发光装置及其制造方法Light-emitting device and method of manufacturing the same
技术领域technical field
本发明涉及一种发光装置的制造方法。The present invention relates to a manufacturing method of a light-emitting device.
背景技术Background technique
发光二极管(light-emitting diode;LED)具有耗能低、低发热、操作寿命长、防震、体积小、反应速度快以及输出的光波长稳定等良好光电特性,因此发光二极管慢慢地取代传统的照明产品。随着光电科技的发展,固态照明在照明效率、操作寿命以及亮度等方面有显著的进步,因此近年来发光二极管已经被应用于一般的家用照明上。目前,发光二极管灯泡的成本仍高于传统的白炽灯泡,该如何降低发光二极管灯泡的制作成本,仍是一个重要的议题。Light-emitting diodes (LEDs) have good optoelectronic properties such as low energy consumption, low heat generation, long operating life, shock resistance, small size, fast response and stable output light wavelengths. Lighting Products. With the development of optoelectronic technology, solid-state lighting has made significant progress in lighting efficiency, operating life, and brightness. Therefore, light-emitting diodes have been used in general household lighting in recent years. At present, the cost of LED bulbs is still higher than that of traditional incandescent bulbs. How to reduce the manufacturing cost of LED bulbs is still an important issue.
发明内容SUMMARY OF THE INVENTION
因此,本发明的目的在于提供一种制造发光装置的方法,以解决上述问题。Therefore, an object of the present invention is to provide a method for manufacturing a light-emitting device to solve the above problems.
为达上述目的,本发明提供一种制造发光装置的方法,包含:提供多个物理性相分离的支撑体;提供一第一发光元件及一第二发光元件,分别固定于支撑体上;以及改变第一发光元件与第二发光元件的相对位置使第一发光元件与第二发光元件实质上不位于同一直线上。In order to achieve the above objects, the present invention provides a method for manufacturing a light-emitting device, comprising: providing a plurality of physically separated supports; providing a first light-emitting element and a second light-emitting element, respectively fixed on the support; and The relative positions of the first light-emitting element and the second light-emitting element are changed so that the first light-emitting element and the second light-emitting element are not substantially located on the same straight line.
为让本发明的上述和其他目的、特征和优点能更明显易懂,下文特举优选实施例,并配合所附的附图,作详细说明如下In order to make the above-mentioned and other objects, features and advantages of the present invention more obvious and easy to understand, preferred embodiments are given below, and are described in detail as follows in conjunction with the accompanying drawings.
附图说明Description of drawings
图1A~图1D为本发明的第一实施例中一发光装置的制造流程图;1A-1D are a manufacturing flow chart of a light-emitting device according to the first embodiment of the present invention;
图2A~图2E为本发明的第二实施例中一发光装置的制造流程图;2A-2E are a manufacturing flow chart of a light-emitting device according to a second embodiment of the present invention;
图2F为本发明的另一实施例中一发光装置的示意图;2F is a schematic diagram of a light-emitting device in another embodiment of the present invention;
图2G为本发明的另一实施例中一发光装置的示意图;2G is a schematic diagram of a light-emitting device in another embodiment of the present invention;
图3A~图3B为一发光元件设置在两延伸支架间的制造流程剖视图;3A-3B are cross-sectional views of a manufacturing process of a light-emitting element disposed between two extending brackets;
图3C为本发明的另一实施例中一发光元件设置在两延伸支架间的剖视图;3C is a cross-sectional view of a light-emitting element disposed between two extending brackets in another embodiment of the present invention;
图3D为本发明的另一实施例中一发光元件设置在两延伸支架间的剖视图;3D is a cross-sectional view of a light-emitting element disposed between two extending brackets in another embodiment of the present invention;
图3E为本发明的另一实施例中一发光元件设置在两延伸支架间的剖视图;3E is a cross-sectional view of a light-emitting element disposed between two extending brackets in another embodiment of the present invention;
图4A~图4B为本发明的第三实施例中一发光装置的制造流程图;4A-4B are a manufacturing flow chart of a light-emitting device in a third embodiment of the present invention;
图4C为本发明的第三实施例中一发光装置的示意图;4C is a schematic diagram of a light-emitting device in the third embodiment of the present invention;
图4D为本发明的另一实施例中一发光装置的示意图;4D is a schematic diagram of a light-emitting device in another embodiment of the present invention;
图4E为图4D的发光装置设置于一灯泡内的示意图;4E is a schematic diagram of the light-emitting device of FIG. 4D being disposed in a light bulb;
图5A为本发明的第四实施例中发光元件固定于载具上的示意图;5A is a schematic diagram of a light-emitting element being fixed on a carrier according to the fourth embodiment of the present invention;
图5B为本发明的第五实施例中发光元件固定于载具上的示意图;5B is a schematic diagram of the light-emitting element being fixed on the carrier according to the fifth embodiment of the present invention;
图5C为本发明的第六实施例中发光元件固定于载具上的示意图;5C is a schematic diagram of the light-emitting element being fixed on the carrier according to the sixth embodiment of the present invention;
图5D为本发明的第六实施例中一发光装置的示意图;5D is a schematic diagram of a light-emitting device in the sixth embodiment of the present invention;
图6A为本发明的第七实施例中发光元件固定于载具上的示意图;6A is a schematic diagram of a light-emitting element being fixed on a carrier according to a seventh embodiment of the present invention;
图6B为本发明的第七实施例中发光装置的示意图;6B is a schematic diagram of a light-emitting device in a seventh embodiment of the present invention;
图6C为图6B的发光装置设置于一灯泡内的示意图;FIG. 6C is a schematic diagram of the light-emitting device of FIG. 6B disposed in a light bulb;
图6D为一电路示意图;6D is a schematic diagram of a circuit;
图6E为另一电路示意图;6E is a schematic diagram of another circuit;
图6F为本发明的第八实施例发光元件固定于载具上的示意图;FIG. 6F is a schematic diagram of the light-emitting element fixed on the carrier according to the eighth embodiment of the present invention;
图6G为图6F的发光装置设置于一灯泡内的示意图;6G is a schematic diagram of the light-emitting device of FIG. 6F being disposed in a light bulb;
图7A~图7B为本发明的第九实施例中一发光装置的部分制造流程剖视图;7A-7B are partial cross-sectional views of a manufacturing process of a light-emitting device according to a ninth embodiment of the present invention;
图8为本发明的第十实施例中发光元件固定于载具上的示意图;FIG. 8 is a schematic diagram of the light-emitting element being fixed on the carrier according to the tenth embodiment of the present invention;
图9A~图9F为本发明的第十一实施例中一发光装置的制造流程剖视图;9A-9F are cross-sectional views of a manufacturing process of a light-emitting device according to an eleventh embodiment of the present invention;
图9G为第十一实施例中发光装置接合于一基座上的示意图;9G is a schematic diagram of the light-emitting device being bonded to a base in the eleventh embodiment;
图10A~图10C为金属层的上视图;10A to 10C are top views of the metal layer;
图11A~图11D为本发明的第十二实施例中一发光装置的制造流程剖视图;11A-11D are cross-sectional views of a manufacturing process of a light-emitting device according to a twelfth embodiment of the present invention;
图12A~图12C为本发明的中发光单元的剖视图。12A to 12C are cross-sectional views of the middle light emitting unit of the present invention.
符号说明Symbol Description
10、21 载具10, 21 Vehicles
100、200、300、600、700、800、900、1000、1100 发光装置100, 200, 300, 600, 700, 800, 900, 1000, 1100 light-emitting devices
101 支撑支架101 Support bracket
102、102A、102B、102C、102D 延伸支架102, 102A, 102B, 102C, 102D Extension Brackets
1021 第一区域1021 First area
1022 第二区域1022 Second area
1023 孔洞1023 Holes
1025 接触部分1025 Contact part
103 连接支架103 Attachment bracket
104 中间支架104 Intermediate bracket
11 第一发光群组11 The first light-emitting group
12 第二发光群组12 The second light-emitting group
111、111A、121、121A 发光单元111, 111A, 121, 121A Light-emitting unit
20、20A、20B、20C、20D、20E、20F 发光元件20, 20A, 20B, 20C, 20D, 20E, 20F light-emitting element
201、7000 基板201, 7000 substrates
202 发光单元202 Lighting unit
2021、7001 第一型半导体层2021, 7001 Type 1 semiconductor layer
2022、7002 活性层2022, 7002 active layer
2023、7003 第二型半导体层2023, 7003 Type II semiconductor layer
203 电极垫203 Electrode pad
204 电连接结构204 Electrical connection structure
205 绝缘结构205 Insulation structure
221 图案化晶种层221 Patterned seed layer
2211 第一区域2211 First area
2212 第二区域2212 Second area
2213 第三区域2213 Third area
222 图案化金属层222 Patterned metal layer
222A、222B 金属层222A, 222B metal layer
2221 第一区域2221 First area
2222 第二区域2222 Second area
2223 第三区域2223 Third area
211 第一载具部211 First Vehicle Department
2111 第一表面2111 First surface
2112 第二表面2112 Second surface
212 第二载具部212 Second Vehicle Department
2121 第三表面2121 Third surface
2122 第四表面2122 Fourth surface
23 导电件23 Conductive parts
30 第一包覆结构30 The first cladding structure
301、401 突出部301, 401 Protrusion
40 第二包覆结构40 Second cladding structure
7004 第一导电部7004 The first conductive part
7005 第二导电部7005 Second conductive part
70041、70051 电极接触面70041, 70051 Electrode Contact Surface
7006 保护层7006 Protective layer
7008 孔隙7008 Pore
7015 导线结构7015 Wire Construction
7024 第一扩大电极部7024 The first enlarged electrode part
7025 第二扩大电极部7025 Second enlarged electrode part
7026 第一透明结构7026 The first transparent structure
7027 第二透明结构7027 Second transparent structure
70241、70251、70061、70062 侧边70241, 70251, 70061, 70062 Side
80 基座80 base
81 凹槽81 groove
90、901 灯壳90, 901 lamp housing
902、91 导线支架902, 91 Wire Holder
903 基座903 base
904、92 电连接件904, 92 Electrical connectors
具体实施方式Detailed ways
以下实施例将伴随着附图说明本发明的概念,在附图或说明中,相似或相同的部分使用相同的标号,并且在附图中,元件的形状或厚度可扩大或缩小。需特别注意的是,图中未绘示或描述的元件,可以是熟悉此技术的人士所知的形式。The following embodiments will illustrate the concept of the present invention with the accompanying drawings, in which similar or identical parts use the same reference numerals, and in the drawings, the shapes or thicknesses of elements may be enlarged or reduced. It should be noted that the elements not shown or described in the figures may be in the form known to those skilled in the art.
