US20070007558A1 - Light emitting diode package and method for making same - Google Patents
Light emitting diode package and method for making same Download PDFInfo
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- US20070007558A1 US20070007558A1 US11/475,292 US47529206A US2007007558A1 US 20070007558 A1 US20070007558 A1 US 20070007558A1 US 47529206 A US47529206 A US 47529206A US 2007007558 A1 US2007007558 A1 US 2007007558A1
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- pwb
- led
- heat sink
- led package
- layer
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K1/00—Printed circuits
- H05K1/02—Details
- H05K1/0201—Thermal arrangements, e.g. for cooling, heating or preventing overheating
- H05K1/0203—Cooling of mounted components
- H05K1/021—Components thermally connected to metal substrates or heat-sinks by insert mounting
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L33/00—Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L33/48—Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor body packages
- H01L33/64—Heat extraction or cooling elements
- H01L33/641—Heat extraction or cooling elements characterized by the materials
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/30—Assembling printed circuits with electric components, e.g. with resistor
- H05K3/32—Assembling printed circuits with electric components, e.g. with resistor electrically connecting electric components or wires to printed circuits
- H05K3/34—Assembling printed circuits with electric components, e.g. with resistor electrically connecting electric components or wires to printed circuits by soldering
- H05K3/341—Surface mounted components
- H05K3/3431—Leadless components
- H05K3/3442—Leadless components having edge contacts, e.g. leadless chip capacitors, chip carriers
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2224/00—Indexing scheme for arrangements for connecting or disconnecting semiconductor or solid-state bodies and methods related thereto as covered by H01L24/00
- H01L2224/01—Means for bonding being attached to, or being formed on, the surface to be connected, e.g. chip-to-package, die-attach, "first-level" interconnects; Manufacturing methods related thereto
- H01L2224/42—Wire connectors; Manufacturing methods related thereto
- H01L2224/47—Structure, shape, material or disposition of the wire connectors after the connecting process
- H01L2224/48—Structure, shape, material or disposition of the wire connectors after the connecting process of an individual wire connector
- H01L2224/481—Disposition
- H01L2224/48135—Connecting between different semiconductor or solid-state bodies, i.e. chip-to-chip
- H01L2224/48137—Connecting between different semiconductor or solid-state bodies, i.e. chip-to-chip the bodies being arranged next to each other, e.g. on a common substrate
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
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- H01L2224/01—Means for bonding being attached to, or being formed on, the surface to be connected, e.g. chip-to-package, die-attach, "first-level" interconnects; Manufacturing methods related thereto
- H01L2224/42—Wire connectors; Manufacturing methods related thereto
- H01L2224/47—Structure, shape, material or disposition of the wire connectors after the connecting process
- H01L2224/48—Structure, shape, material or disposition of the wire connectors after the connecting process of an individual wire connector
- H01L2224/481—Disposition
- H01L2224/48151—Connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive
- H01L2224/48221—Connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked
- H01L2224/48225—Connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked the item being non-metallic, e.g. insulating substrate with or without metallisation
- H01L2224/48227—Connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked the item being non-metallic, e.g. insulating substrate with or without metallisation connecting the wire to a bond pad of the item
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- H—ELECTRICITY
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- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L25/00—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof
- H01L25/03—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof all the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. assemblies of rectifier diodes
- H01L25/04—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof all the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. assemblies of rectifier diodes the devices not having separate containers
- H01L25/075—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof all the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. assemblies of rectifier diodes the devices not having separate containers the devices being of a type provided for in group H01L33/00
- H01L25/0753—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof all the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. assemblies of rectifier diodes the devices not having separate containers the devices being of a type provided for in group H01L33/00 the devices being arranged next to each other
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L33/00—Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L33/48—Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor body packages
- H01L33/483—Containers
- H01L33/486—Containers adapted for surface mounting
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K1/00—Printed circuits
- H05K1/02—Details
- H05K1/14—Structural association of two or more printed circuits
- H05K1/141—One or more single auxiliary printed circuits mounted on a main printed circuit, e.g. modules, adapters
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- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K1/00—Printed circuits
- H05K1/18—Printed circuits structurally associated with non-printed electric components
- H05K1/182—Printed circuits structurally associated with non-printed electric components associated with components mounted in the printed circuit board, e.g. insert mounted components [IMC]
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/09—Shape and layout
- H05K2201/09009—Substrate related
- H05K2201/09127—PCB or component having an integral separable or breakable part
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/09—Shape and layout
- H05K2201/09145—Edge details
- H05K2201/09181—Notches in edge pads
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/09—Shape and layout
- H05K2201/09818—Shape or layout details not covered by a single group of H05K2201/09009 - H05K2201/09809
- H05K2201/09845—Stepped hole, via, edge, bump or conductor
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/10—Details of components or other objects attached to or integrated in a printed circuit board
- H05K2201/10007—Types of components
- H05K2201/10106—Light emitting diode [LED]
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2203/00—Indexing scheme relating to apparatus or processes for manufacturing printed circuits covered by H05K3/00
- H05K2203/06—Lamination
- H05K2203/063—Lamination of preperforated insulating layer
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/0058—Laminating printed circuit boards onto other substrates, e.g. metallic substrates
- H05K3/0061—Laminating printed circuit boards onto other substrates, e.g. metallic substrates onto a metallic substrate, e.g. a heat sink
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/40—Forming printed elements for providing electric connections to or between printed circuits
- H05K3/403—Edge contacts; Windows or holes in the substrate having plural connections on the walls thereof
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/12—Surface bonding means and/or assembly means with cutting, punching, piercing, severing or tearing
- Y10T156/13—Severing followed by associating with part from same source
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
- Y10T29/49124—On flat or curved insulated base, e.g., printed circuit, etc.
- Y10T29/49126—Assembling bases
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
- Y10T29/49124—On flat or curved insulated base, e.g., printed circuit, etc.
- Y10T29/4913—Assembling to base an electrical component, e.g., capacitor, etc.
- Y10T29/49139—Assembling to base an electrical component, e.g., capacitor, etc. by inserting component lead or terminal into base aperture
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
- Y10T29/49124—On flat or curved insulated base, e.g., printed circuit, etc.
- Y10T29/49155—Manufacturing circuit on or in base
Definitions
- the present invention relates generally to a light emitting diode (LED) package and method for making same, and, in particular to a LED package adapted for high temperature operation.
- LED light emitting diode
- LED packages include a specialized, moldable plastic housing having a separate transparent cover exhibiting specific optical properties.
