CN100533787C - Light emitting diode package with multi-molding resin - Google Patents

Abstract

A Light Emitting Diode (LED) package with a multi-molding resin is disclosed. The LED package includes a pair of lead terminals. At least a portion of the pair of lead terminals is embedded in a package body. The package body has an opening through which the pair of lead terminals are exposed. An LED die is mounted in the opening and electrically connected to the pair of lead terminals. A first molding resin covers the LED die. A second molding resin having a higher hardness than the first molding resin covers the first molding resin. Therefore, stress applied to the LED die can be reduced and deformation of the molding resins can be prevented.

Description

LED package with multi-molding resin

technical field

The present invention relates to LED packages with molding resin, and in particular to a LED package. One of the LED dies is covered with a molding resin having a lower hardness and then covered with another molding resin having a higher hardness to relieve the stress applied to the LED die and prevent the upper surface of the molding resin from collapsing. out of shape.

Background technique

In summary, a light emitting diode (LED) package includes molding resin for covering a mounted LED die. The molding resin protects the LED die from external environment. That is, the molding resin protects the LED die and bonding wires from external forces and prevents damage to the LED die by blocking moisture from the atmosphere. Additionally, the molding resin may contain phosphors that can alter the wavelength of light emitted from the LED die. As a result, white light can be obtained using LED dies that emit ultraviolet or blue light.

In addition, heat is generated when the LED die emits light. This heat is transferred to the surroundings of the LED die. Therefore, the molding resin covering the LED die undergoes a thermal cycle due to the repeated operation of the LED die. In case the molding resin has higher hardness, the molding resin may be cracked or peeled off during the heat cycle. In addition, the LED die may be damaged or the bonding wire may be disconnected due to thermal stress generated by the difference in thermal expansion coefficient of the molding resin and the LED die. Cracks and peeling of the molding resin lead to non-uniformity of emitted light and deteriorate water resistance. In addition, in the case where the molding resin is formed of a thermoplastic resin, the residual stress after curing is large, so the above-mentioned problem will be more serious.

In US Patent No. 6,747,293 (Nitta et al.), entitled "Light emitting device," an LED package capable of resisting cracking and delamination of molded resin due to thermal cycling is disclosed. Figure 1 is a cross-sectional view showing an LED package 500 disclosed in the aforementioned '293 patent.

Referring to FIG. 1, an LED package 500 includes lead terminals 501 and 502 formed to the outside of a lead frame and a body 503 integrally formed with the lead terminals. The main body 503 is made of thermoplastic resin. The lead terminals 501 and 502 are placed such that one end faces each other and the other end thereof extends in the opposite direction to protrude from the main body 503 to the outside.

Meanwhile, the main body 503 has an opening 505 and an LED die 506 is mounted on a bottom surface of the opening. LED die 506 can be attached to one lead terminal 501 using a conductive adhesive 507 and connected to the other lead terminal 502 via a wire bond 509 . The opening 505 has an inclined inner wall 504 so that the light emitted by the LED die 506 can be reflected to the outside.

A sealing resin 511 is placed in the opening 505 so as to cover the top of the LED die 506 . The sealing resin 511 is a silicone resin having a relatively high hardness of 50 to 90 in JISA of Japanese Industrial Standards (JIS). A lens 513 is provided above the sealing resin 511 to collect light.

The hardness of the sealing resin 511 of the LED package 500 is lower than that of epoxy resin having a hardness of 95 in JISA and thus cracking or peeling of the sealing resin can be prevented. In addition, because the hardness of the sealing resin 511 of the LED package 500 is higher than that of silicone resin having a hardness of 30 to 40 in JISA, the external force has less influence on the LED die 506 . However, since the sealing resin 511 of the LED package 500 has relatively high hardness compared with silicone resin, it may cause a relatively large amount of residual stress when cured. Furthermore, relatively high thermal stresses are generated due to thermal cycling. Specifically, in the case of an increase in the size of the opening or the input power, the above-mentioned stress is further increased, thereby reducing the reliability of the LED die 506 and causing the bonding wire 507 to break.

At the same time, the luminous power of the LED is roughly proportional to the input power. Therefore, high luminous power can be obtained by increasing the electrical power input to the LED. However, increasing the input power leads to an increase in the junction temperature of the LED. An increase in the junction temperature of an LED can cause a loss in photometric efficiency, which represents the conversion rate of input energy into visible light. Therefore, it is necessary to prevent an increase in the junction temperature of the LED due to an increase in input power.

In US Patent No. 6,274,924B1 entitled "Surface mountable LED package", an example of an LED package using a heat sink to prevent the temperature rise of the LED junction is disclosed. As disclosed in the '924 patent, the LED die is thermally coupled to a heat sink and thus maintained at a lower junction temperature. Therefore, relatively high input power can be supplied to the LED die to obtain high luminous power.

However, in this conventional LED package, the heat sink can be easily separated from the package body, which causes structural instability. When the heat sink is separated from the main body of the package, the bonding wire electrically connecting the LED die mounted on the heat sink with the lead wire is cut off, thereby causing irreparable damage to the LED package. Therefore, it is necessary to provide an LED package that can prevent the heat sink from being separated from the package body.

Contents of the invention

The present invention is devised to solve the above-mentioned problems in the art. An object of the present invention is to provide a light emitting diode package. Among them, the LED die can be protected from the surrounding environment such as external force and moisture, the stress applied to the LED die can be relieved, and the deformation of the molding resin can be prevented during the process of sorting or assembling the LED package.