图1A~图1D显示本发明的第一实施例中一发光装置100的制造流程图。参照图1A,提供一载具10及多个发光元件20。载具10包含一对支撑支架 101及多对延伸支架102,每一对延伸支架102彼此平行排列且与支撑支架 101彼此物理性连接。多个发光元件20分别放置并固定于每对延伸支架102 上且发光元件20具有一大于延伸支架102的宽度。当然,根据实际的设计应用,发光元件20可具有小于或等于延伸支架102的宽度。延伸支架102 作为一支撑体以支撑发光元件20。参照图1B,形成一第一包覆结构30于发光元件20及部分延伸支架102上以完全地覆盖并包覆发光元件20。部分延伸支架102未被第一包覆结构30所包覆或覆盖而曝露于外界环境(例如:空气)。参照图1C,形成一第二包覆结构40于第一包覆结构30上且完全地覆盖并包覆第一包覆结构30以提供进一步保护(例如:可以防水气或防尘)。参照图1D所示,分离延伸支架102及支撑支架101以形成发光装置100。在本实施例中,发光装置100仅包含一对延伸支架102及一发光元件20。需注意的是,延伸支架102及发光元件20可随发光装置100长度的实际需求所调整,例如:发光元件20的长度为1厘米且当发光元件20设置在延伸支架102之上时,设计延伸支架102的长度使发光装置总长为4厘米;或者发光元件20为0.5厘米时,增长延伸支架102的长度使发光装置总长仍为4 厘米;或者发光元件20为3厘米时,设计延伸支架102的长度使发光装置总长为4厘米。需注意的是,上述发光装置总长为4厘米仅作为例示而非用来限制本发明。1A-1D show a manufacturing flow chart of a light-emitting device 100 according to the first embodiment of the present invention. Referring to FIG. 1A , a carrier 10 and a plurality of light-emitting elements 20 are provided. The carrier 10 includes a pair of support brackets 101 and a plurality of pairs of extension brackets 102, each pair of extension brackets 102 are arranged in parallel with each other and are physically connected to the support brackets 101. A plurality of light-emitting elements 20 are respectively placed and fixed on each pair of extension brackets 102 , and the light-emitting elements 20 have a width larger than that of the extension brackets 102 . Of course, according to the actual design application, the light emitting element 20 may have a width smaller than or equal to the extension bracket 102 . The extension bracket 102 serves as a support to support the light-emitting element 20 . Referring to FIG. 1B , a first cladding structure 30 is formed on the light emitting element 20 and part of the extending bracket 102 to completely cover and cover the light emitting element 20 . Part of the extending bracket 102 is not covered or covered by the first covering structure 30 and is exposed to the external environment (eg, air). Referring to FIG. 1C , a second cladding structure 40 is formed on the first cladding structure 30 and completely covers and wraps the first cladding structure 30 to provide further protection (eg, can be waterproof or dustproof). Referring to FIG. 1D , the extension bracket 102 and the support bracket 101 are separated to form the light emitting device 100 . In this embodiment, the light-emitting device 100 only includes a pair of extending brackets 102 and a light-emitting element 20 . It should be noted that the extension bracket 102 and the light-emitting element 20 can be adjusted according to the actual needs of the length of the light-emitting device 100. For example, the length of the light-emitting element 20 is 1 cm, and when the light-emitting element 20 is arranged on the extension bracket 102, the design is extended. The length of the bracket 102 makes the total length of the light-emitting device 4 cm; or when the light-emitting element 20 is 0.5 cm, the length of the extension bracket 102 is increased so that the total length of the light-emitting device is still 4 cm; or when the light-emitting element 20 is 3 cm, the length of the extension bracket 102 is designed. The length is such that the total length of the light-emitting device is 4 cm. It should be noted that the total length of the above-mentioned light-emitting device is 4 cm only for illustration and not for limiting the present invention.
图2A~图2D显示本发明的第二实施例中一发光装置200的制造流程图。参照图2A,提供一载具10及多个发光元件20。载具10包含一对支撑支架 101及多个延伸支架组,每一延伸支架组彼此平行排列且与支撑支架101彼此物理性连接。每一延伸支架组包含多个延伸支架102,多个发光元件20 分别放置于两延伸支架102间且固定于两延伸支架102上(本实施例中,每一延伸支架组包含五个延伸支架,且四个发光元件设置在延伸支架上)。发光元件20通过延伸支架102彼此串联电连接。延伸支架102作为一支撑体以支撑发光元件20且发光元件20彼此排列于同一直线上。参照图2B所示,形成第一包覆结构30于多个发光元件20及部分延伸支架102上以完全地覆盖并包覆发光元件20。部分延伸支架102未被第一包覆结构30所包覆或覆盖而曝露于外界环境(例如:空气)。参照图2C,形成第二包覆结构40于第一包覆结构30且完全地覆盖并包覆第一包覆结构30以提供进一步保护。参照图2D所示,分离每一延伸支架组的相对两端的延伸支架102A及支撑支架101以形成发光装置200。每一延伸支架组中,不与支撑支架101相连接的延伸支架102B与固定其上的发光元件20彼此连接且不分离。参照图 2E所示,弯折延伸支架102B形成一角度(θ1为锐角)于发光元件20之间,由此,形成一具有M型结构的发光装置200且发光元件20排列于非同一直线上。需注意的是,如图2E所示,发光元件20彼此实质上位于同一平面,且具有发光单元(请参图3A)的一侧都朝向同一方向。在其他实施例中,可弯折延伸支架102B使发光元件20彼此位于不同平面(请参图2F),且具有发光单元的一侧可朝向不同方向。如图2G所示,发光装置200也可具有菱形(θ2为锐角以及θ3钝角)或其他形状。同样地,被弯折的延伸支架102B 及部分延伸支架102A也未被第一包覆结构30及第二包覆结构40所包覆或覆盖而曝露于外界环境(例如:空气)。延伸支架102与发光元件20的数目可依实际需求或依照所需的形状而增加或减少。支撑支架及延伸支架包含可弯折、可饶性、可延展、可形变的金属。支撑支架的材料与延伸支架的材料可相同或相异。在本实施例中,支撑支架用以支撑延伸支架,且仅弯折延伸支架,因此支撑支架的延展性可低于延伸支架。支撑支架的材料可包含铜、金、铂、银、钢、铁、铝或其合金。延伸支架的材料可包含铜、金、铂、银、铝或其合金。一般来说,可弯折或可延展的金属材料的晶格属于面心立方晶格(FCC);较不可弯折或较不可延展的金属材料的晶格属于密排六方晶格 (HCP)。2A-2D show a manufacturing flow chart of a light-emitting device 200 according to the second embodiment of the present invention. Referring to FIG. 2A , a carrier 10 and a plurality of light-emitting elements 20 are provided. The carrier 10 includes a pair of support brackets 101 and a plurality of extension bracket groups. Each extension bracket group is arranged in parallel with each other and is physically connected to the support bracket 101 . Each extension bracket group includes a plurality of extension brackets 102, and a plurality of light-emitting elements 20 are respectively placed between the two extension brackets 102 and fixed on the two extension brackets 102 (in this embodiment, each extension bracket group includes five extension brackets, And four light-emitting elements are arranged on the extension bracket). The light emitting elements 20 are electrically connected to each other in series through the extension bracket 102 . The extension bracket 102 serves as a support to support the light-emitting elements 20 and the light-emitting elements 20 are arranged on the same straight line. Referring to FIG. 2B , the first cladding structure 30 is formed on the plurality of light emitting elements 20 and part of the extending bracket 102 to completely cover and cover the light emitting elements 20 . Part of the extending bracket 102 is not covered or covered by the first covering structure 30 and is exposed to the external environment (eg, air). Referring to FIG. 2C , a second cladding structure 40 is formed on the first cladding structure 30 and completely covers and wraps the first cladding structure 30 to provide further protection. Referring to FIG. 2D , the extension brackets 102A and the support brackets 101 at opposite ends of each extension bracket group are separated to form the light-emitting device 200 . In each extension bracket group, the extension bracket 102B that is not connected to the support bracket 101 and the light emitting element 20 fixed thereon are connected to each other and are not separated from each other. Referring to FIG. 2E , the bending extension bracket 102B forms an angle (θ 1 is an acute angle) between the light-emitting elements 20 , thereby forming a light-emitting device 200 having an M-type structure and the light-emitting elements 20 are arranged on non-identical straight lines . It should be noted that, as shown in FIG. 2E , the light-emitting elements 20 are substantially located on the same plane, and the side with the light-emitting unit (please refer to FIG. 3A ) all face the same direction. In other embodiments, the extension bracket 102B can be bent so that the light emitting elements 20 are located on different planes (please refer to FIG. 2F ), and the side with the light emitting unit can be oriented in different directions. As shown in FIG. 2G , the light emitting device 200 may also have a diamond shape (θ 2 is an acute angle and θ 3 is an obtuse angle) or other shapes. Likewise, the bent extension bracket 102B and part of the extension bracket 102A are not covered or covered by the first cladding structure 30 and the second cladding structure 40 and are exposed to the external environment (eg, air). The number of the extension brackets 102 and the light-emitting elements 20 can be increased or decreased according to actual needs or according to the desired shape. The support bracket and the extension bracket include bendable, flexible, extensible and deformable metals. The material of the support stent can be the same or different from the material of the extension stent. In this embodiment, the support bracket is used to support the extension bracket, and only the extension bracket is bent, so the ductility of the support bracket can be lower than that of the extension bracket. The material supporting the stent may comprise copper, gold, platinum, silver, steel, iron, aluminum or alloys thereof. The material of the extension stent may comprise copper, gold, platinum, silver, aluminum or alloys thereof. Generally speaking, the crystal lattice of a metal material that is bendable or ductile is classified as a face-centered cubic lattice (FCC); the lattice of a metal material that is less bendable or less malleable is classified as a hexagonal close-packed lattice (HCP).
在图2A中,因每一延伸支架组的延伸支架102彼此不相连,因此载具 10设置于一载板(图未示)上,以使支撑支架101及延伸支架102可固定于载板上。接着,再固定发光元件20于延伸支架102上。或者,载板具有多个凹槽以设置支撑支架101及延伸支架102于其内。固定发光元件20于延伸支架102上后,移除载板。之后,形成第一包覆结构及/或第二包覆结构(图 2B及图2C)。第一包覆结构及第二包覆结构可利用点胶、喷涂或铸模(例如:射出铸模或挤压铸模)等方式而形成。In FIG. 2A , since the extension brackets 102 of each extension bracket group are not connected to each other, the carrier 10 is disposed on a carrier board (not shown), so that the support bracket 101 and the extension bracket 102 can be fixed on the carrier board . Next, the light-emitting element 20 is fixed on the extension bracket 102 . Alternatively, the carrier plate has a plurality of grooves for disposing the support bracket 101 and the extension bracket 102 therein. After fixing the light-emitting element 20 on the extension bracket 102, the carrier plate is removed. After that, the first cladding structure and/or the second cladding structure are formed (FIG. 2B and FIG. 2C). The first cladding structure and the second cladding structure can be formed by dispensing, spraying, or casting (eg, injection casting or extrusion casting).