- these LED packages are designed exclusively for direct surface mount technology (SMT) connection to a printed wire board (PWB).
- SMT surface mount technology
- PWB printed wire board
- conventional packages require a special, molded plastic housing (i.e., liquid crystal polymer) and optical element, the packages are not well suited for multi-die arrays that may be easily, quickly, and inexpensively modified to suit a particular lighting application.
- LED packages Another fabrication and design challenge faced by high-temperature operation LED packages is the need to effectively manage the heat generated by the array of LEDs.
- conventional LED packages include a large, homogeneous metal carrier or heat sink, which spans the entire bottom of the LED package.
- the metal carrier is generally composed of a relatively expensive material (e.g., molybdenum copper), adding significant cost to the fabrication of the LED package. Accordingly, there is a need in the art for an improved light emitting package adapted for high temperature operation in a variety of lighting applications.
- the present invention relates to a LED package assembly including a PWB having one or more through-holes or apertures. Inserted into each of the apertures is a heat sink stud to form an integrated/monolithic assembly.
- one or more light sources i.e., LED die
- the assembly may be mounted on an external component, such as an external heat sink.
- an external heat sink such as an external heat sink.
- the LED package assembly utilizes PWB techniques, SMT assembly techniques, and/or chip-on-board (COB) semiconductor die attachment techniques.
- the LED package assembly of the present invention reduces the cost and design cycle time for light emitting components, and is suitable for use in a variety of lighting applications including but not limited to general illumination, accent lighting, electronic display illumination, machine vision, etc.
- an array of LED die may be arranged in a single, low-cost, versatile package which is operable in high temperature environments.
- a LED package may be fabricated by thermally coupling one or more heat sink studs to an external heat sink, placing a printed wire board (substrate) over the external heat sink, wherein the printed wire board (substrate) includes one or more openings/apertures in registration with the one or more heat sink studs, and mounting one or more LED die to each of the one or more heat sink studs, wherein the heat sink studs are embedded at least partially in the external heat sink.
- the one or more LED die are electrically connected to the printed wire board, preferably to one or more conductors attached to the PWB, preferably by a wire bond.
- one or more reflectors may be arranged on the printed wire board, such that the one or more reflectors form a cavity at least partially surrounding the one or more LED die.
- An encapsulant material may be introduced into the cavity in order to cover or encapsulate the LED die.
- the one or more heat sink studs may be thermally coupled to the external heat sink using a thermal grease.
- the PWB may include one or more castellations, adapted to allow the LED package to be assembled onto a secondary component, such as a mother PWB.
- an outer edge of the heat sink studs may be knurled to allow the heat sink studs to be fitted within the corresponding opening of the printed wire board.
- the openings of the PWB may plated with a solderable material, such that the solderable material may be flowed to join the PWB and the heat sink stud.
- a LED package may comprise an external heat sink, one or more heat sink studs in thermal contact with the external heat sink, a printed wire board overlying the external heat sink, wherein the printed wire board includes one or more openings aligned with the one or more heat sink studs, and one or more LED die mounted on each of the one or more heat sink studs.
- the one or more heat sink studs may be embedded in the external heat sink.
- one or more reflectors may be attached to the printed wire board, wherein each of the one or more reflectors forms a cavity around the one or more LED die.
- the printed wire board may comprise a standard fiberglass reinforced epoxy laminate material (FR4) or a high temperature fiberglass reinforced epoxy laminate material (FR4-5) and the LED die is composed of a material having a thermal coefficient of expansion (TCE) that is closely matched to that of the heat sink stud material.
- the one or more sink studs comprise a high thermal conductivity material, such as copper molybdenum copper.
- the LED package may comprise multi-color LEDs.
- An exemplary LED package according to an embodiment of the present invention may comprise an external heat sink, a formed heat sink thermally connected to the external heat sink, a PWB mounted above the formed heat sink, and one or more LED die mounted on the formed heat sink.
- An exemplary LED package may comprise a metal layer, a PWB having one or more layers and a cavity, wherein the printed wire board is mounted on the metal layer, one or more isolators or interposers disposed in the cavity of the PWB and mounted on the metal layer, and one or more LED die mounted on the isolator wherein the isolator comprises a material having a TCE that matches that of the one or more LED die mounted thereon.
- the metal layer may comprise copper.
- an encapsulant may be disposed over the one or more LED die.
- the LED assembly may further comprise a reflector attached to the PWB.
- a method for fabricating an LED assembly including a stepped cavity formed or buried in a multi-layer PWB structure.
- the multi-layer PWB structure includes a plurality of layers of PWB secured together using one or more adhesive layers.
- the adhesive is a pressure sensitive adhesive (PSA).
- PSA pressure sensitive adhesive
- the adhesive layers are comprised of pre-impregnated composite fiber, herein referred to as “pre-preg” material.
- FIG. 1 shows a side cross-section view of a LED package, according to an embodiment of the present invention
- FIG. 2 shows a top view of a LED package, according to an embodiment of the present invention
- FIG. 3 illustrates a top view of a LED package including an array of LED assemblies, according to an embodiment of the present invention
- FIG. 4 shows a top view of a LED package including an array of LED assemblies, wherein the package includes castellations for SMT-type mounting, according to an embodiment of the present invention
- FIG. 5 illustrates a side view of a LED package including castellations mounted upon a secondary PWB using a SMT technique, according to an embodiment of the present invention
- FIG. 6 shows a side cross section view of a LED package including a formed heat sink providing a reflective cavity, according to an embodiment of the present invention
- FIG. 7 depicts a top view of a LED array package including a formed heat sink, according to an embodiment of the present invention.
- FIG. 8 shows a side cross section view of a LED package including a PWB arranged above a formed heat sink, according to an embodiment of the present invention
- FIG. 9 shows a side cross section view of a LED array package including a PWB arranged above a formed heat sink thermally coupled to an external heat sink, according to an embodiment of the present invention
- FIG. 10 shows a side cross section view of a LED array package including a direct external heat sink connection, according to an embodiment of the present invention
- FIG. 11 shows a side cross section view of a LED package including an isolator, according to an embodiment of the present invention.
- FIG. 12 shows a side cross section view of a LED package including an isolator and an optical element, according to an embodiment of the present invention
- FIG. 13 shows a side cross section view of a LED package including one or more LED die disposed directly on a metal layer composed of a TCE matching material
- FIG. 14 illustrates the steps of an exemplary process for fabricating a PWB assembly having a stepped cavity, according to an embodiment of the present invention
- FIG. 15A-15I illustrate a cross section of an exemplary PWB assembly with stepped cavity at different stages of a fabrication process, according to an embodiment of the present invention
- FIG. 16 illustrates the steps of an exemplary process for fabricating a LED package including a PWB having a stepped cavity
- FIGS. 17A-17D illustrate a cross section of an exemplary multi-layer LED package at different stages of a fabrication process, according to an embodiment of the present invention.