Another object of the present invention is to provide a light emitting diode package. The heat sink is used to smoothly dissipate the heat generated by the LED die to the outside and also prevent the heat sink from being separated from the package body.

According to an aspect of the present invention for solving the above technical problems, a light emitting diode package with multiple molding resins is provided. The LED package includes a pair of lead terminals. At least part of the pair of lead terminals is embedded in a package body. The package body has an opening through which the pair of lead terminals is exposed. An LED chip is disposed in the opening and electrically connected to the pair of lead terminals. The first molding resin covers the LED die. In addition, a second molding resin having a higher hardness than the first molding resin covers the first molding resin. Therefore, the first molding resin can be used to relieve the stress applied to the light-emitting diode, and can prevent the second molding resin from being deformed by external force.

The first molding resin may have a Durometer Shore value of less than 50A and the second molding resin may have a Durometer Shore value of not less than 50A.

The first and second molding resins may be formed of epoxy resin or silicone resin. In addition, at least one of the first and second molding resins may contain phosphor.

In addition, the first molding resin may be relatively thicker than the second molding resin. As a result, the stress applied to the LED die under the first molding resin can be further reduced.

A heat sink can be coupled to the bottom of the package body. The heat sink is partially exposed through the opening. The LED die is mounted on the exposed upper surface of the heat sink. Therefore, the heat generated by the LED die can be smoothly dissipated to the outside through the heat sink.

The heat sink may have a base and a protrusion protruding upward from a central portion of the base. Therefore, since the heat dissipation surface can be increased without increasing the size of the LED package, the heat dissipation efficiency can be improved.

The heat sink may be formed with a latching step on at least one side of the base and/or the protrusion. The locking step is coupled to the package body to prevent the heat sink from being separated from the package body.

According to another aspect of the present invention, a light emitting diode package with multiple molding resins is provided. The package includes a heat sink support ring. A heat sink fits into the support ring. At least two lead terminals are spaced apart from the support ring and the heat sink, and are placed on opposite sides of the support ring. The package body is molded together with the heat sink and lead terminals to support the heat sink and lead terminals. The package body has an opening through which the upper end of the heat sink and the part of the lead terminal are exposed. At least one light emitting diode die is mounted on the upper surface of the heat sink. Bonding wires are used to electrically connect the LED die and lead terminals to each other. The first molding resin covers the LED dies, and the second molding resin covers the first molding resin. The second molding resin is harder than the first molding resin. Therefore, the first molding resin relieves the stress applied to the LED die, and prevents the second molding resin from being deformed by external force. In addition, since the heat sink is assembled and fixed to the supporting ring, it is possible to prevent the heat sink from being separated from the package body.

The first molding resin may have a Shore durometer value of less than 50A and the second molding resin may have a Shaw durometer value of not less than 50A.

The first and the second molding resin may be formed of epoxy resin or silicone resin. In addition, at least one of the first and second molding resins may contain phosphor.

Additionally, the first molding resin may be relatively thicker than the second molding resin. As a result, the stress applied to the LED die under the first molding resin can be further reduced.

Meanwhile, the heat sink may have a base and a protrusion protruding upward from the center of the base, and the protrusion is inserted into the supporting ring.

The cooling fin may form a support ring receiving groove on one side of the protruding part. A support ring can be fastened in the receiving groove. Therefore, it is possible to further prevent the heat sink from being separated from the package body.

In order to make the above and other objects, features and advantages of the present invention more comprehensible, preferred embodiments will be described in detail below together with the accompanying drawings.

Description of drawings

FIG. 1 is a cross-sectional view illustrating a conventional LED package.

FIG. 2 is a cross-sectional view illustrating a light emitting diode package according to an embodiment of the present invention.

FIG. 3 is a cross-sectional view illustrating a light emitting diode package according to another embodiment of the present invention.

4 to 12 illustrate an LED package using a heat sink and a method for manufacturing the LED package according to an embodiment of the present invention.

13 to 26 illustrate an LED package using a heat sink and a method for manufacturing the LED package according to another embodiment of the present invention.

10, 50, 500: LED packaging

11, 13, 51, 140, 217a, 217b, 217c, 219a, 219b, 219c, 501, 502: lead terminals

14, 54, 163, 504: inner wall

15, 55, 230, 230a, 503: package body

17, 57, 160, 240, 241, 241a, 243, 245, 506: LED die

19, 59, 507: Adhesives

21, 61, 62, 162: welding wire 23, 63, 165: first molding resin

25, 65, 167: Second molding resin 26, 66, 50: Opening

27, 67, 166, 250, 513: lens 56, 153, 220: heat sink

101: Lead panel 141: Connection frame

142, 215a, 215b: supporting leads 144: hollow part

150: The first package cover 151: The second package cover

152: Connection frame storage slot 154, 223: Protruding part

154a: Locking steps 155, 158: Through holes

156: LED assembly part 159, 159a, 159b: Step part

210: Lead frame 211: External frame

213: Support rings 216a, 216b: Cut support rings

221: Base 223a: Support ring storage slot

511: sealing resin

Detailed ways

FIG. 2 is a cross-sectional view illustrating an LED package 10 according to an embodiment of the present invention.