图3A~图3B仅例示一发光元件20设置在两延伸支架102间。参照图 3A所示,发光元件20包含基板201;多个发光单元202形成在基板201上;及两电极垫203,形成在基板201的两端且与多个发光单元202形成电连接。每一发光单元202包含一第一型半导体层2021、一活性层2022、及一第二型半导体层2023,第一型半导体层2021及第二型半导体层2023例如为包覆层(cladding layer)或限制层(confinement layer),可分别提供电子、空穴,使电子、空穴于活性层2022中结合以发光。在此实施例中,基板201为成长基板且多个发光单元202共同外延形成在基板201上。发光元件20还包含一电连接结构204形成在基板201上;及一绝缘结构205形成在电连接结构204与发光单元202与基板201之间。电连接结构204电连接发光单元202 及电极垫203,由此彼此串联连接。在另一实施例中,发光单元202彼此可并联、反向并联、或以桥式结构而形成电连接。注意的是,每一发光单元202 可各自形成正负电极(图未示),且通过电连接结构204连接每一发光单元 202的正负电极以彼此串联连接。电极垫203与延伸支架102可利用焊接制作工艺(soldering process)或黏着制作工艺(adhesive process)彼此固定并完成电连接。在焊接制作工艺时,电极垫203的材料可为合金(alloy)、金属(metal)或焊料(solder),且通过一共晶焊接(eutectic soldering)制作工艺将发光元件20与延伸支架102相连接。在黏着制作工艺时,可于电极垫203 与延伸支架102间形成一粘着剂,例如膏状形式或薄膜形式的各向异性导电胶(anisotropicallyconductive adhesive;ACA),即各向异性导电膜 (anisotropically conductive film;ACF),在结合压力和热的共同作用下,完成电连接,并使粘着剂永久地固化(cure)及热稳定。粘着剂也包含银胶或锡膏。在一实施例中,发光单元202可利用一接合层固定在基板201上以形成发光元件20。第一型半导体层2021、一活性层2022、及一第二型半导体层2023的材料可包含Ⅲ-Ⅴ族半导体材料,例如AlxInyGa(1-x-y)N或 AlxInyGa(1-x-y)P,其中0≦x,y≦1;(x+y)≦1。依据活性层2022的材料,发光元件20可发出波长介于610nm及650nm之间的红光,波长介于530nm及 570nm之间的绿光,或是波长介于450nm及490nm之间的蓝光。形成第一型半导体层2021、一活性层2022、及一第二型半导体层2023的方法没有特别限制,除了有机金属化学气相沉积法(MOCVD),也可使用分子束外延 (MBE)、氢化物气相沉积法(HVPE)、蒸镀法或离子电镀方法。在一实施例中,基板201为长条状且具有一长度及一宽度;长度至少为宽度的10倍以上。3A-3B only illustrate that a light-emitting element 20 is disposed between the two extending brackets 102 . Referring to FIG. 3A , the light-emitting element 20 includes a substrate 201 ; a plurality of light-emitting units 202 are formed on the substrate 201 ; Each light-emitting unit 202 includes a first-type semiconductor layer 2021, an active layer 2022, and a second-type semiconductor layer 2023. The first-type semiconductor layer 2021 and the second-type semiconductor layer 2023 are, for example, cladding layers. Or a confinement layer, which can provide electrons and holes, respectively, so that the electrons and holes are combined in the active layer 2022 to emit light. In this embodiment, the substrate 201 is a growth substrate and a plurality of light emitting units 202 are jointly epitaxially formed on the substrate 201 . The light emitting element 20 further includes an electrical connection structure 204 formed on the substrate 201 ; and an insulating structure 205 formed between the electrical connection structure 204 and the light emitting unit 202 and the substrate 201 . The electrical connection structure 204 electrically connects the light emitting unit 202 and the electrode pad 203, thereby being connected to each other in series. In another embodiment, the light emitting units 202 can be electrically connected in parallel, anti-parallel, or in a bridge structure. It is noted that each light emitting unit 202 can be formed with positive and negative electrodes (not shown), and the positive and negative electrodes of each light emitting unit 202 are connected to each other in series through the electrical connection structure 204 . The electrode pads 203 and the extension bracket 102 can be fixed to each other and electrically connected by a soldering process or an adhesive process. During the soldering process, the material of the electrode pads 203 can be alloy, metal or solder, and the light emitting element 20 and the extension bracket 102 are connected through an eutectic soldering process. During the adhesive manufacturing process, an adhesive, such as anisotropically conductive adhesive (ACA) in the form of a paste or a film, can be formed between the electrode pad 203 and the extension support 102, that is, an anisotropic conductive film (anisotropically conductive film). film; ACF), under the combined action of combined pressure and heat, completes the electrical connection and permanently cures and thermally stabilizes the adhesive. Adhesives also contain silver glue or solder paste. In one embodiment, the light emitting unit 202 can be fixed on the substrate 201 by a bonding layer to form the light emitting element 20 . The materials of the first type semiconductor layer 2021, an active layer 2022, and a second type semiconductor layer 2023 may include III-V semiconductor materials, such as AlxInyGa ( 1-xy) N or AlxInyGa ( 1-xy) P, where 0≦x, y≦1; (x+y)≦1. Depending on the material of the active layer 2022, the light emitting element 20 can emit red light with wavelengths between 610 nm and 650 nm, green light with wavelengths between 530 nm and 570 nm, or blue light with wavelengths between 450 nm and 490 nm. The method for forming the first-type semiconductor layer 2021, an active layer 2022, and a second-type semiconductor layer 2023 is not particularly limited. In addition to metal organic chemical vapor deposition (MOCVD), molecular beam epitaxy (MBE), hydride Vapor Deposition (HVPE), Evaporation or Ion Plating. In one embodiment, the substrate 201 is elongated and has a length and a width; the length is at least 10 times the width.
参照图3A所示,第一包覆结构30完全地包覆发光元件20并覆盖部分的延伸支架102,由此发光元件20中并未被曝露出且未与外界环境(空气) 接触。此外,第一包覆结构30直接接触成长基板201。参照图3B,第二包覆结构40也完全地包覆第一包覆结构30且覆盖部分的延伸支架102以提供进一步保护。第一包覆结构30或/及第二包覆结构40可包含波长转换材料、扩散粉、散热粒子或其组合。当第二包覆结构40含有波长转换材料时,可进一步形成一第三包覆结构包覆第二包覆结构40以达到防水气或防尘的功用。包覆结构的数目可依实际需求做变化。波长转换材料用以吸收发光单元 202所发出的第一波长光以发射出与第一波长的光,第一波长不同的第二波长。波长转换材料包含但不限于黄绿色荧光粉及红色荧光粉。黄绿色荧光粉的成分例如铝氧化物(YAG或TAG)、硅酸盐、钒酸盐、碱土金属硒化物、或金属氮化物。红色荧光粉的成分例如硅酸盐、钒酸盐、碱土金属硫化物、金属氮氧化物、或钨钼酸盐族混合物。扩散粉包含无机微粒(例如:二氧化硅)或有机物微粒(例如:高分子聚合物)。散热粒子包含金属、金属氧化物(例如:氧化铝)、或非金属氧化物(例如:氧化硼或氮化硼)。在此实施例中,第一包覆结构30具有一第一厚度(t1)(可为平均厚度、或最大、最小厚度),第二包覆结构40具有一第二厚度(t2)形成在第一包覆结构30 上;其中第二厚度为一均匀厚度,且第一厚度(t1)大于第二厚度(t2)。在另一实施例中,第一厚度可小于或等于第二厚度。或者,第二厚度可为一非均匀厚度。第一包覆结构30与第二包覆结构40可利用点胶、喷涂或铸模(例如:射出铸模或挤压铸模)等方式而形成。需注意的是,当利用点胶或喷涂形成第一包覆结构30与第二包覆结构40时,其剖面可呈一椭圆或半圆形状 (例如:图3B所示)。当利用铸模方式而形成第一包覆结构30与第二包覆结构40时,其剖面可呈一似长方形(图3C所示)。也可设计模具形状,使第一包覆结构30或/及第二包覆结构40具有椭圆、半圆形或其他形状。更者,可设计模具形状使第一包覆结构30或/及第二包覆结构40具有突出部301、 401。突出部301、401的位置对应每一发光单元202以改变发光元件20的发光光形(如图3D所示)。突出部301、401具有半圆形的剖面,但也可具有弧形、三角形、梯形、或其他多边形的剖面。在另一实施例中,如图3E 所示,突出部301、401的位置未对应每一发光单元202的位置,即突出部 301、401与发光单元202彼此交错排列且实质上未互相重叠,由此可减少光于不同材料的界面处所产生的全反射,以增加出光效率。Referring to FIG. 3A , the first cladding structure 30 completely envelops the light emitting element 20 and covers part of the extending bracket 102 , so that the light emitting element 20 is not exposed and is not in contact with the external environment (air). In addition, the first cladding structure 30 directly contacts the growth substrate 201 . Referring to FIG. 3B , the second cladding structure 40 also completely clads the first cladding structure 30 and covers a portion of the extension stent 102 for further protection. The first cladding structure 30 or/and the second cladding structure 40 may include wavelength conversion materials, diffusion powders, heat dissipation particles, or combinations thereof. When the second cladding structure 40 contains the wavelength conversion material, a third cladding structure can be further formed to coat the second cladding structure 40 to achieve the function of waterproofing or dustproofing. The number of cladding structures can be changed according to actual needs. The wavelength conversion material is used for absorbing the light of the first wavelength emitted by the light-emitting unit 202 to emit light of the first wavelength and a second wavelength different from the first wavelength. The wavelength conversion materials include, but are not limited to, yellow-green phosphors and red phosphors. The composition of the yellow-green phosphor is, for example, aluminum oxide (YAG or TAG), silicate, vanadate, alkaline earth metal selenide, or metal nitride. The components of the red phosphor are, for example, silicates, vanadates, alkaline earth metal sulfides, metal oxynitrides, or tungsten molybdate group mixtures. The diffusing powder contains inorganic particles (eg, silica) or organic particles (eg, high molecular polymers). The heat-dissipating particles include metals, metal oxides (eg, aluminum oxide), or non-metal oxides (eg, boron oxide or boron nitride). In this embodiment, the first cladding structure 30 has a first thickness (t1) (which may be an average thickness, or a maximum or minimum thickness), and the second cladding structure 40 has a second thickness (t2) formed on the On a cladding structure 30; wherein the second thickness is a uniform thickness, and the first thickness (t1) is greater than the second thickness (t2). In another embodiment, the first thickness may be less than or equal to the second thickness. Alternatively, the second thickness may be a non-uniform thickness. The first cladding structure 30 and the second cladding structure 40 can be formed by dispensing, spraying, or casting (eg, injection casting or extrusion casting). It should be noted that when the first cladding structure 30 and the second cladding structure 40 are formed by dispensing or spraying, the cross section thereof may be in an oval or semicircular shape (eg, as shown in FIG. 3B ). When the first cladding structure 30 and the second cladding structure 40 are formed by molding, the cross-section of the first cladding structure 30 and the second cladding structure 40 can be shaped like a rectangle (as shown in FIG. 3C ). The shape of the mold can also be designed so that the first cladding structure 30 or/and the second cladding structure 40 have an ellipse, a semicircle or other shapes. Furthermore, the shape of the mold can be designed so that the first cladding structure 30 or/and the second cladding structure 40 have the protruding parts 301 and 401 . The positions of the protruding parts 301 and 401 correspond to each light-emitting unit 202 to change the light-emitting shape of the light-emitting element 20 (as shown in FIG. 3D ). The protrusions 301, 401 have a semicircular cross-section, but may also have an arcuate, triangular, trapezoidal, or other polygonal cross-section. In another embodiment, as shown in FIG. 3E , the positions of the protrusions 301 and 401 do not correspond to the positions of each light-emitting unit 202 , that is, the protrusions 301 and 401 and the light-emitting unit 202 are staggered and do not substantially overlap each other. Therefore, the total reflection of light at the interface of different materials can be reduced, so as to increase the light extraction efficiency.
第一包覆结构30包含环氧树脂、硅胶(例如:PDMS)、硅橡胶(silicone rubber)、硅树脂(silicone resin)、弹性PU、多孔PU、丙烯酸橡胶(acrylic rubber)、或玻璃。第二包覆结构40包含环氧树脂、硅胶(例如:PDMS)、硅橡胶(silicone rubber)、硅树脂(siliconeresin)、弹性PU、多孔PU、丙烯酸橡胶(acrylic rubber)、或玻璃。第一包覆结构30与第二包覆结构40的材料可为相同或相异。需注意的是,当发光装置具有多层包覆结构时,每一层的包覆结构的材料可相同或相异。The first cladding structure 30 includes epoxy resin, silicone rubber (eg, PDMS), silicone rubber, silicone resin, elastic PU, porous PU, acrylic rubber, or glass. The second cladding structure 40 includes epoxy resin, silicone rubber (eg, PDMS), silicone rubber, silicone resin, elastic PU, porous PU, acrylic rubber, or glass. The materials of the first cladding structure 30 and the second cladding structure 40 may be the same or different. It should be noted that when the light-emitting device has a multi-layered cladding structure, the materials of the cladding structure of each layer may be the same or different.