- the present invention relates to light emitting packages, and methods for making same, wherein the light emitting package comprising at least one light emitting assembly including a printed wired board having one or more heat sink studs integrated therein to form a monolithic integrated base for mounting one or more light sources thereon.
- the term “package” or “LED package” is intended to include, but is not limited to, an LED assembly comprising one LED or an array of LEDs, according to the present invention.
- the term “array” is intended to refer to a plurality of elements, and is not intended to be limited to elements arranged in regular columns and/or rows.
- the LED package may include an array of LED assemblies, with each LED assembly including an array of LED die.
- the one or more light sources comprise light emitting diode (LED) die.
- each of the one or more LED die are mounted directly on a heat sink stud.
- the heat sink stud may be pressed or otherwise attached to the external heat sink.
- the external heat sink may be composed of aluminum, copper, or other suitable material having high thermal conductivity.
- the heat sink studs may be composed of copper, aluminum, or other suitable material with high thermal conductivity.
- a high thermal conductivity material, such as tungsten copper, with a TCE that is close to that of the LED die may be used to reduce thermal mismatch stresses.
- a thermal material such as for example thermal grease or conductive epoxy, may be disposed between the assembly and the external heat sink to strengthen the mechanical and thermal connection therebetween.
- FIG. 1 illustrates an exemplary LED package 100 , shown here with a single LED die 40 , including a PWB 10 having one or more pre-formed through-holes or apertures.
- a heat sink stud or slug 20 is inserted into each of the apertures to form a base assembly 30 for packaging one or more light sources (e.g., LED die 40 ).
- the aperture may be formed in the PWB 10 by drilling, stamping, punching, or other suitable technique.
- the PWB 10 may include any number of parts disposed on a large panel.
- the PWB 10 may be constructed using any of a variety of commonly used PWB materials including, but not limited to, a standard fiberglass reinforced epoxy laminate material such as Flame Retardant 4 (FR4), woven PTFE, polyamide, etc.
- FR4 Flame Retardant 4
- multi-layer PWB structures may be used to minimize total board size, among other design reasons appreciated by one having ordinary skill in the art.
- the PWB 10 has a working temperature of approximately 150 C.
- An exemplary PWB 10 suitable for use in the present invention is the commercially available high temperature fiberglass reinforced epoxy laminate such as Flame Retardant 4-5 (FR4-5).
- FR4-5 Flame Retardant 4-5
- One having ordinary skill in the art will appreciate that other suitable printed wire boards may be used in the present invention, selected in accordance with the desired operating specifications of the assembly.
- a heat sink stud 20 is inserted into each of the apertures of the PWB 10 to form an integral, monolithic base assembly 30 .
- the heat sink stud 20 may be fixed within the aperture of the PWB 10 using an adhesive or by soldering.
- the heat sink stud 20 may be secured in the PWB 10 using a suitable mechanical means to hold the heat sink in place over a variety of environmental conditions, such as temperature changes and mechanical stresses (PWB flexure).
- the outer edge of the heat sink stud 20 may be knurled for fitting the heat sink stud 20 into the aperture of the PWB 10 .
- the knurls may be arranged such that they dig into the PWB 10 to form a fitted connection between the two components.
- the heat sink stud 20 and the aperture of the PWB 10 are shaped and dimensioned such that the heat sink stud 20 may be pressed into the PWB 10 to form a tight friction fit.
- the perimeter edges of the PWB aperture may be plated or lined with a solderable material.
- the heat sink stud 20 may be pressed into the aperture and heated (to approximately 250° C.) causing the solder to flow and bond the heat sink stud 20 to the PWB 10 .
- the heat sink stud 20 may be peened.
- the peened heat sink stud 20 is fitted within the PWB aperture.
- a peening tool may be used to mechanically stretch the perimeter of the heat sink stud 20 such that the heat sink stud 20 is forced into the sides of the aperture and locked in place.
- the heat sink stud 20 may be pressed into the PWB 10 in panel form.
- heat sink stud 20 may be inserted and fixed within the PWB 10 using any combination of techniques described above or otherwise known in the art.
- the heat sink stud 20 may be made of copper, aluminum, molybdenum copper, or other suitable high-thermal conductivity material.
- the heat sink stud 20 may be fabricated using an electrically conductive material or an insulating material, such as, for example, aluminum nitride.
- the assembly 30 may be used as a substrate or base for a light source (or LED) package 100 .
- a light source such as a LED die 40
- the heat generated by the LED die 40 is dissipated by the heat sink stud 20 , thus allowing for high temperature operation of the LED package 100 .
- a heat sink stud 20 material may be selected which has a thermal coefficient of expansion (TCE) that is closely matched to that of the LED die 40 .
- the heat sink stud 20 may comprise tungsten copper, copper molybdenum copper, aluminum nitride, copper, or boron nitride.
- one or more conductors 50 may be provided on the PWB 10 for external electrical connections and for making electrical connections to the LED die 40 , using, for example, wire-bonds 60 .
- the LED package 100 may include a reflector 70 for providing improved light extraction or for beam forming. Arrangement of the reflector 70 may, also provide a cavity surrounding the LED die 40 , as shown in FIG. 1 , that protects the LED die 40 and provides a retention area for encapsulation of the LED die 40 with, for example, an epoxy resin or silicone.
- the reflector 70 may be composed of any suitable material, such as a high-temperature plastic (e.g., a liquid crystal polymer, or other suitable plastic), ceramic, aluminum, or other optically reflective and electrically insulating material.
- the reflector material may also compose electrically conductive materials, such as, for example, aluminum or nickel, provided an electrically insulating layer is disposed between the reflector 70 and each of the one or more PWB conductors 50 .
- the reflector 70 may be attached to the PWB 10 using any suitable adhesive.
- the LED die 40 may be attached to the heat sink stud 20 using any common chip-and-wire materials, such as an epoxy or solder. Encapsulation of the LED die 40 may be carried out by dispensing an encapsulant 80 into the reflector 70 .
- the optical element may be a transparent dome, disposed on and attached to the LED package 100 as a secondary component. The transparent dome may be attached in the LED package 100 using the encapsulant 80 as an adhesive, using a secondary adhesive, or by any suitable mechanical retention means.