Referring to FIG. 2 , a light emitting diode (LED) package 10 includes a pair of lead terminals 11 and 13 and a package body 15 formed out of a lead frame. The main body 15 may be formed of thermoplastic resin or thermosetting resin using an insert molding process. Generally, in order to mass-produce the LED packages 10, a plurality of package bodies 15 are formed in a lead panel in which a plurality of lead frames are arranged. After the molding resin ( 23 , 25 or 27 ) is cured, the lead frame is cut into individual LED packages 10 , and lead terminals 11 and 13 are thus formed. The lead terminals 11 and 13 are placed so that one ends thereof face close to each other and the other ends thereof extend in opposite directions to protrude from the main body 15 to the outside.

At least part of the lead terminals 11 and 13 are embedded in the package body 15 . That is, the main body 15 surrounds at least part of the lead terminals 11 and 13 to fix the lead terminals to the main body 15 . In addition, the package body 15 has an opening 26 through which the lead terminals 11 and 13 are exposed to the outside. An inner wall 14 of the opening 26 can be inclined so that the light emitted by the LED die can be reflected to the outside.

An LED die 17 is mounted on a bottom surface of the opening 26 . As shown, a conductive adhesive 19 may be used to attach the LED die 17 to a lead terminal 11 . The conductive adhesive may include silver (Ag) epoxy. In addition, the LED die 17 can be connected to another lead terminal 13 via a bonding wire 21 . Therefore, the LED die 17 is electrically connected to the lead terminals 11 and 13 .

Meanwhile, the first molding resin 23 covers the LED die 17 . The first molding resin 23 can also cover the bonding wire 21 . The first molding resin 23 has a relatively low hardness, that is, its Shaw hardness value is preferably less than 50A and more preferably not greater than 10A. The first molding resin 23 may be formed of epoxy resin or silicone resin. As shown in this figure, the first molding resin 23 can cover the LED die 17 and the bonding wire 21 , and be bonded to the inner wall of the main body 15 . Alternatively, the first molding resin 23 may cover the LED die 17 but not extend to the inner wall of the package body 15 . That is, the first molding resin may be limited to a specific area in the opening.

Furthermore, the second molding resin 25 covers the first molding resin 23 . The second molding resin 25 is filled into the opening 26 and bonded to the inner wall 14 of the opening 26 . The upper surface of the second molding resin 25 may be flat or curved with a constant curvature. The second molding resin 25 preferably has a relatively higher hardness than the first molding resin 23 , ie, has a Shaw hardness value of at least 50A. In addition, another molding resin (not shown) may be interposed between the first molding resin 23 and the second molding resin 25 . The second molding resin 25 may be formed of epoxy resin or silicone resin. The second molding resin 25 and the other molding resin may be formed of the same material as the first molding resin 23 . For example, when the first molding resin 23 is silicone resin, the second molding resin 25 is also silicone resin. If the first molding resin 23 and the second molding resin 25 are formed of the same material, light loss due to reflection at the interface between the first and second molding resins can be reduced, and the moldings can be increased. Adhesion between resins to improve their water resistance. In addition, the first molding resin 23 may be thicker than the second molding resin 25 . Here, the thicknesses of the first and second molding resins 23 and 25 are defined as values measured from the upper surface of the LED die 17 in the vertical direction. Since the first molding resin 23 having lower hardness is thicker than the second molding resin 25, stress applied to the LED die 17 can be minimized.

The first and second molding resins 23 and 25 may be molded using a molding cup or dispenser or using a transfer molding process.

In addition, US Patent No. 6,274,924 has proposed an LED package using a molding resin having a Schore hardness value not exceeding 1OA to protect the LED die. The encapsulation proposed in the '924 patent has advantages in that thermal stress can be mitigated using a molding resin having a relatively low hardness. However, molding resins with low hardness may be easily deformed by external force.

Generally, after the molding resin has been formed within the LED package, the lead frame is diced into individual individual packages as described above. Then, sort or assemble the individual packages. At this time, the molding resin having lower hardness may be deformed by external force. In detail, deformation of the upper surface of the molding resin prevents uniform emission of light generated by the LED die.

In contrast, in this embodiment of the present invention, the second molding resin 25 having relatively high hardness covers the top of the first molding resin 23 . Therefore, deformation of the upper surface of the molding resin can be prevented. In addition, because the first molding resin 23 with relatively low hardness is interposed between the second molding resin 25 and the LED die 17 , thermal stress and residual stress in the molding resin can be alleviated. This stress relief results in the prevention of cracking and peeling of the molding resins 23 and 25 . Therefore, moisture penetration can be prevented, thereby improving the reliability of the LED package.

In addition, the first molding resin 23 and/or the second molding resin 25 may contain a phosphor. The phosphor can be used to change the wavelength of light emitted by the LED die. In addition, a lens 25 may be provided on the second molding resin 25 . The lens 27 is used to allow the light emitted by the LED die 17 to be emitted at a desired viewing angle. Alternatively, the second molding resin 25 may be made in the form of a lens, such as a semicircular or Fresnel lens type.

FIG. 3 is a cross-sectional view illustrating an LED package 50 according to another embodiment of the present invention.

Referring to FIG. 3, the LED package 50 includes a pair of lead terminals 51 and 53, a main body 55, an LED die 57, a conductive adhesive 59, a first molding resin 63 and a second molding resin, which are similar to those described with reference to FIG. . Similarly, the body 55 has an opening 66, the inner wall 54 of which may be sloped.