图4A~图4C显示本发明的第三实施例中一发光装置300的制造流程图。载具10包含一对支撑支架101及多个延伸支架组,每一延伸支架组彼此平行排列且与支撑支架101彼此物理性连接。每一延伸支架组包含多个延伸支架102。载具10还包含多个连接支架103。连接支架103以一平行于支撑支架101的方向彼此排列并物理性连接延伸支架102,由此载具10形成一网络结构(net structure)。多个发光元件20分别放置于两延伸支架102间且固定于两延伸支架102上。发光元件20可通过延伸支架102彼此电连接。在本实施例中,发光元件20未设置在连接支架103上。延伸支架102或/且连接支架103可作为一支撑体而支撑发光元件20且发光元件20彼此排列于同一直线上。参照图4B所示,形成一第一包覆结构30于多个发光元件20及部分延伸支架102上以完全地覆盖并包覆发光元件20。部分延伸支架102及连接支架103曝露于外界环境(例如:空气)。在此实施例中,第一包覆结构 30可包含波长转换材料、扩散粉、散热粒子或其组合。选择性地,第二包覆结构40(图未示)也可完全地包覆第一包覆结构30并覆盖部分的延伸支架 102以提供进一步保护。接着,分离每一延伸支架组的相对两端的延伸支架 102A及支撑支架101,且选择性地分离连接支架103,由此以形成不同形状的发光装置300。例如,在此实施例中,参照图4C,发光装置300包含四个彼此平行排列且位于同一平面但不同直线上并电连接的发光元件20;接着,参照图4D,弯折连接支架103使得延伸支架102C往延伸支架102B的方向靠近,由此发光元件20彼此不位于同一平面且具有发光单元的一侧朝向不同方向。选择性地,可弯折延伸支架102或/及连接支架103使发光元件20 彼此位于同一平面。当然,在另一实施例中,可选择性地切割延伸支架102 或/及连接支架103,且根据所需形状而弯折未切割的延伸支架102或/及连接支架103。同样地,被弯折的延伸支架102及连接支架103也未被第一包覆结构3所包覆或覆盖而曝露于外界环境(例如:空气)。4A to 4C show a manufacturing flow chart of a light-emitting device 300 according to the third embodiment of the present invention. The carrier 10 includes a pair of support brackets 101 and a plurality of extension bracket groups. Each extension bracket group is arranged in parallel with each other and is physically connected to the support bracket 101 . Each extension bracket set includes a plurality of extension brackets 102 . The carrier 10 also includes a plurality of connecting brackets 103 . The connecting brackets 103 are arranged with each other in a direction parallel to the supporting bracket 101 and physically connect the extending brackets 102 , so that the carrier 10 forms a net structure. The plurality of light-emitting elements 20 are respectively placed between the two extending brackets 102 and fixed on the two extending brackets 102 . The light emitting elements 20 may be electrically connected to each other through the extension bracket 102 . In this embodiment, the light-emitting element 20 is not disposed on the connecting bracket 103 . The extending bracket 102 or/and the connecting bracket 103 can be used as a support to support the light emitting elements 20 and the light emitting elements 20 are arranged on the same straight line. Referring to FIG. 4B , a first cladding structure 30 is formed on the plurality of light emitting elements 20 and part of the extending bracket 102 to completely cover and cover the light emitting elements 20 . Part of the extending bracket 102 and the connecting bracket 103 are exposed to the external environment (eg, air). In this embodiment, the first cladding structure 30 may include wavelength conversion material, diffusing powder, heat dissipating particles, or a combination thereof. Optionally, the second cladding structure 40 (not shown) can also completely encapsulate the first cladding structure 30 and cover a portion of the extension stent 102 for further protection. Next, the extension brackets 102A and the support brackets 101 at opposite ends of each extension bracket group are separated, and the connecting brackets 103 are selectively separated, thereby forming light-emitting devices 300 of different shapes. For example, in this embodiment, referring to FIG. 4C , the light emitting device 300 includes four light emitting elements 20 that are arranged parallel to each other and located on the same plane but on different straight lines and are electrically connected; then, referring to FIG. 4D , the connecting bracket 103 is bent so as to extend The brackets 102C are approached in the direction of extending the brackets 102B, so that the light-emitting elements 20 are not located on the same plane with each other, and the side with the light-emitting units faces in different directions. Optionally, the extension bracket 102 or/and the connecting bracket 103 can be bent so that the light emitting elements 20 are located on the same plane. Of course, in another embodiment, the extension bracket 102 or/and the connection bracket 103 can be selectively cut, and the uncut extension bracket 102 or/and the connection bracket 103 can be bent according to the desired shape. Likewise, the bent extension bracket 102 and the connecting bracket 103 are not covered or covered by the first covering structure 3 and are exposed to the external environment (eg, air).
图4E显示图4D的发光装置300设置于一灯泡内的示意图。灯泡包含一灯壳90、发光装置300、导线支架91及电连接件92。导线支架91电连接至发光装置300使得发光元件20彼此串联连接。此外,导线支架91也用以支撑发光装置300使得发光装置300可以一预定形状位于灯泡内的一特定位置。发光元件20是往各个方向发光以使灯泡具有一发光角度大于270度的全周光。导线支架91包含铜、金、铂、银、钢、铁、铝或其合金。电连接件92用以与外部电路电连接。电连接件92可为螺旋式(例如:E12、E14、 E72等)灯头、或接头式(例如:B22)灯头。FIG. 4E shows a schematic diagram of the light-emitting device 300 of FIG. 4D being disposed in a light bulb. The light bulb includes a lamp housing 90 , a light-emitting device 300 , a wire support 91 and an electrical connector 92 . The lead holder 91 is electrically connected to the light emitting device 300 so that the light emitting elements 20 are connected to each other in series. In addition, the wire support 91 is also used to support the light emitting device 300 so that the light emitting device 300 can be located in a specific position in the bulb in a predetermined shape. The light-emitting element 20 emits light in all directions so that the bulb has a full-circumferential light with a light-emitting angle greater than 270 degrees. The lead holder 91 comprises copper, gold, platinum, silver, steel, iron, aluminum or alloys thereof. The electrical connector 92 is used for electrical connection with an external circuit. The electrical connector 92 can be a screw type (eg, E12, E14, E72, etc.) lamp holder, or a connector type (eg, B22) lamp holder.
图5A显示本发明的第四实施例中一发光元件20位于载具10上的示意图。载具10包含一对支撑支架101及多个延伸支架组,每一延伸支架组彼此平行排列且与支撑支架101彼此物理性连接。每一延伸支架组包含多个延伸支架102。需注意的是,与支撑支架101相连的延伸支架102具有一T型形状,而未与支撑支架101连接的延伸支架102具有十字形状,亦即每一延伸支架102具有一第一区域1021及一第二区域1022且第二区域1022的宽度大于第一区域1021的宽度。多个发光元件20分别放置于两延伸支架102 间且固定于两延伸支架102的第一区域1021上。通过第二区域1022宽度的设计,可增加发光装置的散热面积,由此帮助发光元件20所产生的热传至外界。同样地,如同图2A,因每一延伸支架组的延伸支架102彼此不相连,因此载具10设置于一载板(图未示)上,以使支撑支架101及延伸支架102 可固定于载板上。接着,再固定发光元件200于延伸支架102上。或者,载板具有多个凹槽以设置支撑支架101及延伸支架102于其内。固定发光元件 200于延伸支架102上后,移除载板。之后,参照图2B~图2G,可形成第一包覆结构30或/且第二包覆结构40;接着分离延伸支架102及支撑支架101 并弯折延伸支架102以形成具有一预定结构的发光装置。FIG. 5A shows a schematic diagram of a light-emitting element 20 on the carrier 10 according to the fourth embodiment of the present invention. The carrier 10 includes a pair of support brackets 101 and a plurality of extension bracket groups. Each extension bracket group is arranged in parallel with each other and is physically connected to the support bracket 101 . Each extension bracket set includes a plurality of extension brackets 102 . It should be noted that the extension bracket 102 connected to the support bracket 101 has a T-shape, while the extension bracket 102 not connected to the support bracket 101 has a cross shape, that is, each extension bracket 102 has a first area 1021 and a The second area 1022 and the width of the second area 1022 is greater than the width of the first area 1021 . The plurality of light emitting elements 20 are respectively placed between the two extending brackets 102 and fixed on the first regions 1021 of the two extending brackets 102 . Through the design of the width of the second region 1022, the heat dissipation area of the light emitting device can be increased, thereby helping the heat generated by the light emitting element 20 to be transferred to the outside. Similarly, as shown in FIG. 2A, since the extension brackets 102 of each extension bracket group are not connected to each other, the carrier 10 is disposed on a carrier plate (not shown), so that the support bracket 101 and the extension bracket 102 can be fixed on the carrier. board. Next, the light-emitting element 200 is fixed on the extension bracket 102 . Alternatively, the carrier plate has a plurality of grooves for disposing the support bracket 101 and the extension bracket 102 therein. After fixing the light-emitting element 200 on the extension bracket 102, the carrier plate is removed. Then, referring to FIGS. 2B to 2G , the first cladding structure 30 and/or the second cladding structure 40 can be formed; then the extension bracket 102 and the support bracket 101 are separated and the extension bracket 102 is bent to form a light emitting device with a predetermined structure device.