- FIG. 1 shows an LED package 100 including a single LED die 40 , one having ordinary skill in the art will appreciate that the package may include any number of LED die 40 .
- FIG. 2 shows a top view of an exemplary LED package 100 , according to an embodiment of the present invention. As shown, external electrical connections may be made to the LED die 40 by attaching it to the one or more PWB conductors 50 .
- FIG. 3 shows an exemplary LED package including an array of LED assemblies, according to an embodiment of the present invention.
- pairs of LED die 40 are connected to separate heat sink studs 20 to form LED assemblies.
- the array of LED assemblies are packaged together into a single LED array package 200 .
- Spreading the heat sink studs 20 out over the PWB 10 reduces any stress that may result from a TCE mismatch between the materials of the PWB 10 and one or more of the heat sink studs 20 .
- Mounting holes 11 are provided for part-mounting to ensure a mechanical connection and to minimize the resistance of the thermal connection both initially, and over time.
- FIG. 4 depicts an exemplary LED array package 300 wherein the PWB 10 of the LED array package 300 includes terminals (e.g., metallized inset terminations), known as castellations 310 , adapted for making one or more external connections (e.g, physical and/or electrical connections).
- the castellations 310 are useful for assembling the LED array package 300 onto a secondary component, such as a larger PWB (not shown in FIG. 4 ), using, for example, Surface Mount Technology (SMT) techniques.
- SMT Surface Mount Technology
- the castellations 310 may be soldered or plated, to facilitate the mounting of the entire LED package 310 to another PWB or other secondary component.
- FIG. 5 shows a side view of the LED package 300 depicted in FIG. 4 (“daughter board”) mounted and/or soldered onto a larger PWB 400 (“mother board”) using common SMT techniques.
- the thermal connections to the heat sink studs may be made using any suitable material having a low thermal resistance, such as, for example, conductive epoxy, thermal grease, or solder.
- solder or epoxy fillets 315 may be used to connect the daughter board 300 , at the sites of the one or more castellations, to a conductive region 320 of the mother board 400 .
- FIG. 6 shows yet another embodiment of the present invention wherein the LED package 500 includes a sheet-like heat sink which is formed with concavities which align or register with one or more apertures of the PWB 10 , herein referred to as a formed heat sink 520 .
- a formed heat sink 520 i.e., a concavity
- the end portions of the formed heat sink 520 may extend out of the aperture and are attached to the surface of the PWB 10 .
- the ends of the formed heat sink 520 may be attached directly to the surface of the PWB 10 , or attached to a PWB conductor 50 (as shown in FIG. 10 ). As shown, the formed heat sink 520 may be arranged such that it forms a pocket or cavity for disposal therein of one or more LED die 40 . The formed heat sink 520 may be attached to the PWB 10 using any suitable adhesive or mechanical attachment technique.
- the cavity portion of the formed heat sink 520 may be composed of, or coated with, a reflective material, such as for example aluminum or nickel, to provide a reflective cavity 70 around the one or more LED die 40 .
- the formed heat sink cavity may be filled with an encapsulant 80 to protect and manage the light extraction from the LED die 40 .
- the formed heat sink 520 may be composed of any suitable thermally conductive material, such as, for example, aluminum or copper.
- the sheet-type heat sink layer 520 may also be composed of a material that is both thermally conductive and has a TCE that is closely matched to the LED die 40 , such as tungsten copper or copper-molybdenum-copper.
- FIG. 7 shows a top view of a LED array package 600 including a formed heat sink 520 , as described in connection with FIG. 6 above.
- the formed heat sink 520 may be isolated (i.e., one heat sink per LED die 40 or LED cluster 45 ).
- the formed heat sink 520 may include one or more openings for allowing the connection of the one or more wire bonds 60 to the PWB conductors 50 .
- a solder mask, or other electrically insulating layer may be provided between the formed heat sink 520 and the PWB conductors 50 to prevent making an electrical connection between the electrical conductor and the formed heat sink 520 .
- FIG. 8 depicts a LED package 600 wherein the PWB 10 is mounted above the formed heat sink 520 , which is formed with concavities in registration with the apertures of the PWB 10 .
- the formed heat sink 520 may be shaped such that it forms a cavity 70 in which the one or more LED die 40 may be disposed. By disposing the formed heat sink 520 below the PWB 10 , an improved thermal connection may be made to an external heat sink.
- the formed heat sink 520 may be attached to the PWB 10 using any suitable means, including an adhesive or a mechanical means.
- FIG. 9 shows an LED package 600 according to embodiment of the present invention in a typical connection arrangement with an external heat sink 720 .
- Materials and construction for the embodiment depicted in FIGS. 8 and 9 are similar to the those depicted in FIG. 6 and described in detail above.
- one or more holes, or eyelets 725 may be punched or otherwise formed in the formed heat sink 520 .
- the eyelets are adapted to accept a securing mechanism, such as a screw or rivet, for connecting the formed heat sink 520 .
- a securing mechanism such as a screw or rivet
- one or more clamping screws 730 may be used to secure together the formed heat sink 520 , the PWB 10 , and the external heat sink 720 .
- the LED package 600 and the external heat sink 720 may be joined using a suitable adhesive, such as, for example, thermal grease 735 .
- FIG. 10 illustrates an embodiment of the present invention wherein one or more grooves, notches, or holes are formed in the surface of an external heat sink 820 .
- One or more heat sink studs 20 are pressed into the grooves of the external heat sink 820 .
- a PWB 10 having openings or apertures aligning with the heat sink studs 20 is laid over the protruding heat sink studs 20 and attached to the external heat sink 820 .
- the LED dice 40 are then mounted on the heat sink studs 20 .
- reflectors 70 are arranged around each of the LED dice 40 , using, for example, an adhesive. Further, the LED dice 40 may be electrically connected to the PWB conductor 50 using one or more wire bonds 60 , and may be encapsulated by encapsulant 80 .
- the LED package 800 may be attached to the external heat sink 820 by a low thermal resistance connection where the heat sink stud 20 is pressed into the external heat sink 820 , and between the external heat sink stud 820 and the PWB 10 .
- the low thermal resistance attachment may be made using, for example, a thermally-conductive epoxy, thermal grease, solder, or other suitable material.
- Heat produced by each of the one or more LED die 40 during operation is carried away from the LED die 40 through the heat sink stud 20 , and into the external heat sink 820 .
- removing the heat generated by the LED die 40 increases both the LED die life and the light output. Another advantage of this arrangement is that it eliminates the additional expenses associated with adding the thermal resistance of a secondary assembly.