Additionally, LED package 50 includes a thermally conductive block or heat sink 56 attached to a lower portion of body 55 . As shown in this figure, the heat sink 56 is partially exposed through the opening 66 , and the LED die 57 is mounted on the exposed upper surface of the heat sink 56 . The heat sink may have a base and a protrusion protruding upward from a central portion of the base. The protruding portion is exposed to the outside through the opening 66 . In addition, the heat sink 56 is configured in such a way that its bottom surface has a larger area than the exposed upper surface to easily dissipate heat to the outside.

The LED die 57 is attached to the upper surface of the heat sink 56 by means of a conductive adhesive 59 . A bonding wire 62 connects the heat sink 56 to one lead terminal 51 , and another bonding wire 61 connects the LED die 57 to the other lead terminal 53 . As a result, the LED die 57 is electrically connected to the pair of lead terminals 51 and 53 .

In this embodiment, the heat sink 56 is used to easily dissipate the heat generated by the LED die 57 . Accordingly, thermal stress due to thermal cycles can be further reduced.

Hereinafter, another embodiment of an LED package using a heat sink will be described in detail.

4 to 12 illustrate an LED package using a heat sink and a method of manufacturing the same according to an embodiment of the present invention, and FIGS. 13 to 25 illustrate an LED using a heat sink according to another embodiment of the present invention. Packaging and a method of manufacturing the above-mentioned LED packaging.

4 is a plan view illustrating an LED lead panel for mass production of an LED package according to an embodiment of the present invention, FIG. 5 is an exploded perspective view illustrating an LED package according to an embodiment of the present invention, and FIG. A plan view of a state in which the LED package of the embodiment of the invention has been formed on the LED lead panel.

Referring to FIG. 4, an LED lead panel 101 for manufacturing the LED package of the present invention includes a plurality of lead frames arranged at regular intervals. The lead frame includes lead terminals 140 and a connection frame 141 connecting the lead terminals to each other. The connection frames 141 are paired to form a symmetrical structure and are formed with a hollow portion 144 having a predetermined shape at the center.

In addition, the connecting frame 141 is fixed to an external frame through the lead terminal 140 and the supporting lead 142 . The outer frame is configured to surround the connection frame 141 .

Although it is described in this embodiment that the hollow portion 144 formed at the center of the symmetrical connection frame 141 takes a hexagonal shape, the present invention is not limited thereto. The hollow portion 144 may take the shape of a circle or other polygon having at least four endpoints.

Referring to FIG. 5 , after the LED lead panel 101 is formed, the package body composed of the first and second housings 150 and 151 and a heat sink 153 is sequentially fixed to the LED lead panel 101 .

That is, the first package housing 150 having a predetermined shape (such as a rectangle) is placed on top of the pair of connection frames 141 integrally formed in the LED lead panel together with the lead terminals 140, and the second package The housing 151 is placed on the bottom of the pair of connection frames 141 .

The first encapsulation cover 150 is formed with a concave portion at its central portion to accommodate molding resin. A through hole 158 through which the hollow portion 144 of the connection frame 141 and the terminals are exposed is formed in the bottom of the first package cover 150 . The via hole 158 may have the same area as the recessed portion, and as shown in the figure, a smaller area than the recessed portion. The recessed portion and the through hole 158 form an opening of the package body. On an inner wall of the recessed portion, a stepped portion 159 is formed where a molding resin of the LED package is accommodated, which will be described later.

A receiving groove 152 having the same shape as the connection frame 141 is formed on an upper surface of the second package cover 151, and a heat sink fitting groove 157 is formed on a bottom surface of the second package cover 151, into which a heat sink 153 is inserted. And installed in the heat sink assembly groove 157.

In addition, a circular through hole 155 is formed at the center of the second packaging cover 151 for receiving the protruding portion 154 of the heat sink 153 . The upper surface of the protruding portion 154 may be recessed, which in turn becomes an LED mounting portion 156, where an LED die 160, which will be explained below, is mounted and fixed.

The first and second packaging covers 150 and 151 may be formed of thermally conductive plastic material or high thermally conductive ceramic material. Examples of thermally conductive plastic materials include ABS (Acrylonitrile Butadiene Styrene), LCP (Liquid Crystalline Polymer), PA (Polyamide), PPS (Polyphenylene Sulfide) Ether (Polyphenylene Sulfide)), TPE (Thermoplastic Elastomer) and the like. Examples of high thermal conductivity ceramic materials include Al ₂ O ₃ (aluminum oxide), SiC (silicon carbide), AlN (aluminum nitride), and the like. Aluminum nitride (AlN) has the same properties as aluminum oxide (Al ₂ O ₃ ) and is widely used because it is superior to aluminum oxide in thermal conductivity.

In case the first and second packaging covers 150 and 151 are formed of thermally conductive plastic material, these covers can be respectively placed on the top and bottom of the symmetrical connection frame 141 and pressed at high temperature to fix them to the LED lead panel 101. Here, after the first and second package covers 150 and 151 are placed on the LED lead panel 101, the package covers may be thermally pressed by using a pressing member having a protrusion corresponding to the shape of the through hole 158 and the stepped portion 159. 150 to form a through hole 158 and a stepped portion 159 . Alternatively, the first and second packaging covers 150 and 151 may be integrally formed using an insert molding technique.