图5B显示本发明的第五实施例中发光元件20位于载具10上的示意图。载具10包含一对支撑支架101及多个延伸支架组,每一延伸支架组彼此平行排列且与支撑支架101彼此物理性连接。每一延伸支架组包含多个延伸支架102。载具10还包含多个连接支架103。连接支架103以一平行于支撑支架101的方向彼此排列并物理性连接延伸支架102,由此,载具10形成一网络结构(net structure)。多个发光元件20分别放置于两延伸支架102间且固定于两延伸支架102上。发光元件20可通过延伸支架102彼此电连接。在本实施例中,发光元件20未设置在连接支架103。延伸支架102或/且连接支架103可作为一支撑体以支撑发光元件20且发光元件20彼此排列于同一直线上。如同图5A,与支撑支架101相连的延伸支架102具有一T型形状,而未与支撑支架101连接的延伸支架102具有十字形状,亦即每一延伸支架 102具有一第一区域1021及一第二区域1022且第二区域1022的宽度大于第一区域1021的宽度。多个发光元件20分别放置于两延伸支架102间且固定于两延伸支架102的第一区域1021上。通过第二区域1022宽度的设计,可增加发光装置的散热面积,由此帮助发光元件20所产生的热传至外界。当然,也可设计连接支架103的宽度,也可帮助发光元件20所产生的热传至外界。同样地,参照图4B~图4D,可形成第一包覆结构30或/且第二包覆结构40;接着,可选择性地分离延伸支架102及连接支架103并弯折延伸支架 102或/且连接支架103以形成具有一预定结构的发光装置。FIG. 5B shows a schematic diagram of the light-emitting element 20 on the carrier 10 according to the fifth embodiment of the present invention. The carrier 10 includes a pair of support brackets 101 and a plurality of extension bracket groups. Each extension bracket group is arranged in parallel with each other and is physically connected to the support bracket 101 . Each extension bracket set includes a plurality of extension brackets 102 . The carrier 10 also includes a plurality of connecting brackets 103 . The connecting brackets 103 are arranged with each other in a direction parallel to the supporting bracket 101 and physically connect the extending brackets 102 , thereby, the carrier 10 forms a net structure. The plurality of light-emitting elements 20 are respectively placed between the two extending brackets 102 and fixed on the two extending brackets 102 . The light emitting elements 20 may be electrically connected to each other through the extension bracket 102 . In this embodiment, the light-emitting element 20 is not disposed on the connecting bracket 103 . The extension bracket 102 or/and the connection bracket 103 can be used as a support to support the light emitting elements 20 and the light emitting elements 20 are arranged on the same line. As shown in FIG. 5A , the extension brackets 102 connected to the support bracket 101 have a T-shape, while the extension brackets 102 not connected to the support bracket 101 have a cross shape, that is, each extension bracket 102 has a first area 1021 and a first area 1021 There are two areas 1022 and the width of the second area 1022 is greater than the width of the first area 1021 . The plurality of light-emitting elements 20 are respectively placed between the two extending brackets 102 and fixed on the first regions 1021 of the two extending brackets 102 . Through the design of the width of the second region 1022, the heat dissipation area of the light emitting device can be increased, thereby helping the heat generated by the light emitting element 20 to be transferred to the outside. Of course, the width of the connecting bracket 103 can also be designed, which can also help the heat generated by the light-emitting element 20 to be transferred to the outside. Similarly, referring to FIGS. 4B to 4D , the first cladding structure 30 or/and the second cladding structure 40 can be formed; then, the extension bracket 102 and the connecting bracket 103 can be selectively separated and the extension bracket 102 or/or can be bent. And the bracket 103 is connected to form a light emitting device with a predetermined structure.
图5C显示本发明的第六实施例中发光元件20位于载具10上的示意图。载具10包含一对支撑支架101及多个延伸支架组,每一延伸支架组彼此平行排列且与支撑支架101彼此物理性连接。每一延伸支架组包含多个延伸支架102。发光元件20包含第一发光群组20A及第二发光群组20B。第一发光群组20A放置且固定于每一延伸支架组的两延伸支架102间;第二发光群组20B与第一发光群组20A垂直地且设置于邻近的延伸支架组的两延伸支架102间,由此,发光元件20形成一网络结构(net structure)且彼此可以桥式方式形成电连接。第一发光群组20A延着第一方向(D1)排列,第二发光群组20B延着第二方向(D2)排列,第一方向垂直第二方向。同样地,可形成第一包覆结构30或/且第二包覆结构40;接着选择性地分离延伸支架 102并弯折延伸支架102以形成具有一预定结构的发光装置。参照图5D,发光装置600以桥式方式形成电连接,且具有发光单元的一侧朝向相同方向。如同图5A,延伸支架102的设计也帮助散热。FIG. 5C shows a schematic diagram of the light-emitting element 20 on the carrier 10 according to the sixth embodiment of the present invention. The carrier 10 includes a pair of support brackets 101 and a plurality of extension bracket groups. Each extension bracket group is arranged in parallel with each other and is physically connected to the support bracket 101 . Each extension bracket set includes a plurality of extension brackets 102 . The light-emitting element 20 includes a first light-emitting group 20A and a second light-emitting group 20B. The first light-emitting group 20A is placed and fixed between the two extension brackets 102 of each extension bracket group; the second light-emitting group 20B is perpendicular to the first light-emitting group 20A and is disposed on the two extension brackets 102 of the adjacent extension bracket group Thus, the light emitting elements 20 form a net structure and can be electrically connected to each other in a bridge manner. The first light-emitting groups 20A are arranged along the first direction ( D1 ), and the second light-emitting groups 20B are arranged along the second direction ( D2 ), and the first direction is perpendicular to the second direction. Similarly, the first cladding structure 30 and/or the second cladding structure 40 can be formed; then the extension bracket 102 is selectively separated and the extension bracket 102 is bent to form a light emitting device having a predetermined structure. Referring to FIG. 5D , the light emitting device 600 is electrically connected in a bridge manner, and the side with the light emitting unit faces the same direction. As with Figure 5A, the design of the extension bracket 102 also aids in heat dissipation.
图6A显示本发明第七实施例的发光元件20位于载具10上的示意图。载具10包含一对支撑支架101及多个延伸支架组,每一延伸支架组彼此平行排列且与支撑支架101彼此物理性连接。每一延伸支架组包含多个延伸支架102。在此实施例中,以四个延伸支架组为例,且每一延伸支架组包含三个延伸支架102及两个发光元件20设置于延伸支架102上。载具10还包含多个连接支架103。连接支架103以一平行于支撑支架101的方向彼此排列并物理性连接延伸支架102。需注意的是,连接支架103仅连接相邻的两延伸支架组。接着,分离延伸支架102及支撑支架101以形成一发光装置700。如图6B所示,弯折延伸支架102或/及连接支架103使得发光装置700成为一预定形状。发光装置700包含两组延伸支架组、四个发光元件20。如图 6C所示,发光装置700设置于一蜡烛灯中。蜡烛灯包含一灯壳901、一导线支架902、一基座903及一电连接件904。电连接件904可为螺旋式(例如: E12、E14、E72等)灯头、或接头式(例如:B22)灯头。FIG. 6A shows a schematic diagram of the light-emitting element 20 located on the carrier 10 according to the seventh embodiment of the present invention. The carrier 10 includes a pair of support brackets 101 and a plurality of extension bracket groups. Each extension bracket group is arranged in parallel with each other and is physically connected to the support bracket 101 . Each extension bracket set includes a plurality of extension brackets 102 . In this embodiment, four extension bracket groups are taken as an example, and each extension bracket group includes three extension brackets 102 and two light-emitting elements 20 disposed on the extension brackets 102 . The carrier 10 also includes a plurality of connecting brackets 103 . The connecting brackets 103 are arranged with each other in a direction parallel to the supporting bracket 101 and physically connect the extending brackets 102 . It should be noted that the connecting brackets 103 only connect two adjacent extension bracket groups. Next, the extension bracket 102 and the support bracket 101 are separated to form a light-emitting device 700 . As shown in FIG. 6B , the extension bracket 102 or/and the connecting bracket 103 are bent to make the light emitting device 700 into a predetermined shape. The light-emitting device 700 includes two sets of extending brackets and four light-emitting elements 20 . As shown in FIG. 6C, the light-emitting device 700 is disposed in a candle light. The candle lamp includes a lamp housing 901 , a wire support 902 , a base 903 and an electrical connector 904 . The electrical connector 904 can be a screw-type (eg, E12, E14, E72, etc.) lamp holder, or a connector-type (eg, B22) lamp holder.
发光装置700利用延伸支架102固定于并电连接至导线支架902。导线支架902也用以支撑发光装置700使得发光装置700可以一预定形状位于蜡烛灯内的一特定位置。图6D显示于图6C中发光装置700的电路示意图。发光元件20C、20D为并联连接;发光元件20E、20F为并联连接;之后,彼此再串联连接。或者,发光装置700可电连接至一交流电源且图6E显示发光装置700的另一电路示意图,在正循环下时,发光元件20C、20F会发光;在负循环下,发光元件20D、20E会发光。The light emitting device 700 is fixed to and electrically connected to the wire support 902 using the extension support 102 . The wire support 902 is also used to support the light emitting device 700 so that the light emitting device 700 can be positioned in a specific position in the candle light in a predetermined shape. FIG. 6D shows a schematic circuit diagram of the light emitting device 700 in FIG. 6C . The light-emitting elements 20C and 20D are connected in parallel; the light-emitting elements 20E and 20F are connected in parallel; after that, they are connected in series with each other. Alternatively, the light-emitting device 700 can be electrically connected to an AC power source and FIG. 6E shows another schematic circuit diagram of the light-emitting device 700. In a positive cycle, the light-emitting elements 20C and 20F will emit light; in a negative cycle, the light-emitting elements 20D and 20E will emit light. glow.
图6F显示本发明第八实施例的发光元件20位于载具10上的示意图。载具10包含一对支撑支架101及多个延伸支架组,每一延伸支架组彼此平行排列且与支撑支架101彼此物理性连接。每一延伸支架组包含多个延伸支架102。延伸支架102具有一第一区域1021及一第二区域1022且第二区域 1022的宽度或面积大于第一区域1021的宽度或面积。第二区域1022与支撑支架101物理性连接。同样地,如同图2A,因每一延伸支架组的延伸支架 102彼此不相连,因此载具10设置于一载板(图未示)上,以使支撑支架 101及延伸支架102可固定于载板上。接着,再固定发光元件20于延伸支架 102上。或者,载板具有多个凹槽以设置支撑支架101及延伸支架102于其内。固定发光元件20于延伸支架102上后,移除载板。接着,分离延伸支架102及支撑支架101以形成一发光装置800,并弯折延伸支架102使得发光装置800成为一预定形状。如图6G所示,发光装置800设置于一蜡烛灯中。在此实施例中,由于延伸支架的第二区域1022具有较大面积,除了可增加发光装置800的散热面积,也可作为一支撑使得发光装置800直接固定于基座903上。蜡烛灯也包含一灯壳901及一电连接件904。FIG. 6F shows a schematic diagram of the light-emitting element 20 on the carrier 10 according to the eighth embodiment of the present invention. The carrier 10 includes a pair of support brackets 101 and a plurality of extension bracket groups. Each extension bracket group is arranged in parallel with each other and is physically connected to the support bracket 101 . Each extension bracket set includes a plurality of extension brackets 102 . The extension bracket 102 has a first area 1021 and a second area 1022, and the width or area of the second area 1022 is larger than the width or area of the first area 1021. The second area 1022 is physically connected to the support bracket 101 . Similarly, as in FIG. 2A , since the extension brackets 102 of each extension bracket group are not connected to each other, the carrier 10 is disposed on a carrier plate (not shown), so that the support bracket 101 and the extension bracket 102 can be fixed on the carrier board. Next, the light-emitting element 20 is fixed on the extension bracket 102. Alternatively, the carrier plate has a plurality of grooves for disposing the support bracket 101 and the extension bracket 102 therein. After fixing the light-emitting element 20 on the extension bracket 102, the carrier plate is removed. Next, the extension bracket 102 and the support bracket 101 are separated to form a light-emitting device 800 , and the extension bracket 102 is bent so that the light-emitting device 800 has a predetermined shape. As shown in FIG. 6G, the light-emitting device 800 is disposed in a candle light. In this embodiment, since the second area 1022 of the extension bracket has a larger area, in addition to increasing the heat dissipation area of the light emitting device 800 , it can also be used as a support so that the light emitting device 800 can be directly fixed on the base 903 . The candle light also includes a lamp housing 901 and an electrical connector 904 .