- FIG. 10 depicts the LED package 800 attached to the external heat sink 820 , one having ordinary skill in the art will appreciate that the LED package 800 may be attached to or mounted on any suitable component.
- FIG. 11 illustrates a LED package 900 according to an embodiment of the present invention, wherein a metal layer 920 is disposed underlying a PWB 930 .
- the metal layer 920 may be attached or laminated to the PWB 930 using any suitable PWB laminate (e.g., pressure sensitive adhesive or pre-punched pre-preg material) according to any suitable lamination process.
- the metal layer 920 may be composed of any suitable material having a high thermal conductivity (TC) and a low TCE, such as, for example, copper.
- TC thermal conductivity
- TCE low TCE
- the LED package 900 further includes one or more LED die 40 arranged on an isolator 910 .
- the isolator 910 and LED die 40 assembly are disposed in an aperture or cavity formed in a PWB 930 , as shown in FIG. 11 .
- the one or more LED die 40 may be attached to the isolator 910 using any suitable attachment means including, but not limited to, a conductive epoxy, a solder, etc.
- the isolator 910 may be attached directly to the metal layer 920 , according to any suitable attachment means or material, such as conductive epoxy, solder, brazing, mechanical means, etc.
- any suitable attachment means or material such as conductive epoxy, solder, brazing, mechanical means, etc.
- the isolator 910 and LED die 40 assembly may be disposed on the metal layer 920 , followed by the disposition of the PWB 930 onto the metal layer 910 such that the aperture or cavity of the PWB 930 aligns with or corresponds to the isolator 910 and LED die 40 assembly.
- the PWB 930 may be disposed on the metal layer 920 , followed by the disposition of the isolator 910 and LED die 40 assembly in the aperture or cavity of the PWB 930 .
- the PWB 930 may comprise one or more layers, and may include one or more PWB conductor layers 930 A.
- the LED die 40 may be electrically connected to the PWB conductor layer(s) 930 A using any suitable connection means, such as a wire bond 940 , as shown in FIG. 11 .
- a solder pad 950 may be disposed on the PWB 930 .
- the isolator 910 is composed of a material adapted to tolerate expansion excursions cause by the heat produced by the attached LED die 40 .
- the isolator 910 is composed of a material that has a TCE that approximately matches the TCE of the LED die 40 .
- Suitable TCE-matching materials include, but are not limited to, copper-molybdenum-copper (CuMoCu), tungsten-copper (WCu), aluminum-silicon-carbide (AlSiC), aluminum nitride (AlN), silicon (Si), beryllium oxide (BeO), diamond, or other material that has a TCE that is matched to that of the LED.
- the LED package 900 may include a reflector 960 disposed on a layer of the PWB 930 to provide improved light extraction and/or for efficient beam forming.
- the reflector 960 may be composed of any suitable high temperature plastic (e.g., liquid crystal polymer), a ceramic material, or other optically reflective and electrically insulating material.
- the reflector 960 may be attached to the PWB 930 using any suitable adhesive.
- an encapsulant 970 may be disposed in the cavity of the PWB 930 such that the encapsulant 970 covers all or a portion of the LED die 40 .
- the encapsulant material may be composed of any suitable transparent optical material.
- a secondary optical element 980 such as a transparent dome, may be disposed over the LED die 40 .
- the optical element may be attached in the LED package 900 using an encapsulant 970 or other adhesive.
- a plurality of LED dice 40 may be mounted on the isolator 910 , to form an LED assembly including an array of LED dice 40 , included within a single LED package 900 .
- FIG. 13 illustrates an exemplary LED package 1000 , according to an embodiment of the present invention, which is similar to LED package 900 described above in conjunction with FIG. 12 .
- the one or more LED die 40 are attached directly to a metal layer 1020 composed of a material having a TCE that matches that of the LED die 40 .
- the metal layer 1020 is preferably a low TCE material, such as, for example, copper-molybdenum-copper (CuMoCu), tungsten-copper (WCu), aluminum-silicon-carbide (AlSiC), aluminum nitride (AlN), silicon (Si), beryllium oxide (BeO), diamond, or other material that has a TCE that is matched to that of the LED die 40 .
- the LED die 40 may be attached or adhered to the TCE-matching metal layer 1020 using a conductive epoxy, solder, or other suitable attachment means or material.
- the heat generated by the LED die 40 and the stresses associated with the thermal expansion of the LED die 40 and the metal layer 1020 are efficiently managed by using the TCE-matching metal layer 1020 .
- the one or more LED die 40 are disposed within a cavity of a PWB 1030 .
- the PWB 1030 may be comprised of one or more layers, and include a conductive layer 1030 A that is electrically connected to the LED die 40 using any suitable connection means, such as, for example, a wire bond 1040 .
- the LED package 1000 may include a reflector 1060 attached to the PWB 1030 and at least partially surrounding the LED die 40 .
- the LED package 1000 may comprise an encapsulant 1070 dispensed in the cavity of the PWB 1030 and/or the reflector 1060 , such that it at least partially covers the LED die 40 .
- a method for fabricating a multi-layer PWB assembly having a stepped cavity formed therein, particularly suited for housing light emitting devices, such as, for example, one or more LED die 40 .
- the stepped cavity is buried in the PWB assembly.
- the present invention further relates to a PWB assembly including a stepped cavity made according to the fabrication method.
- the present application describes a method for fabricating a LED package comprising a PWB assembly having a stepped cavity
- FIG. 14 illustrates an exemplary process for fabricating a PWB assembly having a stepped cavity, according to an embodiment of the present invention.
- FIGS. 15A-15I depict an exemplary PWB assembly at different stages of the fabrication process illustrated in FIG. 14 and described in detail below.
- FIG. 15I depicts an exemplary PWB assembly 2000 including a stepped cavity 1900 , fabricated according to an embodiment of the present invention.
- step 1 a number of PWB layers 1500 to be assembled are provided.
- the exemplary embodiment described herein and illustrated in FIGS. 14 and 15 A- 15 I includes three PWB layers 1500 A, 1500 B, 1500 C, one having ordinary skill in the art will appreciate that the PWB assembly 2000 may include any suitable number of PWB layers 1500 .
- each of the PWB layers 1500 A, 1500 B, 1500 C may comprise any suitable number of layers.
- each of the PWB layers 1500 A, 1500 B, 1500 C comprises a double sided FR4 (or FR4-5) board, which includes a dielectric layer (e.g., a layer of FR4 material) 1502 disposed between a top metal layer 1501 and a bottom metal layer 1503 , as shown in FIG. 15A .