In case the first and second package covers 150 and 151 are formed of ceramic material, the first and second package covers 150 and 151 should be manufactured in advance to have precise size and shape. Then, the first and second package covers 150 and 151 formed of ceramic material are placed above and below the connection frame 141 of the LED lead panel 101, and then fixed to the LED lead panel using a strong adhesive or the like. 101.

Referring to FIG. 6 , the LED package is formed in a lead frame, which has been formed on the LED lead panel 101 . Accordingly, a plurality of LED packages are formed in the LED lead panel 101 .

One or more LED dies 160 are mounted in the LED mounting portion 156 at the center of the heat sink 153 and the dies are connected to the connection frame 141 via bonding wires 162 .

To electrically protect the LED die 160 mounted in the LED mounting portion 156, a Zener diode 161 may be mounted. The zener diode 161 can maintain a constant voltage and thus protect the LED die 160 when static electricity or fast high current is applied, thereby improving product reliability.

7 and 8 are perspective views of the LED package according to this embodiment viewed from above and below, respectively. 9 is a cross-sectional view of an LED package using a heat sink according to the present invention. 10 to 12 are cross-sectional views illustrating a molding resin and a lens formed in an LED package.

A plurality of LED packages are formed on the LED lead panel 101 , and each of the formed LED packages is cut off from the LED lead panel according to the first and second package covers 150 and 151 .

Referring to FIG. 7, the lead terminal 140 is cut to have a desired length and bent at a desired angle so that it can be mounted on a PCB substrate (not shown).

In addition, as shown in FIG. 8 , the heat sink 153 is inserted from below the second package cover 151 and fixed to the package body. At this time, the heat sink 153 may protrude downward beyond the bottom surface of the second package cover 151 . Therefore, the surface of the downwardly protruding heat sink 140 can be directly contacted with the PCB substrate, thereby maximizing the heat dissipation effect.

Referring to FIG. 9, two stepped portions 159a and 159b are formed in an inner space of the first package cover 150. Referring to FIG. These stepped portions serve as a fixed step when forming a molding resin or a lens to be explained below.

In addition, the heat sink 153 may form a locking step 154 a on the side of the protruding portion 154 , so that the locking step 154 a may be inserted and fixed into a recess formed in the inner wall of the through hole 155 of the second package housing 151 . Accordingly, the protrusion 154 of the heat sink 153 is fixed to the through hole 155 of the second package cover 151 so that the heat sink 153 can be prevented from being separated from the package body. A latching step 154a may be formed in the base portion of the heat sink. A locking step 154 a may be formed on the uppermost edge of the protrusion 154 . At this time, the locking step 154a is coupled to the upper surface of the second package cover 151 so that the heat sink 153 can be fixed to the package body.

Referring to FIG. 10 , a first molding resin 165 is formed in the inner space of the first packaging cover 150 , which transmits the light emitted by the LED die 160 while protecting the LED die 160 and the bonding wire 162 .

The first molding resin 165 can be epoxy resin or silicone resin, and also contains a phosphor for converting the light emitted by the LED die 160 . In addition, the first molding resin 165 may contain a light diffuser for uniformly spreading light.

Referring to FIG. 11 , the second molding resin 167 covers the first molding resin 165 . The second molding resin 167 is epoxy resin or silicone resin, and its hardness is higher than that of the first molding resin 165 . The second molding resin 167 may contain phosphors and/or light diffusers.

The first and second molding resins 165 and 167 may be formed in the interior space of the first packaging enclosure 150 using a molding cup or dispenser or using a transfer molding technique.

Referring to FIG. 12 , a lens 166 is mounted on top of the second molding resin 167 . The lens can be a convex lens for refracting the light emitted by the LED die 160 within a specific viewing angle range. The lens curvature varies according to the desired viewing angle. The lens 166 is fixed in the stepped portion 159 b of the first package cover 150 .

Hereinafter, another embodiment of the LED package according to the present invention will be described with reference to FIGS. 13 to 26 .

FIG. 13 is a perspective view illustrating a lead frame 210 according to another embodiment of the present invention.

Referring to FIG. 13, the lead frame 210 is formed with a heat sink support ring 213 into which a heat sink can be inserted. As shown in this figure, the support ring 213 may be in the shape of a circular ring, but the invention is not limited thereto. The supporting ring 213 may be in the shape of a polygonal ring.

In addition, an outer frame 211 surrounds the support ring 213 . The outer frame 211 is spaced apart from the support ring 213 . As shown in this figure, the outer frame 211 may be rectangular, but the present invention is not limited thereto. The outer frame 211 may be circular or polygonal.

The support ring 213 is connected to the outer frame 211 by means of at least two support leads 215a and 215b. The support leads 215 a and 215 b are located on opposite sides of the support ring 213 and connect the support ring 213 to the outer frame 211 . In addition to the support leads 215a and 215b, additional support leads may be provided to connect the support ring 213 and the outer frame 211 to each other.

In addition, at least two lead terminals 217 a to 217 c and 219 a to 219 c extend from the outer frame 211 toward the support ring 213 . However, these lead terminals are spaced apart from the support ring 213 . As shown in this figure, each of the lead terminals 217 a to 217 c and 219 a to 219 c may be formed with a larger termination portion near the support ring 213 . The lead terminals are preferably located near opposite sides of the support ring 213 .