图7A~图7B显示本发明的第九实施例的一发光装置900的制造流程示意图。图7A类似图1C,不同的是,延伸支架102与支撑支架101的接触部分1025具有锥形(tapered)的结构,由此,延伸支架102与支撑支架101 的连接强度较图1C小。因此,如图7B所示,当施加一力于接触部分1025 时,延伸支架102与支撑支架101可轻易地分离。通过接触部分1025的设置,可简化制作工艺流程。再者,延伸支架102还包含一孔洞1023。一连接导线(图未示)可穿过孔洞1023并使发光装置900固定于一灯泡内。或者,当多个发光装置900设置于一灯泡内时,连接导线可穿过每一发光装置900 的孔洞,由此固定并支撑每一发光装置成一预定形状。连接导线包含金属,可并联、串联、或串并联接多个发光装置。7A-7B are schematic diagrams illustrating a manufacturing process of a light-emitting device 900 according to the ninth embodiment of the present invention. 7A is similar to FIG. 1C , the difference is that the contact portion 1025 between the extension bracket 102 and the support bracket 101 has a tapered structure, so that the connection strength between the extension bracket 102 and the support bracket 101 is smaller than that in FIG. 1C . Therefore, as shown in FIG. 7B, when a force is applied to the contact portion 1025, the extension bracket 102 and the support bracket 101 can be easily separated. Through the arrangement of the contact portion 1025, the manufacturing process flow can be simplified. Furthermore, the extension bracket 102 further includes a hole 1023 . A connecting wire (not shown) can pass through the hole 1023 and fix the light emitting device 900 in a light bulb. Alternatively, when a plurality of light-emitting devices 900 are disposed in a light bulb, the connecting wires may pass through the holes of each light-emitting device 900, thereby fixing and supporting each light-emitting device into a predetermined shape. The connecting wire contains metal, and can connect multiple light-emitting devices in parallel, in series, or in series and parallel.
图8显示本发明的第十实施例中发光元件20位于载具10上的示意图。多个发光元件20分别放置于两延伸支架102间且固定于两延伸支架102上。发光元件20通过延伸支架102彼此串联电连接。延伸支架102作为一支撑体以支撑发光元件20且发光元件20彼此排列于同一直线上。更者,第一包覆结构30(图未示)可形成于多个发光元件20及部分延伸支架102上以完全地覆盖并包覆发光元件20。部分延伸支架102未被第一包覆结构30所包覆或覆盖而曝露于外界环境(例如:空气)。第二包覆结构40(图未示)可完全地覆盖并包覆第一包覆结构30以提供进一步保护。在本实施例中,载具10还包含一连接支架103,以一平行于支撑支架101的方向彼此排列;及一中间支架104用以物理性连接延伸支架102、102D及连接支架103,由此载具10形成一网络结构(net structure)。此外,部分延伸支架102D仅用以提供支撑,并未设置发光元件20于其上。连接支架103与延伸支架102、102D 的接触部分具有锥形(tapered)的结构,以及中间支架104与延伸支架102、 102D及连接支架103的接触部分也具有锥形(tapered)的结构,因此,当施加一力于接触部分时,可轻易地分离连接支架103与延伸支架102、102D,由此形成发光装置。中间支架104的设置也可简化制作工艺流程。FIG. 8 shows a schematic diagram of the light-emitting element 20 on the carrier 10 according to the tenth embodiment of the present invention. The plurality of light-emitting elements 20 are respectively placed between the two extending brackets 102 and fixed on the two extending brackets 102 . The light emitting elements 20 are electrically connected to each other in series through the extension bracket 102 . The extension bracket 102 serves as a support to support the light-emitting elements 20 and the light-emitting elements 20 are arranged on the same straight line. Furthermore, the first cladding structure 30 (not shown) can be formed on the plurality of light emitting elements 20 and part of the extending bracket 102 to completely cover and cover the light emitting elements 20 . Part of the extending bracket 102 is not covered or covered by the first covering structure 30 and is exposed to the external environment (eg, air). The second cladding structure 40 (not shown) can completely cover and wrap the first cladding structure 30 to provide further protection. In this embodiment, the carrier 10 further includes a connecting bracket 103 arranged in a direction parallel to the supporting bracket 101 ; and an intermediate bracket 104 for physically connecting the extension brackets 102 , 102D and the connecting bracket 103 , thereby The carrier 10 forms a net structure. In addition, part of the extending bracket 102D is only used for supporting, and the light-emitting element 20 is not disposed thereon. The contact portion of the connection bracket 103 and the extension brackets 102 and 102D has a tapered structure, and the contact portion of the intermediate bracket 104 with the extension brackets 102 and 102D and the connection bracket 103 also has a tapered structure. Therefore, When a force is applied to the contact portion, the connecting bracket 103 and the extending brackets 102 and 102D can be easily separated, thereby forming a light emitting device. The arrangement of the intermediate support 104 can also simplify the manufacturing process.
图9A~图9F显示本发明的第十一实施例的一发光装置1000的制造流程剖视图。参照图9A,可利用光刻蚀刻制作工艺以形成一图案化晶种结构221 于一载具21上。图案化晶种结构221包含一第一区域2211、一第二区域2212 及一第三区域2213。第一区域2211及第三区域2213包含多个彼此物理性分离的晶种层。第二区域2212设置在第一区域2211及第三区域2213之间并电连接第一区域2211及第三区域2213(参照图10A)。参照图9B,同样地,也可利用光刻蚀刻制作工艺以形成一图案化金属层222于相对应的图案化晶种结构221上,金属层222的面积及形状与晶种结构221的面积及形状实质上相等。金属层222也包含一第一区域2221,对应于晶种结构221的第一区域2211;一第二区域2222,对应于晶种结构221的第二区域2212;及一第三区域2223,对应于晶种结构221的第三区域2213。参照图9C,一第一发光群组11包含多个发光单元111分别设置在金属层222的第一区域2221;及一第二发光群组12包含多个发光单元121分别设置在金属层222的第三区域2223;金属层222的第二区域2222上无设置发光单元111、121。通过设计金属层的相对位置,可使设置其上的发光单元111,121以串联、并联、串并连接、桥式连接、或反向并联等方式彼此连接。参照图9D,进行一蚀刻步骤以移除晶种结构221。在本实施例中,因晶种结构221第二区域2212 的晶种层线宽(或面积)比第一区域2211晶种层线宽(或面积)较小(参照图10A),当第二区域2212完全被蚀刻或移除时,第一区域2211仅一部分被蚀刻且仍有一部分形成于载具21上,由此发光单元111、121仍固定于载具21上。再者,因晶种结构221的第二区域2212完全被蚀刻或移除,金属层222的第二区域2222呈现一悬空状态,亦即金属层222的第二区域2222 未与载具21直接接触,但仍与金属层222的第一区域2221及第三区域2223 电连接。相对地,晶种结构221的第一区域2211未被完全蚀刻或移除,因此金属层222的第一区域2221仍连接在载具21上而未呈现悬空状态。需注意的是,在移除晶种结构221步骤之后,晶种结构221的第一区域2211(第三区域2213)的线宽(面积)小于形成于其上的金属层222的第一区域2221 (第三区域2223)的线宽(面积)。金属层222与相对应晶种结构221共同形成一T形剖面。参照图9E及图10B,相对于悬空的金属层222第二区域 2222的位置,切割载具21以形成一第一载具部211及一第二载具部212。第一载具部211具有一第一表面2111及一第二表面2112,第二载具部212 具有一第三表面2121及一第四表面2122。第一发光群组11位于第二表面上 2112及第二发光群组12位于第四表面2122上。参照图9F,改变第一发光群组11及第二发光群组12的相对位置,使第一发光群组11及第二发光群组12实质上不位于同一直线上。此外,因金属层222的第二区域2222悬空并具有可延展性,当改变第一发光群组11及第二发光群组12的相对位置时,金属层222的第二区域2222被拉伸且弯折并造成形状的改变(参照图10C)。需注意的是,金属层222的第二区域2222于拉伸步骤后仍与金属层222的第一区域2221及第三区域2223彼此电连接。在本实施例中,第一发光群组 11及第二发光群组12面向不同方向且彼此串联电连接。第一表面2111及第三表面2121互相平行且相面对。需注意的是,在改变相对位置步骤前,第一表面2111(第二表面2212)与第三表面2121(第四表面2122)实质上位于同一直线,然而在改变相对位置步骤后,第一表面2111(第二表面2212) 与第三表面2121(第四表面2122)不位于同一直线上。更者,在改变相对位置步骤前,位于第一载具部211的金属层222A及位于第二载具部212的金属层222B面向同一方向且位于载具21的同一侧,然而在改变相对位置步骤后,金属层222A与金属层222B面对不同方向。由于金属层222A、222B面对不同方向,发光装置1000可视为以载具的同一侧的不同两面与外部电路(例如:电源供应器、电路板、或电子元件)电连接。举例来说,如图9G 所示,一基座80,其具有一对凹槽81。发光装置1000以金属层222A、222B 接合于对应的凹槽81中以形成电连接。在一实施例中,基座80可为灯泡中的电路板,且发光装置1000可为灯泡中的发光灯条。9A-9F are cross-sectional views showing the manufacturing process of a light-emitting device 1000 according to the eleventh embodiment of the present invention. Referring to FIG. 9A , a patterned seed crystal structure 221 may be formed on a carrier 21 using a photolithographic etching process. The patterned seed structure 221 includes a first region 2211 , a second region 2212 and a third region 2213 . The first region 2211 and the third region 2213 include a plurality of seed layers that are physically separated from each other. The second area 2212 is provided between the first area 2211 and the third area 2213 and electrically connects the first area 2211 and the third area 2213 (see FIG. 10A ). 9B , similarly, a photolithographic etching process can also be used to form a patterned metal layer 222 on the corresponding patterned seed crystal structure 221 . The area and shape of the metal layer 222 are the same as the area and shape of the seed crystal structure 221 The shapes are substantially equal. The metal layer 222 also includes a first region 2221, corresponding to the first region 2211 of the seed structure 221; a second region 2222, corresponding to the second region 2212 of the seed structure 221; and a third region 2223, corresponding to The third region 2213 of the seed structure 221 . 9C , a first light-emitting group 11 includes a plurality of light-emitting units 111 disposed in the first region 2221 of the metal layer 222 respectively; and a second light-emitting group 12 includes a plurality of light-emitting units 121 disposed in the metal layer 222 respectively. The third region 2223 ; the second region 2222 of the metal layer 222 is not provided with the light emitting units 111 and 121 . By designing the relative positions of the metal layers, the light emitting units 111 and 121 disposed thereon can be connected to each other in series, parallel, series-parallel connection, bridge connection, or anti-parallel connection. Referring to FIG. 9D , an etching step is performed to remove the seed structure 221 . In this embodiment, because the line width (or area) of the seed layer in the second region 2212 of the seed structure 221 is smaller than the line width (or area) of the seed layer in the first region 2211 (refer to FIG. 10A ), when the second region 2212 has a smaller line width (or area) When the region 2212 is completely etched or removed, only a part of the first region 2211 is etched and a part of the first region 2211 is still formed on the carrier 21 , so that the light emitting units 111 and 121 are still fixed on the carrier 21 . Furthermore, since the second region 2212 of the seed structure 221 is completely etched or removed, the second region 2222 of the metal layer 222 is in a floating state, that is, the second region 2222 of the metal layer 222 is not in direct contact with the carrier 21 . , but still electrically connected to the first region 2221 and the third region 2223 of the metal layer 222 . In contrast, the first region 2211 of the seed structure 221 is not completely etched or removed, so the first region 2221 of the metal layer 222 is still connected to the carrier 21 and does not appear in a floating state. It should be noted that, after the step of removing the seed structure 221, the line width (area) of the first region 2211 (third region 2213) of the seed structure 221 is smaller than that of the first region 2221 of the metal layer 222 formed thereon The line width (area) of the (third region 2223). The metal layer 222 and the corresponding seed structure 221 together form a T-shaped cross-section. Referring to FIGS. 9E and 10B , the carrier 21 is cut to form a first carrier portion 211 and a second carrier portion 212 relative to the position of the second region 2222 of the suspended metal layer 222 . The first carrier part 211 has a first surface 2111 and a second surface 2112 , and the second carrier part 212 has a third surface 2121 and a fourth surface 2122 . The first light-emitting group 11 is located on the second surface 2112 and the second light-emitting group 12 is located on the fourth surface 2122. Referring to FIG. 9F , the relative positions of the first light-emitting group 11 and the second light-emitting group 12 are changed, so that the first light-emitting group 11 and the second light-emitting group 12 are not substantially located on the same straight line. In addition, because the second region 2222 of the metal layer 222 is suspended and has extensibility, when the relative positions of the first light-emitting group 11 and the second light-emitting group 12 are changed, the second region 2222 of the metal layer 222 is stretched and stretched. Bend and cause a change in shape (see Figure 10C). It should be noted that the second region 2222 of the metal layer 222 is still electrically connected to the first region 2221 and the third region 2223 of the metal layer 222 after the stretching step. In this embodiment, the first light-emitting group 11 and the second light-emitting group 12 face different directions and are electrically connected in series with each other. The first surface 2111 and the third surface 2121 are parallel to each other and face each other. It should be noted that before the step of changing the relative position, the first surface 2111 (the second surface 2212 ) and the third surface 2121 (the fourth surface 2122 ) are substantially in the same line, but after the step of changing the relative position, the first surface 2111 (the second surface 2212) and the third surface 2121 (the fourth surface 2122) are not located on the same straight line. Furthermore, before the step of changing the relative position, the metal layer 222A on the first carrier portion 211 and the metal layer 222B on the second carrier portion 212 face the same direction and are on the same side of the carrier 21, but after changing the relative position After the step, the metal layer 222A and the metal layer 222B face different directions. Since the metal layers 222A and 222B face in different directions, the light emitting device 1000 can be regarded as being electrically connected to external circuits (eg, power supplies, circuit boards, or electronic components) on different sides of the same side of the carrier. For example, as shown in FIG. 9G , a base 80 has a pair of grooves 81 . The light emitting device 1000 is bonded into the corresponding grooves 81 with the metal layers 222A, 222B to form electrical connections. In one embodiment, the base 80 may be a circuit board in a light bulb, and the light emitting device 1000 may be a light bar in the light bulb.