- the metal layers 1501 , 1503 of the PWB layer 1500 may be composed of any suitable metal, including but not limited to copper.
- the PWB layers 1500 A, 1500 B, 1500 C may be of any suitable thickness (e.g., approximately 0.002 inches thick). According to an embodiment of the present invention, the bottom-most PWB layer ( 1500 C in FIG. 15A ) is thicker than the other PWB layers (e.g., approximately 0.004 inches thick).
- one or more of metal layers 1501 , 1503 are patterned with wiring traces appropriately to enable assembly of the PWB layers such that the metal portions of the individual PWB layers are properly aligned for desired interconnection.
- the bottom metal layer 1503 A of PWB layer 1500 A is patterned to include features adapted for assembly with adjacent PWB layer 1500 B, and so on, as described in detail below.
- one or more of the metal layers 1501 , 1503 may be plated with a suitable metal for electrical connectivity with a light emitting device.
- a suitable metal for electrical connectivity with a light emitting device Any suitable material may be used for the plating, such as, for example, nickel or gold.
- step 4 the process of forming a stepped cavity is initiated. Specifically, an aperture is formed in the dielectric layer 1502 of each of the one or more intermediate PWB layers. In the exemplary embodiment illustrated in FIG. 15C , the aperture or hole is formed in the dielectric layer 1502 B of PWB layer 1500 B.
- the aperture may be of any suitable size and/or shape, such as a circle, square, etc.
- the aperture may be formed according to any suitable method, such as, for example, punching, routing or drilling.
- the plurality of PWB layers 1500 A, 1500 B, 1500 C are laminated together, as shown in FIG. 15D to form a multi-layer PWB structure.
- a suitable adhesive layer 1600 is disposed in between each adjacent PWB layer, and the layers are pressed together.
- the adhesive layer 1600 may be comprised of any suitable adhesive material.
- the adhesive layer 1600 is composed of a suitable pressure sensitive adhesive (PSA), such as, for example, 3MTM High Tack Tape PSA 3794.
- PSA pressure sensitive adhesive
- the adhesive layer 1600 may be composed of a pre-punched pre-preg material, such as, for example, Arlon 49N and Arlon 37N.
- via holes may be formed through the PWB layers 1500 A, 1500 B, 1500 C according to any suitable method (e.g., drilling), as shown in FIG. 15E .
- the via holes may be plated with a suitable metallization material 1700 (e.g., copper) for electrical continuity, as shown in FIG. 15F .
- step 6 formation of the stepped cavity in the PWB assembly is finalized, by removing at least a portion of the top and bottom dielectric layers 1502 A and 1502 B.
- a portion of the top dielectric layer 1502 A is removed using any suitable technique or tool, such as, for example, a piercing tool, a routing tool or a flat bottom drill, as shown in FIG. 15G .
- a portion of the bottom dielectric layer 1502 C is removed, as shown in FIG. 15H .
- the PWB assembly 2000 including a stepped cavity 1900 is formed, as shown in FIG. 15I .
- the PWB assembly 2000 with stepped cavity 1900 may be used to fabricate a LED package, particularly those suited for high temperature operation.
- FIG. 16 illustrates an exemplary process for the fabrication of a LED package 5000 (shown in FIG. 17D ) including a stepped-cavity PWB assembly 2000 .
- a LED package 5000 shown in FIG. 17D
- a stepped-cavity PWB assembly 2000 One having ordinary skill in the art will appreciate that the steps set forth in the process illustrated in FIG. 16 , and described in detail below, do not necessarily need to be performed in the order provided.
- a layer which acts to electrically isolate the electrical connections of the PWB assembly 2000 from a metal base 3000 .
- the “insulating layer” 2500 may be composed of any suitable dielectric material.
- the insulating layer 2500 may be comprised of a PWB layer.
- the PWB layer may be composed of any suitable material, such as for example, a fiberglass reinforced material (e.g., FR4 board) or a high temperature fiberglass reinforced material (e.g., FR4-5 board).
- the insulating layer 2500 includes an aperture or hole 2510 adapted to correspond to the bottommost opening of the stepped cavity of the PWB assembly 2000 , as shown in FIG. 17A .
- the insulating layer 2500 may be comprised of one or more pre-preg layers having a desired voltage breakdown. Preferably, a breakdown voltage of greater than or equal to 250 Volts is maintained.
- the insulating layer 2500 may be of any suitable thickness. Preferably, the insulating layer 2500 is at least approximately 0.002 inches thick.
- the metal base 3000 is provided which serves as a heat sink in the LED package 5000 .
- the metal base 3000 may be composed of any suitable metal, such as, for example, copper.
- the metal base 3000 may be of any suitable thickness sufficient to manage the heat generated by the one or more LED die of the LED package 5000 .
- the insulating layer 2500 advantageously isolates the plated vias of the PWB assembly 2000 from the metal base 3000 .
- step S 2 the PWB assembly 2000 , the insulating layer 2500 , and the metal base 3000 are laminated together, as shown in FIG. 17B .
- one or more laminate layers 2800 are disposed between the PWB assembly 2000 and the insulating layer 2500 , and the insulating layer 2500 and the metal base 3000 .
- the laminate layers 2800 include an aperture or opening which corresponds to the bottommost opening of the stepped cavity of the PWB assembly 2000 and the aperture of the insulating layer 2500 , as shown in FIG. 17A .
- the laminate layers 2800 may be composed of any suitable laminate material, including, but not limited to, a pressure sensitive adhesive, a pre-punched pre-preg material, or a combination of both.
- the top dielectric layer 1502 A may be left in place until after the PWB assembly 2000 is laminated to the metal base 3000 .
- the PWB assembly 2000 is a more robust and stronger assembly, able to withstand process variations experienced during the lamination process.
- leaving the top dielectric layer 1502 A intact during integration of the PWB assembly 2000 into the LED package 5000 may result in less pre-punched pre-preg material running out onto the PWB layers and/or the metal base, and less deformation of the stepped cavity 1900 due to the stresses of the lamination process.
- one or more dams may be applied to the laminate layers 2800 .
- the dams 2900 shown in FIG. 17C , may be fabricated according to any suitable technique, including, but not limited to, a photo-imageable solder mask technique, a screen printed maskant technique, or by pre-scoring the laminate layers 2800 to include the one or more dams.
- the dams 2900 may be composed of any suitable material, such as, for example, DuPont Vacrel® 8100 Series Photopolymer Dry Film Solder Mask.
- step S 4 one or more LED die 40 are introduced into the stepped cavity of the LED package 5000 .