The desired number of lead terminals is determined depending on the type and number of diodes to be mounted and the connection pattern of the bonding wires. However, the lead frame 210 preferably has a certain number of lead terminals so that it can be used in various situations. As shown in this figure, since the lead terminals 217a to 217c and 219a to 219c are arranged perpendicular to the support leads 215a and 215b, a number of lead terminals can be arranged in the same direction.

Although six lead terminals are illustrated in FIG. 13, fewer lead terminals may be provided, or additional lead terminals may be provided. The additional lead terminals may be arranged in the same direction as the supporting leads 215a and 215b.

The lead frame 210 according to this embodiment of the present invention can be manufactured by pressing a phosphor bronze plate made of a copper alloy with a die. Although only a single lead frame 210 is illustrated in FIG. 13, a plurality of lead frames 210 may be fabricated from a single phosphor copper plate and arranged on the phosphor copper plate. In detail, for mass production of LED packages, a plurality of lead frames 210 made of a single phosphor copper plate may be used.

FIG. 14 is a flowchart illustrating a process of manufacturing an LED package according to an embodiment of the present invention. 15 to 26 are perspective and plan views illustrating a method of manufacturing an LED package according to the process of FIG. 14 .

Referring to FIG. 14, the lead frame 210 of FIG. 13 is first prepared (S01). As mentioned above, the lead frame 210 may be manufactured by pressing a phosphor bronze plate. In addition, a plurality of lead frames can be made from a single phosphor bronze plate and can be arranged on the phosphor bronze plate.

Referring to FIGS. 14 and 15 , a heat sink 220 insertable and fixed to the support ring 213 of the lead frame 210 is prepared. The heat sink 220 has an upper surface on which an LED die can be mounted. Preferably, the size of the upper surface of the cooling fin 220 is smaller than the inner diameter of the supporting ring 213 so that the cooling fin 220 can be easily inserted into the supporting ring 213 , and the outer diameter of the side of the cooling fin 220 is larger than the inner diameter of the supporting ring 213 .

In addition, the heat sink 220 may form a supporting ring receiving groove 223a, and the supporting ring 213 is inserted into and coupled to the receiving groove. In addition, the receiving groove 223a may be provided in a spiral form so that the supporting ring 213 can be easily fastened to the groove 223a.

The heat sink 220 may have a base 221 and a protrusion 223 protruding upward from a central portion of the base 221 . Here, the receiving groove 223a is formed on the protruding portion 223 side. As shown in the figure, the base 221 and the protrusion 223 may be cylindrical, but the invention is not limited thereto. The base and protrusions may take the shape of a polygonal shell. The shape of the protrusion 223 may be similar to the inner shape of the support ring 213, but the present invention is not limited thereto. That is, the support ring 213 may take the shape of a circular ring and the protrusion 223 may take the shape of a rectangular shell.

The heat sink 220 may be formed of metal with high thermal conductivity or thermally conductive resin using a pressing or molding technique. In addition, the heat sink 220 is manufactured separately from the lead frame 210 . Therefore, the order of the step S01 of preparing the lead frame 210 and the step S03 of preparing the heat sink 220 may be changed or these steps may be performed simultaneously.

Referring to FIGS. 14 and 16 , the heat sink 220 is inserted and fixed to the supporting ring 213 of the lead frame 210 ( S05 ). Since the outer diameter of the heat sink 220 side is larger than the inner diameter of the support ring 213 , the heat sink 220 can be forcibly inserted and fixed to the support ring 213 .

On the other hand, in the case of forming the supporting ring receiving groove 223 a, the supporting ring 213 is received into the receiving groove 223 a to support the cooling fin 220 . At this time, a part of the supporting ring 213 is received in the receiving groove 223 a and the remaining part preferably protrudes outward from the protruding portion 223 . In addition, in the case where the receiving groove 223 a is spiral, the heat sink 220 can be inserted into the supporting ring 213 by rotating the heat sink 220 .

Referring to FIG. 14 and FIG. 17 , after the heat sink 220 is fixed to the lead frame 210 , a package body 230 is formed using insert molding technology ( S07 ). The package body 230 may be formed of thermosetting or thermoplastic resin using an injection molding process.

The package body 230 is formed around the heat sink 220 to support the support ring 213 , the support leads 215 a and 215 b , the lead terminals 217 a to 217 c and 219 a to 219 c and the heat sink 220 . The supporting leads and the lead terminals partially protrude outward from the package body. In addition, the package body 230 has an opening through which an upper end of the heat sink 210 and the lead terminals are exposed.

As shown in FIG. 17, portions of the support leads 215a and 215b and the support ring 213 may be exposed through the opening. Therefore, a groove or depression is formed in the package body 230a. Alternatively, as shown in FIG. 18 , the package body 230a may cover most of the heat sink 220 , the support ring, the support leads and the lead terminals (excluding the upper end of the heat sink and the part of the lead terminals). For this, several openings can be provided. Even in this case, as shown in the figure, a groove or depression surrounded by the sidewall of the main body 230a may be formed in the upper portion of the package main body 230a. In addition, the bottom surface of the heat sink 220 is exposed to the outside. In addition, the side surface of the base 221 may be exposed to the outside. In this way, heat dissipation through the heat sink 220 may be increased.

As shown in FIGS. 17 and 18 , the package body 230 or 230 a may be cylindrical in shape, but the present invention is not limited thereto. The body may be shaped as a polygonal shell, such as a rectangular shell.