图10A显示于改变第一发光群组11及第二发光群组12的相对位置步骤之前,金属层222的上视图(相对应于图9D,但为了使附图清楚,仅绘制金属层222)。金属层222的第二区域2222具有多个曲折部。图10B显示切割载具21后的上视图。参照图10C,第一载具部211及第二载具部212朝相对方向移动,由此金属层222的第二区域2222被拉长且相较于图10A,第二区域2222的曲折部具有一较大的曲率半径,亦即曲折部较为平缓。再者,图10C中第一载具部211及第二载具部212之间的距离大于图10B中第一载具部211及第二载具部212之间的距离。在图10C中,仅显示拉伸但未弯折金属层222的第二区域2222,而后可弯折金属层222的第二区域2222 以形成图9F中的发光装置1000。在另一实施例中,可直接弯折金属层222 的第二区域2222以形成图9F中的发光装置1000。在另一实施例中,未拉伸前的金属层222的第二区域2222的图案可为螺旋状、锯齿状、或半圆状。FIG. 10A shows a top view of the metal layer 222 before the step of changing the relative positions of the first light-emitting group 11 and the second light-emitting group 12 (corresponding to FIG. 9D , but only the metal layer 222 is drawn for clarity of the drawing) . The second region 2222 of the metal layer 222 has a plurality of meanders. FIG. 10B shows a top view of the carrier 21 after cutting. Referring to FIG. 10C , the first carrier part 211 and the second carrier part 212 move in opposite directions, whereby the second region 2222 of the metal layer 222 is elongated and compared with FIG. 10A , the meandering part of the second region 2222 has A larger radius of curvature means that the inflection portion is gentler. Furthermore, the distance between the first carrier portion 211 and the second carrier portion 212 in FIG. 10C is greater than the distance between the first carrier portion 211 and the second carrier portion 212 in FIG. 10B . In FIG. 10C, only the second region 2222 of the metal layer 222 is stretched but not bent, and then the second region 2222 of the metal layer 222 can be bent to form the light emitting device 1000 in FIG. 9F. In another embodiment, the second region 2222 of the metal layer 222 can be directly bent to form the light emitting device 1000 in FIG. 9F. In another embodiment, the pattern of the second region 2222 of the unstretched metal layer 222 may be spiral, zigzag, or semicircular.
图11A~图11D显示第十二实施例发光装置1100的一制造流程剖视图。参照图11A,发光装置1100包含一载具21;一图案化金属层222形成在载具21上,第一发光群组11及第二发光群组12位于图案化金属层222上。每一发光群组包含多个彼此电连接的发光单元111、121。第一发光群组11 中,最靠近第二发光群组12的发光单元111A与第二发光群组12中,最靠近第一发光群组11的发光单元121A,两发光单元111A、121A之间的间距 (D1)大于第一发光群组11或第二发光群组12中,邻近发光单元111、121 间的间距(D2)。参照图11B,一可延伸且可挠的导电件23设置在发光单元 111A、121A之间且电连接发光单元111A、121A。参照图11C,相对于导电件23的位置,切割载具21以形成一第一载具部211及一第二载具部212。第一载具部211与第二载具部212彼此不相连且分隔一段距离。再者,导电件23的一部分未与载具21连接且呈现悬空状态。第一载具部211具有一第一表面2111及一第二表面2112,第二载具部212具有一第三表面2121及一第四表面2122。第一发光群组11位于第二表面2112上及第二发光群组12 位于第四表面2122上。参照图11D,改变第一发光群组11及第二发光群组 12的相对位置,使第一发光群组11及第二发光群组12实质上不位于同一直线上。此外,因导电件23悬空并具有可延展性,当改变第一发光群组11及第二发光群组12的相对位置时,导电件23被拉伸且弯折造成形状的改变。需注意的是,导电件23于拉伸步骤后仍与第一发光群组11及第二发光群组12彼此电连接。在本实施例中,第一发光群组11及第二发光群组12面向不同方向且彼此串联电连接。第一表面2111及第三表面2121互相平行且相面对。需注意的是,在改变相对位置步骤前,第一表面2111(第二表面 2212)与第三表面2121(第四表面2122)实质上位于同一直线,然而在改变相对位置步骤后,第一表面2111(第二表面2212)与第三表面2121(第四表面2122)不位于同一直线上。更者,在改变相对位置步骤前,位于第一载具部211的金属层222A及位于第二载具部的金属层222B面向同一方向且位于载具21的同一侧,然而在改变相对位置步骤后,金属层222A与金属层222B面对不同方向。由于金属层222A、222B面对不同方向,发光装置 1100可视为以载具21同一侧的不同两面与外部电路(例如:电源供应器、电路板、或电子元件)电连接。同样地,如图9G所示,发光装置1100也连接至基板80的凹槽且设置于灯泡中。导电件23可通过打线、表面黏着技术 (SMT)的方式固定在载具21上。未拉伸前的导电件23的上视图图案可为蜿蜒状、螺旋状、锯齿状、或半圆状。11A-11D are cross-sectional views showing a manufacturing process of the light-emitting device 1100 according to the twelfth embodiment. 11A , the light-emitting device 1100 includes a carrier 21 ; a patterned metal layer 222 is formed on the carrier 21 , and the first light-emitting group 11 and the second light-emitting group 12 are located on the patterned metal layer 222 . Each light-emitting group includes a plurality of light-emitting units 111 and 121 that are electrically connected to each other. In the first light-emitting group 11, the light-emitting unit 111A closest to the second light-emitting group 12 and the light-emitting unit 121A closest to the first light-emitting group 11 in the second light-emitting group 12, between the two light-emitting units 111A, 121A The distance ( D1 ) is greater than the distance ( D2 ) between the adjacent light-emitting units 111 and 121 in the first light-emitting group 11 or the second light-emitting group 12 . Referring to FIG. 11B, an extendable and flexible conductive member 23 is disposed between the light-emitting units 111A, 121A and electrically connects the light-emitting units 111A, 121A. Referring to FIG. 11C , the carrier 21 is cut to form a first carrier portion 211 and a second carrier portion 212 relative to the position of the conductive member 23 . The first carrier part 211 and the second carrier part 212 are not connected to each other and are separated by a distance. Furthermore, a part of the conductive member 23 is not connected to the carrier 21 and is in a suspended state. The first carrier part 211 has a first surface 2111 and a second surface 2112 , and the second carrier part 212 has a third surface 2121 and a fourth surface 2122 . The first light emitting group 11 is located on the second surface 2112 and the second light emitting group 12 is located on the fourth surface 2122 . 11D, the relative positions of the first light-emitting group 11 and the second light-emitting group 12 are changed, so that the first light-emitting group 11 and the second light-emitting group 12 are not substantially located on the same straight line. In addition, since the conductive member 23 is suspended and has extensibility, when the relative positions of the first light-emitting group 11 and the second light-emitting group 12 are changed, the conductive member 23 is stretched and bent to change the shape. It should be noted that the conductive member 23 is still electrically connected to the first light-emitting group 11 and the second light-emitting group 12 after the stretching step. In this embodiment, the first light-emitting group 11 and the second light-emitting group 12 face different directions and are electrically connected in series with each other. The first surface 2111 and the third surface 2121 are parallel to each other and face each other. It should be noted that before the step of changing the relative position, the first surface 2111 (the second surface 2212 ) and the third surface 2121 (the fourth surface 2122 ) are substantially in the same line, but after the step of changing the relative position, the first surface 2111 (the second surface 2212 ) and the third surface 2121 (the fourth surface 2122 ) are not located on the same straight line. Furthermore, before the step of changing the relative position, the metal layer 222A on the first carrier portion 211 and the metal layer 222B on the second carrier portion face the same direction and are on the same side of the carrier 21, but before the step of changing the relative position Afterwards, the metal layer 222A and the metal layer 222B face different directions. Since the metal layers 222A and 222B face in different directions, the light emitting device 1100 can be regarded as being electrically connected to external circuits (such as power supplies, circuit boards, or electronic components) on two different sides of the same side of the carrier 21 . Likewise, as shown in FIG. 9G , the light emitting device 1100 is also connected to the groove of the substrate 80 and disposed in the bulb. The conductive member 23 can be fixed on the carrier 21 by means of wire bonding and surface mount technology (SMT). The top-view pattern of the unstretched conductive member 23 may be meandering, spiral, zigzag, or semicircular.
载具10、21包含有机材料、无机材料、或及其组合。有机材料,例如环氧树脂(Epoxy)、聚亚酰胺(PI)、苯并环丁烯(BCB)、过氟环丁烷(PFCB)、 Su8、丙烯酸树脂(AcrylicResin)、聚甲基丙烯酸甲酯(PMMA)、聚对苯二甲酸乙二酯(PET)、聚碳酸酯(PC)、聚醚酰亚胺(Polyetherimide)、氟碳聚合物(Fluorocarbon Polymer)。无机材料,例如蓝宝石、氧化锌、钻石、玻璃、石英或氮化铝。载具10、21可为透明或不透明。金属层包含铜、金、铂、银、铝或其合金。晶种层包含钛、铜或其合金。导电件包含铜、金、铂、银、铝或其合金。The carriers 10, 21 comprise organic materials, inorganic materials, or combinations thereof. Organic materials, such as epoxy resin (Epoxy), polyimide (PI), benzocyclobutene (BCB), perfluorocyclobutane (PFCB), Su8, acrylic resin (AcrylicResin), polymethyl methacrylate (PMMA), polyethylene terephthalate (PET), polycarbonate (PC), polyetherimide (Polyetherimide), Fluorocarbon Polymer. Inorganic materials such as sapphire, zinc oxide, diamond, glass, quartz or aluminum nitride. The carriers 10, 21 may be transparent or opaque. The metal layer contains copper, gold, platinum, silver, aluminum or alloys thereof. The seed layer contains titanium, copper or alloys thereof. The conductive member includes copper, gold, platinum, silver, aluminum or alloys thereof.