- the one or more LED die 40 may be disposed directly on the metal base 3000 , or, alternatively, the LED die 40 may be disposed on an interposer 3100 , as shown in FIG. 17D . If the interposer 3100 is not included, one having ordinary skill in the art will appreciate that the metal base 3000 may be advantageously composed of CuMoCu, WCu, or other suitable TCE-matching material.
- the one or more LED die 40 may be electrically connected to a metal layer of the PWB assembly 2000 by any suitable means, including, but not limited to, wire bonds 3120 .
- the LED package 5000 may include a reflector 3130 which reflects at least a portion of the light emitted by the one or more LED die 40 .
- the reflector 3130 may be composed of any suitable reflective material, including, but not limited to, aluminum, polycarbonate, and liquid crystal polymer (LCP).
- the LED package 5000 may include an optical element 3140 , such as a lens.
- the optical element 3140 may be composed of any suitable material, including but not limited to, glass, silicone and polycarbonate.
- the reflector 3130 and the optical element 3140 may be adapted to produce a desired radiation pattern, such as, for example, a focused, narrow light beam.
- the pattern forming reflector 3130 may be molded or machined plastic (metallized or un-metallized), molded or machined aluminum, other suitable reflective material, or a stamped metal part with a reflective surface.
- the reflector 3130 or reflective surface may be roughened to improve color mixing and avoid creating undesirable, non-uniform light output.
Abstract
Description
- This application claims the benefit of U.S. Provisional Application No. 60/694,788 filed on Jun. 27, 2005, U.S. Provisional Application No. 60/738,478 filed Nov. 21, 2005, and U.S. Provisional Application No. 60/763,828 filed Jan. 31, 2006. U.S. Provisional Application Nos. 60/694,788, 60/738,478, and 60/763,828 are hereby incorporated by reference herein.
- The present invention relates generally to a light emitting diode (LED) package and method for making same, and, in particular to a LED package adapted for high temperature operation.
- Conventional light emitting diode (LED) packages include a specialized, moldable plastic housing having a separate transparent cover exhibiting specific optical properties. Generally, these LED packages are designed exclusively for direct surface mount technology (SMT) connection to a printed wire board (PWB). However, because conventional packages require a special, molded plastic housing (i.e., liquid crystal polymer) and optical element, the packages are not well suited for multi-die arrays that may be easily, quickly, and inexpensively modified to suit a particular lighting application.
- Another fabrication and design challenge faced by high-temperature operation LED packages is the need to effectively manage the heat generated by the array of LEDs. Traditionally, to deal with heat management issues, conventional LED packages include a large, homogeneous metal carrier or heat sink, which spans the entire bottom of the LED package. The metal carrier is generally composed of a relatively expensive material (e.g., molybdenum copper), adding significant cost to the fabrication of the LED package. Accordingly, there is a need in the art for an improved light emitting package adapted for high temperature operation in a variety of lighting applications.
- The present invention relates to a LED package assembly including a PWB having one or more through-holes or apertures. Inserted into each of the apertures is a heat sink stud to form an integrated/monolithic assembly. According to an embodiment of the present invention, one or more light sources (i.e., LED die) may be placed (directly) on the heat sink stud, which carries away the heat generated by the LED die. In application, the assembly may be mounted on an external component, such as an external heat sink. Advantageously, the use of discretely-sized heat sink studs, integrated into the PWB allows for a compact, versatile and cost-efficient construction.
- According to an embodiment of the present invention, the LED package assembly utilizes PWB techniques, SMT assembly techniques, and/or chip-on-board (COB) semiconductor die attachment techniques. Advantageously, the LED package assembly of the present invention reduces the cost and design cycle time for light emitting components, and is suitable for use in a variety of lighting applications including but not limited to general illumination, accent lighting, electronic display illumination, machine vision, etc. Advantageously, an array of LED die may be arranged in a single, low-cost, versatile package which is operable in high temperature environments.
- According to an embodiment of the present invention, a LED package may be fabricated by thermally coupling one or more heat sink studs to an external heat sink, placing a printed wire board (substrate) over the external heat sink, wherein the printed wire board (substrate) includes one or more openings/apertures in registration with the one or more heat sink studs, and mounting one or more LED die to each of the one or more heat sink studs, wherein the heat sink studs are embedded at least partially in the external heat sink.
- The one or more LED die are electrically connected to the printed wire board, preferably to one or more conductors attached to the PWB, preferably by a wire bond. Optionally, one or more reflectors may be arranged on the printed wire board, such that the one or more reflectors form a cavity at least partially surrounding the one or more LED die. An encapsulant material may be introduced into the cavity in order to cover or encapsulate the LED die.
- According to an embodiment of the present invention, the one or more heat sink studs may be thermally coupled to the external heat sink using a thermal grease. In addition, the PWB may include one or more castellations, adapted to allow the LED package to be assembled onto a secondary component, such as a mother PWB.
- According to an embodiment of the present invention, an outer edge of the heat sink studs may be knurled to allow the heat sink studs to be fitted within the corresponding opening of the printed wire board. Optionally, the openings of the PWB may plated with a solderable material, such that the solderable material may be flowed to join the PWB and the heat sink stud.
- According to an embodiment of the present invention, a LED package may comprise an external heat sink, one or more heat sink studs in thermal contact with the external heat sink, a printed wire board overlying the external heat sink, wherein the printed wire board includes one or more openings aligned with the one or more heat sink studs, and one or more LED die mounted on each of the one or more heat sink studs. The one or more heat sink studs may be embedded in the external heat sink. In addition, one or more reflectors may be attached to the printed wire board, wherein each of the one or more reflectors forms a cavity around the one or more LED die. Preferably, the printed wire board may comprise a standard fiberglass reinforced epoxy laminate material (FR4) or a high temperature fiberglass reinforced epoxy laminate material (FR4-5) and the LED die is composed of a material having a thermal coefficient of expansion (TCE) that is closely matched to that of the heat sink stud material. Preferably, the one or more sink studs comprise a high thermal conductivity material, such as copper molybdenum copper. Optionally, the LED package may comprise multi-color LEDs.
- An exemplary LED package according to an embodiment of the present invention may comprise an external heat sink, a formed heat sink thermally connected to the external heat sink, a PWB mounted above the formed heat sink, and one or more LED die mounted on the formed heat sink.