Since the heat sink 220 is coupled to the lead frame 210 and then the package body 230 is formed of thermosetting resin or thermoplastic resin using an injection molding process, the heat sink 220 can be firmly coupled to the package body 230 .

14 and 19, the supporting leads 215a and 215b protruding outward from the package body 230 are cut and removed (S09). As a result, the severed support leads 216 a and 216 b remain in the package body 230 , and thus the remaining support leads and support ring 213 can further prevent the heat sink 220 from being separated from the package body 230 .

Meanwhile, when the supporting leads are cut off, the lead terminals protruding outward from the package body 230 except the lead terminals for supplying current may also be cut and removed. For example, as shown in Figure 20, if only two lead terminals 217c and 219c are required, the other lead terminals 217a, 217b, 219a and 219b would be severed and removed. In addition, as shown in FIG. 21, if four lead terminals 217a, 217c, 219a, and 219c are required, the other lead terminals 217b and 219b will be severed and removed.

The above steps of cutting and removing the lead terminals are performed only when more lead terminals are prepared in the lead frame 210 than are required in an LED package. Therefore, when the number of lead terminals required for the LED package is the same as that prepared in the lead frame 210, the above step of cutting and removing the lead terminals does not need to be performed. In addition, even if the extra lead terminal remains, it does not affect the operation of the LED package. Therefore, it is not necessary to cut and remove additional lead terminals.

Referring to FIG. 14 and FIG. 22 , an LED die 240 is mounted on the upper surface of the heat sink 220 . The LED die 240 can be a so-called one-bond die with electrodes on its upper and lower surfaces or a so-called two-bond die with two electrodes on its upper surface. die).

In case the LED die 240 is a single solder die, the heat sink is preferably formed of conductive metal. In this case, the LED die 240 is mounted on the heat sink 220 using a conductive adhesive such as silver epoxy. Alternatively, the heat sink 220 need not be conductive in the case where all LED dies mounted on the heat sink 220 are double soldered die. In addition, various thermally conductive adhesives other than silver epoxy can be used to mount the LED die on the heat sink 220 .

Meanwhile, a plurality of LED dies 240 can be installed on the heat sink 220 . Additionally, the plurality of LED dies 240 may include various LED dies that emit light at different wavelengths. For example, as shown in FIG. 22, three LED dies 240 may be mounted on a heat sink. At this time, the three LED chips 240 can emit red light, green light and blue light respectively. Therefore, by using three LED dies 240, the LED package can realize all colors of light.

Referring to FIG. 14 and FIG. 23 , the LED dies 241 , 243 and 245 are electrically connected to the lead terminals 217 a to 217 c and 219 a to 219 c through bonding wires, respectively ( S13 ). In case the LED dies 241 , 243 and 245 are all double bonded dies, each of the LED dies is connected to two corresponding lead terminals via two corresponding bond wires. That is, as shown, the respective LED dies 241 , 243 and 245 can be electrically connected to different pairs of lead terminals, respectively. Alternatively, the individual LED dies are connected to a common lead terminal (eg 217b ) via wire bonding, and are also connected to different lead terminals (eg 219a , 219b and 219c ) opposite to the common lead terminal. In this case, the LED dies can be driven by different currents.

On the other hand, as shown in FIG. 24, single solder die 241a and dual solder die 243 and 245 may be mounted together. At this time, one of the lead terminals 217b is electrically connected to the heat sink 220 via a bonding wire. Therefore, the lead terminal 217b is electrically connected to a bottom surface of the single bonding die 241a through the bonding wire and the heat sink 220 . Since various combinations of single bonded die and dual bonded die can be realized, the wire bonding for each combination can also be performed in various modes.

In addition, lead terminals and LED dies can be connected to each other in various ways, and multiple LED dies can be connected to each other in parallel, series, or series-parallel configurations.

After the LED dies 241 , 243 and 245 are connected to the lead terminals via bonding wires, the LED dies 241 , 243 and 245 are sealed with first and second molding resins (not shown) ( S15 ). The molding resin is filled into the opening of the package body 230 to seal the LED die and the bonding wire.

Additionally, the first and/or second molding resin may incorporate phosphor. For example, the phosphor may be a phosphor that converts blue light into yellow light or green and red light. Therefore, in the case where the LED die for emitting blue light is mounted on the heat sink 220, a part of the light emitted by the LED die can be converted into yellow light or green light and red light, so that the external emission of white light can be provided. LED packaging. Additionally, molding resin can be incorporated into the diffuser. The diffuser disperses light emitted from the LED die so that the LED die and bonding wires can be prevented from being observed from the outside and light can be uniformly radiated to the outside.

After the LED die is encapsulated by the molding resin, as shown in FIG. 26, a lens 250 is formed on the top of the package body 230 (S17). The lens is used to emit light within a certain viewing angle and can be omitted if not required. Specifically, the second molding resin can be cured into a lens form to act as a lens. At this time, the step of forming a lens can be omitted.

14 and 25, the lead terminals 217a to 217c and 219a to 219c are cut and bent from the outer frame 211 (S19). Finally, a surface mountable LED package is completed. Meanwhile, the step S09 of cutting and removing the supporting wire may be performed together with the step S19.

Hereinafter, the LED package according to this embodiment will be described in detail with reference to FIG. 25 .

