7所示的是一个优选的方案是： 所述热沉的上台阶 4a 的柱顶部为一平面或为一下凹的反射杯；如附图 8中 8A所示通孔 2a的轴 与盲孔 2B的轴轴方向相同， 可以共轴或不共轴， 优选的方案是通孔 2a与 盲孔 2b不共轴； 与之对应的， 上台阶 4a的轴与下台阶 4b的轴轴方向相 同， 可以共轴或不共轴； 优选的的方案是上台阶 4a与下台阶 4b不共轴， 这样使得热沉易于定位装配入沉孔中； 进一步的， 如附图 8中 8B所示优 选方案是热沉的上台阶 4a 的顶部横切面略小于其底部横切面， 使得上台 阶呈锥形； 热沉的下台阶 4b 的顶部横切面略小于其底部横切面， 使得下 台阶呈锥形；优选的是热沉的下台阶 4b的柱高等于或大于盲孔 2b的深度， 使其易于实现过盈牢固装配。 也可以通过粘接胶对热沉与沉孔牢固粘接。
实施例二
根据附图 9、 附图 10、 附图 11 , 所示的是本发明的一个用于制造功率
LED的散热基板的优选实施例二， 说明如下。
如附图 9所示的是以前一实施例的散热基板为基本单元结构组成的多 个沉孔的散热基板， 其散热基板的线路基板为一体结构， 上面设置有切割 定位线 5和槽 6和 /或孔 7 (未示出）； 其中线路基板上设置 M列 X N行的 沉孔阵列， M、 N分别为等于或大于 1的整数， 且^1、 N不同时等于 1 ; 所述切割定位线为多条， 各切割定位线对应各沉孔列和 /或各沉孔行的侧 边； 所述槽和 /或孔为多个， 设置在各沉孔列或各沉孔行侧边； 所述切割定 位线 5为多条， 各切割定位线 5对应各沉孔列和 /或沉孔行的侧边； 所述槽 6和 /或孔 7为多个， 设置在各沉孔列或各沉孔行侧边（如附图 10中示出 的在各沉孔行侧边设置的多个孔 7 )。 所述各沉孔中装配有热沉， 并以过盈 配合方式牢固结合或热沉与沉孔牢固粘接， 优选的是过盈方式牢固配合。
一个优选的方案是： 如附图 9所示， 在线路基板对应沉孔列的两端设 置切割定位线 5 , 所述切割定位线 5的条数为 M+1条， 各切割定位线 5 对应各沉孔列间的中间位置； 所述槽 6是贯通各沉孔行侧边的通槽， 槽 6 的个数为 N+1个， 各槽位于各沉孔行间的中间位置。 如附图 9中所示出 的是 5列 χ 4行组成的沉孔阵列， 切割定位线 5的条数为 6条， 槽 6的个 数为 5个。 在此优选方案中， 所述器件电极 3设置在所述通槽两侧的线路 基板上表面、 下表面和侧面。
如附图 10所示的是本发明实施例二的又一个优选方案， 在线路基板 上对应沉孔行的两端设置切割定位线 5a, 所述切割定位线 5a 的条数为 N +1条（如附图 10中示出的是 5列 χ 4行组成的沉孔阵列， 切割定位线 5a 为 5条）， 各切割定位线 5a对应于各沉孔行间的中间位置； 在线路基板上 对应沉孔列的两端设置切割定位线 5b,所述切割定位线 5b的条数为 M+1 条（如附图 10中示出的切割定位线 5b为 6条）， 各切割定位线 5b对应于 各沉孔列间的中间位置； 所述排列设置的多个槽 6 (未示出 )和 /或孔 7与 各沉孔行或各沉孔列的两端设置的切割定位线共线， 优选的是所述在线路 对应设置一个槽 6或一个孔 7 , 在线路基板 1上面沿所述排列的多个槽和 / 或孔两侧对应各个沉孔设置器件电极 3 , 并对应于各个沉孔设置有内部引 线连接部 3a。 所述器件电极 3设置在所述槽 6或孔 7两侧的线路基板上 表面、 下表面和侧面。 如附图 10 中示出的， 是在各沉孔行的侧边设置有 排列设置为一线的多个孔 7 , 各沉孔行中的每个沉孔的侧边对应有一个孔 7 , 根据上述技术方案， 当然也可以将图示孔 7设置为槽 6。
附图 11 所示是本发明的上述实施例的一个优选方案的散热基板进行 封装后制作的功率 LED器件的立体示意图。 如果沿切割定位线进行切割， 很容易将其分离切割为独立的功率 LED器件， 即如附图 13所示独立的功 率 LED器件。