发光单元111、121的细部结构除了可具有如图3A所示的结构外,也可具有如图12A~图12C所示的结构。发光单元111、121包含一基板7000、一第一型半导体层7001、一活性层7002、及一第二型半导体层7003,第一型半导体层7001及第二型半导体层7003例如为包覆层(cladding layer)或限制层(confinement layer),可分别提供电子、空穴,使电子、空穴于活性层7002中结合以发光。一第一导电部7004及一第二导电部7005分别形成在第二型半导体层7003及第一型半导体层上7001。发光二极管单元2000 为一覆晶式发光二极管。第一导电部7004与第二导电部7005之间有一孔隙 7008,且第一导电部7004具有一电极接触面70041且第二导电部7005具有一电极接触面70051;电极接触面70041与电极接触面70051实质上位于相同的水平面。一透明胶体覆盖基板7000、第一型半导体层7001、活性层7002、及第二型半导体层7003且填入孔隙7008内以形成第一透明结构7026。在另一实施例中,透明胶体未完全填满孔隙7008,因此会有空气形成在第一导电部7004与第二导电部7005之间。第一透明结构7026具有一表面70261,实质上与电极接触面70041、70051齐平。接着,保护层7006形成在第一透明结构7026的表面且暴露出第一导电部7004与第二导电部7005。第一扩大电极部7024及第二扩大电极部7025分别形成在第一导电部7004与第二导电部7005,也形成在保护层7006上。发光单元111、121利用第一扩大电极部 7024及第二扩大电极部7025与金属层222直接接触并形成电连接。在此实施例中,第一扩大电极部7024的一侧边70241未与保护层7006的一侧边 70061齐平;第二扩大电极部7025的另一侧边70251未与保护层7006的另一侧边70062齐平。在另一实施例中,第一扩大电极部7024的一侧边70241 可与保护层7006的一侧边70061齐平;第二扩大电极部7025的一侧边70251 可与保护层7006的另一侧边70062齐平。发光单元还包含一第二透明结构 7027形成在第一透明结构7026上。在另一实施例中,发光单元可不具有第二透明结构7027。第一透明结构7026或第二透明结构7027包含环氧树脂 (Epoxy)、聚亚酰胺(PI)、苯并环丁烯(BCB)、过氟环丁烷(PFCB)、SU8、丙烯酸树脂(Acrylic Resin)、聚甲基丙烯酸甲酯(PMMA)、聚对苯二甲酸乙二酯(PET)、聚碳酸酯(PC)、聚醚酰亚胺(Polyetherimide)、氟碳聚合物(Fluorocarbon Polymer)、氧化铝(Al2O3)、SINR、旋涂玻璃(SOG)。第二透明结构7027包含蓝宝石(Sapphire)、钻石(Diamond)、玻璃(Glass)、环氧树脂(Epoxy)、石英(quartz)、丙烯酸树脂(Acrylic Resin)、氧化硅(SiOX)、氧化铝(Al2O3)、氧化锌(ZnO)、或硅胶(Silicone)。保护层7006透明不导电但具有高导热系数的物质(例如:类碳钻),或也可包含高反射率的物质(例如:二氧化钛、二氧化硅或氧化铝)。第一透明结构7026或/且第二透明结构7027可包含波长转换材料、扩散粉、散热粒子或其组合。The detailed structures of the light-emitting units 111 and 121 may not only have the structures shown in FIG. 3A , but also the structures shown in FIGS. 12A to 12C . The light-emitting units 111 and 121 include a substrate 7000, a first-type semiconductor layer 7001, an active layer 7002, and a second-type semiconductor layer 7003. The first-type semiconductor layer 7001 and the second-type semiconductor layer 7003 are, for example, cladding layers The cladding layer or the confinement layer can respectively provide electrons and holes, so that the electrons and holes are combined in the active layer 7002 to emit light. A first conductive portion 7004 and a second conductive portion 7005 are formed on the second-type semiconductor layer 7003 and the first-type semiconductor layer 7001, respectively. The LED unit 2000 is a flip-chip LED. There is a hole 7008 between the first conductive part 7004 and the second conductive part 7005, and the first conductive part 7004 has an electrode contact surface 70041 and the second conductive part 7005 has an electrode contact surface 70051; the electrode contact surface 70041 and the electrode contact surface The 70051 is essentially at the same level. A transparent colloid covers the substrate 7000 , the first-type semiconductor layer 7001 , the active layer 7002 , and the second-type semiconductor layer 7003 and fills the pores 7008 to form the first transparent structure 7026 . In another embodiment, the transparent colloid does not completely fill the pores 7008 , so air is formed between the first conductive portion 7004 and the second conductive portion 7005 . The first transparent structure 7026 has a surface 70261 which is substantially flush with the electrode contact surfaces 70041 and 70051 . Next, a protective layer 7006 is formed on the surface of the first transparent structure 7026 and exposes the first conductive portion 7004 and the second conductive portion 7005 . The first enlarged electrode portion 7024 and the second enlarged electrode portion 7025 are formed on the first conductive portion 7004 and the second conductive portion 7005 , respectively, and are also formed on the protective layer 7006 . The light emitting units 111 and 121 are in direct contact with the metal layer 222 by using the first enlarged electrode portion 7024 and the second enlarged electrode portion 7025 to form electrical connection. In this embodiment, one side 70241 of the first enlarged electrode portion 7024 is not flush with one side 70061 of the protective layer 7006 ; the other side 70251 of the second enlarged electrode portion 7025 is not flush with the other side of the protective layer 7006 Side 70062 flush. In another embodiment, one side 70241 of the first enlarged electrode portion 7024 can be flush with one side 70061 of the protective layer 7006 ; one side 70251 of the second enlarged electrode portion 7025 can be flush with the other side of the protective layer 7006 Side 70062 flush. The light-emitting unit further includes a second transparent structure 7027 formed on the first transparent structure 7026 . In another embodiment, the light emitting unit may not have the second transparent structure 7027 . The first transparent structure 7026 or the second transparent structure 7027 includes epoxy resin (Epoxy), polyimide (PI), benzocyclobutene (BCB), perfluorocyclobutane (PFCB), SU8, acrylic resin (Acrylic Resin), polymethyl methacrylate (PMMA), polyethylene terephthalate (PET), polycarbonate (PC), polyetherimide (Polyetherimide), fluorocarbon polymer (Fluorocarbon Polymer), Alumina (Al 2 O 3 ), SINR, spin-on-glass (SOG). The second transparent structure 7027 includes sapphire, diamond, glass, epoxy, quartz, acrylic resin, silicon oxide (SiO x ), aluminum oxide ( Al 2 O 3 ), zinc oxide (ZnO), or silica gel (Silicone). The protective layer 7006 is a transparent and non-conductive material with high thermal conductivity (eg, carbon-like diamond), or may also include a material with high reflectivity (eg, titanium dioxide, silicon dioxide, or aluminum oxide). The first transparent structure 7026 or/and the second transparent structure 7027 may include wavelength conversion material, diffusing powder, heat dissipation particles, or a combination thereof.
图12B的发光单元具有与图12A的发光结构具有类似的结构。图12A 的发光单元仅包含一发光二极管,然而,图12B的发光单元包含多个发光二极管。在本实施例中,每一发光二极管具有各自的基板7000。在其他实施例中,可如图3A所示,多个发光二极管共同外延形成于一基板上。发光二极管彼此之间利用一电连接结构204而形成电连接(串联、并联或串并联)。在本实施例中,发光二极管的第二导电部7005及相邻的发光二极管的第一导电部7004利用一导线结构7015直接接触并形成串联连接。第一透明结构 7026覆盖多个发光二极管。需注意的是,仅通过第一扩大电极部7024、第二扩大电极部7025与金属层222电连接,即可使多个发光二极管发光。The light emitting unit of FIG. 12B has a structure similar to that of the light emitting structure of FIG. 12A . The light-emitting unit of FIG. 12A includes only one light-emitting diode, however, the light-emitting unit of FIG. 12B includes a plurality of light-emitting diodes. In this embodiment, each light emitting diode has its own substrate 7000 . In other embodiments, as shown in FIG. 3A , a plurality of light emitting diodes are jointly epitaxially formed on a substrate. The light-emitting diodes are electrically connected (series, parallel, or series-parallel) by using an electrical connection structure 204 . In this embodiment, the second conductive portion 7005 of the light emitting diode and the first conductive portion 7004 of the adjacent light emitting diode are in direct contact with each other through a wire structure 7015 and form a series connection. The first transparent structure 7026 covers the plurality of light emitting diodes. It should be noted that the plurality of light emitting diodes can be made to emit light only through the electrical connection between the first enlarged electrode portion 7024 and the second enlarged electrode portion 7025 and the metal layer 222 .
图12C的发光单元具有与图12B的发光结构具有类似的结构,不同的是,图12B的发光单元中,每一发光二极管具有各自的第一扩大电极部7024 及第二扩大电极部7025,且彼此不形成电连接。通过金属层222的设计,使得发光单元中的多个发光二极管在载具上彼此电连接,且可以串联、并联、反向并联、或以桥式结构而形成电连接。The light-emitting unit of FIG. 12C has a similar structure to the light-emitting structure of FIG. 12B , the difference is that in the light-emitting unit of FIG. 12B , each light-emitting diode has its own first enlarged electrode portion 7024 and second enlarged electrode portion 7025 , and No electrical connection is made to each other. Through the design of the metal layer 222 , the plurality of light emitting diodes in the light emitting unit are electrically connected to each other on the carrier, and can be electrically connected in series, in parallel, in reverse parallel, or in a bridge structure.
需注意的是,上述所描述的发光装置可视为一小型发光灯条,当设置于照明装置(例如:A型球泡灯、B型球泡灯、探照灯、豆灯、灯管或灯具) 时,延伸支架102或金属层可与灯泡的电路结构形成电连接。依据不同需要,可通过延伸支架102或/及连接支架103使发光装置具有不同的结构以使照明装置达到全周光的效果。It should be noted that the above-described light-emitting device can be regarded as a small light-emitting light bar, when installed in a lighting device (eg: A-type bulb, B-type bulb, searchlight, bean lamp, lamp tube or lamp) At this time, the extension bracket 102 or the metal layer can form an electrical connection with the circuit structure of the light bulb. According to different needs, the lighting device can have different structures by extending the bracket 102 or/and connecting the bracket 103, so that the lighting device can achieve the effect of all-round light.
需了解的是,本发明中上述的实施例在适当的情况下,是可互相组合或替换,而非仅限于所描述的特定实施例。本发明所列举的各实施例仅用以说明本发明,并非用以限制本发明的范围。任何人对本发明所作的任何显而易见的修饰或变更都不脱离本发明的精神与范围。It should be understood that the above-mentioned embodiments of the present invention can be combined or replaced with each other under appropriate circumstances, and are not limited to the specific embodiments described. The embodiments listed in the present invention are only used to illustrate the present invention, but not to limit the scope of the present invention. Any obvious modifications or changes made by anyone to the present invention do not depart from the spirit and scope of the present invention.