Referring again to FIG. 25 , the LED package includes a heat sink support ring 213 . The support ring 213 is formed of a copper alloy such as phosphor bronze. As shown in the figure, the supporting ring 213 may be in the shape of a circular ring, but the invention is not limited thereto. The support ring may be shaped as a polygonal ring. The severed support leads 216 a and 216 b extend outward from the support ring 213 . The severed support leads 216 a and 216 b may be disposed on opposite sides of the support ring 213 .

The heat sink 220 described with reference to FIG. 15 is inserted into the support ring 213 . Meanwhile, at least two lead terminals 217 a to 217 c and 219 a to 219 c are disposed on both sides of the support ring and spaced apart from the support ring 213 and the heat sink 220 . Lead terminals can be bent for surface mounting.

In addition, the package body 230 is molded to support the heat sink 220 and the lead terminals. The package body 230 has an opening at its upper portion, through which the upper end of the heat sink 220 and portions of the lead terminals are exposed. Meanwhile, the lead terminal passes through the sidewall of the package body 230 and protrudes outward from the sidewall of the body.

As explained with reference to FIG. 17, portions of the support ring 213 and the support leads 215a and 215b may be exposed through the opening. Therefore, a groove or depression is formed in the package body 230 . In addition, as explained with reference to FIG. 18 , the package body 230 a may cover most of the heat sink, support ring, support leads, and lead terminals except the upper end of the heat sink and portions of the lead terminals. Thus, several openings can be formed. Even in this case, as shown in FIG. 18, the package body 230a is preferably formed with a groove or depression surrounded by the sidewall of the package body. The package body 230 may be a plastic resin formed by injection molding of a thermoplastic resin after the heat sink 220 is inserted and fixed to the support ring 213 .

In addition, the LED dies 241 , 243 and 245 are mounted on the upper surface of the heat sink 220 . Although the LED die shown in FIG. 25 is illustrated as a double bonded die, the invention is not so limited. For example, the LED die can be a single-soldered die or a combination of single-soldered and double-soldered dies.

The LED dies are electrically connected to the lead terminals via bonding wires. In case the LED dies are double bonded dies, each LED die is electrically connected to two lead terminals via two bonding wires. Alternatively, in the case that at least one of the LED dies is a single soldered die, the heat sink is electrically connected to at least one of the lead terminals via a bonding wire.

The LED dies can be connected to lead terminals in various ways according to the required characteristics of the LED package.

Meanwhile, the first and second sealing resins (not shown) cover and seal the LED die. The groove formed on the upper portion of the package body 230 is filled with sealing resin. Additionally, the sealing resin may contain phosphors and/or diffusers. As shown in FIG. 26 , a lens 250 may be further formed in the package body 230 . Alternatively, the second sealing resin may be formed in a lens shape so as to function as a lens.

According to the present invention, there is provided an LED package in which the LED die can be protected from the surrounding environment such as external force and moisture, the stress applied to the LED die can be relieved, and the mold resin can be prevented from being molded during sorting and assembly. out of shape. In addition, the present invention can provide an LED package in which a heat sink is used to smoothly dissipate the heat generated by the LED die, and the heat sink cannot be separated from the package body.

The above description is only a preferred embodiment of the present invention, and does not limit the present invention in any form. Although the present invention has been disclosed as above with preferred embodiments, it is not intended to limit the present invention. Anyone familiar with this field Those skilled in the art, without departing from the scope of the technical solution of the present invention, can use the technical content disclosed above to make some changes or modify equivalent embodiments with equivalent changes, but all the content that does not depart from the technical solution of the present invention, according to the present invention Any simple modifications, equivalent changes and modifications made to the above embodiments by the technical essence still belong to the scope of the technical solutions of the present invention.

Claims (8)

1. the LED package of a tool multiple molding resins is characterized in that comprising:

At least one pair of lead terminal;

One package main body, it has and exposes this opening to lead terminal to the open air, and a step part is formed on the inwall of this opening this at least a portion to lead terminal of this package main body embedding;

One LED crystal particle, it is installed in this opening and is lower than this step part, and is electrically connected to this to lead terminal;

One first model resin, it covers this LED crystal particle and extends and be incorporated in to this inwall that is lower than this step part; And

One second model resin, it covers this first model resin and extends and be incorporated in to this inwall that comprises this step part, and this second model resin has than the higher hardness of this first model resin.

2. the LED package of tool multiple molding resins according to claim 1 is characterized in that the wherein said first model resin has one and has a desolate formula durometer value that is not less than 50A less than desolate formula hardometer (Durometer Shore) value of 50A and the second model resin.

3. the LED package of tool multiple molding resins according to claim 2 is characterized in that the wherein said first model resin and the second model resin are formed by epoxy resin or poly-silica resin.

4. the LED package of tool multiple molding resins according to claim 3 is characterized in that the wherein said second model resin-shaped becomes the shape of lens.

5. the LED package of tool multiple molding resins according to claim 3 is characterized in that the wherein said first model resin and/or the second model resin contain a phosphor.

6. the LED package of tool multiple molding resins according to claim 1, it is characterized in that it further comprises a fin, this fin is coupled to the bottom of package main body and exposes to the open air via opening portion ground, and wherein LED crystal particle is installed on the upper surface of this fin.

7. the LED package of tool multiple molding resins according to claim 6 is characterized in that wherein said fin has the protuberance that a substrate and projects upwards from the core of this substrate.

8. the LED package of tool multiple molding resins according to claim 7 is characterized in that wherein said fin is formed with a locking step at least one side of substrate and/or protuberance.

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