附图 12所示是利用本发明的散热基板制造的功率 LED器件的结构示 意图， 所述器件包括： 热沉 4, 具有沉孔结构的线路基板 1 , LED芯片 8, 引线 9, 封装胶体 10, 器件电极 3 , 其中： 所述热沉 4与线路基板 1的沉 孔 2牢固配合； 所述 LED芯片 8安放在热沉 4上； 线路基板 1的金属线 路 3为由内部引线连接部 3a和外部电极 3b组成的器件电极 3 , 所述引线 9连接 LED芯片电极与线路基板上的内部引线连接部； 所述封装胶体 10 覆盖在装有芯片的线路基板一面， 并保留外部电极 3b部分， 所述封装胶 体 10 既是密封层， 它将芯片、 引线密封， 又是所述器件一体成型的光学 透镜。 优选的是， 器件一体成型的光学透镜可为凸透镜、 凹透镜或组合曲 面透镜。 此外， 设置在热沉上的芯片为 1个或多个。
本发明的功率 LED器件相对于现有的功率 LED器件要筒单紧凑， 利 用本发明的散热基板制造功率 LED 器件的功率提升空间大， 尤其适于制 造功率较大的 LED 器件， 实现了低成本、 高效率的制造高性能、 高质量 的功率 LED器件的目的。

Claims

权 利 要 求 书
1. 一种用于制造功率 LED的散热基板结构， 其特征在于所述散热基 板结构包括：
线路基板， 所述线路基板为一体结构， 其上设置有沉孔、 金属线路； 所述的沉孔结构为大小不等的两个孔组合连通， 并垂直于线路基板表 面， 小孔为通孔， 大孔为盲孔， 所述通孔与盲孔的轴方向相同；
热沉， 所述热沉结构为上台阶和下台阶组成的梯台柱状一体结构， 上 台阶的直径与所述通孔的孔径接近， 下台阶的直径与所述盲孔的孔径接 近， 所述上台阶与下台阶的轴方向相同， 并与线路基板的上下表面垂直， 下台阶的柱高等于或大于盲孔的深度；
所述热沉结构与所述沉孔结构相对应匹配， 热沉可装入沉孔中形成牢 固配合。
2. 如权利要求 1所述的散热基板结构， 其特征在于： 所述盲孔的横切 面为任意圓形或任意多边形， 所述通孔的横切面为任意圓形或任意多边 意多边形， 所述上台阶横切面为与通孔的横切面对应的任意圓形或任意多 边形。
3. 如权利要求 1或 2所述的散热基板结构， 其特征在于： 所述的热沉 上台阶的柱高等于或大于通孔的深度。
4. 如权利要求 1或 2所述的散热基板结构， 其特征在于： 所述热沉的 上台阶柱顶部为一平面或为一下 的反射杯。
5. 如权利要求 1或 2所述的散热基板， 其特征在于： 所述的通孔与盲 孔不共轴， 对应的所述的上台阶与下台阶不共轴。
6. 如权利要求 1或 2所述的散热基板结构， 其特征在于： 所述的通孔 与盲孔共轴， 所述的上台阶与下台阶共轴。
7. 如权利要求 2所述的散热基板结构， 其特征在于： 所述盲孔、 下台 阶横切面为圓形， 所述的通孔、 上台阶横切面为圓形或正方形。
8. 如权利要求 1或 2所述的散热基板结构， 其特征在于： 所述热沉的 上台阶的顶部横切面略小于其底部横切面， 使得上台阶呈锥形； 所述热沉 的下台阶的顶部横切面略小于其底部横切面， 使得下台阶呈锥形。
9. 如权利要求 1或 3所述的散热基板结构， 其特征在于： 所述的热沉 与沉孔以过盈配合方式牢固结合， 或热沉与沉孔牢固粘接。
10. 如权利要求 1所述的散热基板结构， 其特征在于所述散热基板结 构包括：
线路基板， 所述线路基板为一体结构， 在线路基板的端部设置有切割 定位线， 在线路基板的中设置有槽和 /或孔。
11. 如权利要求 10所述的散热基板结构， 其特征在于： 所述线路基板 上设置由多个沉孔组成的 M列 χ Ν行的沉孔阵列， 其中 M、 N分别是等 于或大于 1的整数， 且^1、 N不同时等于 1 ;
所述切割定位线为多条，各切割定位线对应各沉孔行和 /或沉孔列的侧 边；
所述槽和 /或孔为多个， 设置在各沉孔行或各沉孔列侧边；
所述各沉孔中装配有热沉， 并以过盈配合方式牢固结合或热沉与沉孔 牢固粘接。
12. 如权利要求 11所述的散热基板结构， 其特征在于： 在线路基板对 应沉孔列的两端设置切割定位线， 所述切割定位线的条数为 M+1条， 各 切割定位线对应各沉孔列间的中间位置； 所述槽是贯通各沉孔行侧边的通 槽， 槽的个数为 N+1个， 各槽位于各沉孔行间的中间位置。
13. 如权利要求 12所述的散热基板结构， 其特征在于： 在线路基板上 沿所述通槽的两侧设置器件电极。
14. 如权利要求 13所述的散热基板结构， 其特征在于： 所述器件电极 与各个沉孔对应， 并对应设置有内部引线连接部。
15. 如权利要求 14所述的散热基板结构， 其特征在于： 所述器件电极 设置在所述通槽两侧的线路基板上表面、 下表面和侧面。
16. 如权利要求 11所述的散热基板结构， 其特征在于：
在线路基板上对应沉孔列的两端设置切割定位线， 所述切割定位线的 条数为 M+1条， 各切割定位线对应于各沉孔列间的中间位置；
在线路基板上对应沉孔行的两端设置切割定位线， 所述切割定位线的 条数为 N+1条， 各切割定位线对应于各沉孔行间的中间位置；
在线路基板对应各沉孔列或各沉孔行的侧边排列设置多个槽和 /或孔。
17. 如权利要求 16所述的散热基板结构， 其特征在于： 所述排列设置 的多个槽和 /或孔与各沉孔行或各沉孔列的两端设置的切割定位线共线。
18. 如权利要求 17所述的散热基板结构， 其特征在于： 所述在线路基 一个槽或一个孔。
19. 如权利要求 17所述的散热基板结构， 其特征在于： 在线路基板上 面沿所述排列的多个槽和 /或孔两侧对应各个沉孔设置器件电极，对应于各 个沉孔设置有内部引线连接部。
20. 如权利要求 19所述的散热基板结构， 其特征在于： 所述器件电极 设置在所述槽或孔两侧的线路基板上表面、 下表面和侧面。
21. 一种利用权利要求 1或 10所述的散热基板结构制造的功率 LED 器件， 其特征在于所述器件包括： 热沉， 具有沉孔结构的线路基板， LED 芯片， 引线， 封装胶体， 其中： 所述热沉与线路基板的沉孔牢固配合； 所 述 LED 芯片安放在热沉上； 线路基板的线路为由内部引线连接部和外部 电极组成的器件电极， 所述引线连接 LED 芯片电极与线路基板上的内部 引线连接部； 所述封装胶体覆盖在装有芯片的线路基板一面， 并保留外部 电极部分， 所述封装胶体既是密封层， 将芯片、 引线密封， 又是所述器件 一体成型的光学透镜。
22. 如权利要求 21所述的功率 LED器件， 其特征在于： 所述器件一 体成型的光学透镜可为凸透镜、 凹透镜或组合曲面透镜； 所述外部电极为 该器件的正负电极， 所述设置在热沉上的芯片为 1个或多个。
PCT/CN2008/001740 2007-10-15 2008-10-15 A structure of heat dissipation substrate for power led and a device manufactured by it Ceased WO2009052702A1 (en)

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EP2202809A1 (en) 2010-06-30
US20100110692A1 (en) 2010-05-06
KR101303777B1 (ko) 2013-09-04
US8174832B2 (en) 2012-05-08
KR20100068333A (ko) 2010-06-23
CN101663768B (zh) 2012-12-26
CN100546058C (zh) 2009-09-30
EP2202809A4 (en) 2013-03-20

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