- An exemplary LED package according to an embodiment of the present invention may comprise a metal layer, a PWB having one or more layers and a cavity, wherein the printed wire board is mounted on the metal layer, one or more isolators or interposers disposed in the cavity of the PWB and mounted on the metal layer, and one or more LED die mounted on the isolator wherein the isolator comprises a material having a TCE that matches that of the one or more LED die mounted thereon. Preferably, the metal layer may comprise copper. Optionally, an encapsulant may be disposed over the one or more LED die. According to another option, the LED assembly may further comprise a reflector attached to the PWB.
- According to an embodiment of the present invention, a method is provided for fabricating an LED assembly including a stepped cavity formed or buried in a multi-layer PWB structure. The multi-layer PWB structure includes a plurality of layers of PWB secured together using one or more adhesive layers. According to an embodiment of the present invention, the adhesive is a pressure sensitive adhesive (PSA). According to another embodiment of the present invention the adhesive layers are comprised of pre-impregnated composite fiber, herein referred to as “pre-preg” material.
- The features and advantages of the present invention will be apparent from the description of the preferred embodiment(s) presented below considered in conjunction with the attached figures, of which:
-
FIG. 1 shows a side cross-section view of a LED package, according to an embodiment of the present invention; -
FIG. 2 shows a top view of a LED package, according to an embodiment of the present invention; -
FIG. 3 illustrates a top view of a LED package including an array of LED assemblies, according to an embodiment of the present invention; -
FIG. 4 shows a top view of a LED package including an array of LED assemblies, wherein the package includes castellations for SMT-type mounting, according to an embodiment of the present invention; -
FIG. 5 illustrates a side view of a LED package including castellations mounted upon a secondary PWB using a SMT technique, according to an embodiment of the present invention; -
FIG. 6 shows a side cross section view of a LED package including a formed heat sink providing a reflective cavity, according to an embodiment of the present invention; -
FIG. 7 depicts a top view of a LED array package including a formed heat sink, according to an embodiment of the present invention; -
FIG. 8 shows a side cross section view of a LED package including a PWB arranged above a formed heat sink, according to an embodiment of the present invention; -
FIG. 9 shows a side cross section view of a LED array package including a PWB arranged above a formed heat sink thermally coupled to an external heat sink, according to an embodiment of the present invention; -
FIG. 10 shows a side cross section view of a LED array package including a direct external heat sink connection, according to an embodiment of the present invention; -
FIG. 11 shows a side cross section view of a LED package including an isolator, according to an embodiment of the present invention; -
FIG. 12 shows a side cross section view of a LED package including an isolator and an optical element, according to an embodiment of the present invention; -
FIG. 13 shows a side cross section view of a LED package including one or more LED die disposed directly on a metal layer composed of a TCE matching material; -
FIG. 14 illustrates the steps of an exemplary process for fabricating a PWB assembly having a stepped cavity, according to an embodiment of the present invention; -
FIG. 15A-15I illustrate a cross section of an exemplary PWB assembly with stepped cavity at different stages of a fabrication process, according to an embodiment of the present invention; -
FIG. 16 illustrates the steps of an exemplary process for fabricating a LED package including a PWB having a stepped cavity; and -
FIGS. 17A-17D illustrate a cross section of an exemplary multi-layer LED package at different stages of a fabrication process, according to an embodiment of the present invention. - It is to be understood that these figures are representative in nature for purposes of illustrating the concepts of the invention and may not be to scale, and are not intended to be exacting in all details.
- The present invention relates to light emitting packages, and methods for making same, wherein the light emitting package comprising at least one light emitting assembly including a printed wired board having one or more heat sink studs integrated therein to form a monolithic integrated base for mounting one or more light sources thereon. As used herein, the term “package” or “LED package” is intended to include, but is not limited to, an LED assembly comprising one LED or an array of LEDs, according to the present invention. As used herein, the term “array” is intended to refer to a plurality of elements, and is not intended to be limited to elements arranged in regular columns and/or rows. According to an embodiment of the present invention, the LED package may include an array of LED assemblies, with each LED assembly including an array of LED die.
- According to an embodiment of the present invention, the one or more light sources comprise light emitting diode (LED) die. According to this embodiment of the present invention, each of the one or more LED die are mounted directly on a heat sink stud. The heat sink stud may be pressed or otherwise attached to the external heat sink. The external heat sink may be composed of aluminum, copper, or other suitable material having high thermal conductivity. The heat sink studs may be composed of copper, aluminum, or other suitable material with high thermal conductivity. A high thermal conductivity material, such as tungsten copper, with a TCE that is close to that of the LED die may be used to reduce thermal mismatch stresses. Preferably, a thermal material, such as for example thermal grease or conductive epoxy, may be disposed between the assembly and the external heat sink to strengthen the mechanical and thermal connection therebetween.
- The present invention relates to a LED package fabricated using widely-available PWB material as a basis for the LED package.
FIG. 1 illustrates anexemplary LED package 100, shown here with a single LED die 40, including aPWB 10 having one or more pre-formed through-holes or apertures. A heat sink stud or slug 20 is inserted into each of the apertures to form abase assembly 30 for packaging one or more light sources (e.g., LED die 40). One having ordinary skill in the art will appreciate that the aperture may be formed in thePWB 10 by drilling, stamping, punching, or other suitable technique. According to an embodiment of the present invention, thePWB 10 may include any number of parts disposed on a large panel. - The
PWB 10 may be constructed using any of a variety of commonly used PWB materials including, but not limited to, a standard fiberglass reinforced epoxy laminate material such as Flame Retardant 4 (FR4), woven PTFE, polyamide, etc. Optionally, multi-layer PWB structures may be used to minimize total board size, among other design reasons appreciated by one having ordinary skill in the art. - In a preferred embodiment, the
PWB 10 has a working temperature of approximately 150 C. Anexemplary PWB 10 suitable for use in the present invention is the commercially available high temperature fiberglass reinforced epoxy laminate such as Flame Retardant 4-5 (FR4-5). One having ordinary skill in the art will appreciate that other suitable printed wire boards may be used in the present invention, selected in accordance with the desired operating specifications of the assembly. - A
heat sink stud 20 is inserted into each of the apertures of thePWB 10 to form an integral,monolithic base assembly 30. One having ordinary skill in the art will appreciate that theheat sink stud 20 may be fixed within the aperture of thePWB 10 using an adhesive or by soldering. Alternatively, theheat sink stud 20 may be secured in thePWB 10 using a suitable mechanical means to hold the heat sink in place over a variety of environmental conditions, such as temperature changes and mechanical stresses (PWB flexure). - According to an embodiment of the present invention, the outer edge of the
heat sink stud 20 may be knurled for fitting theheat sink stud 20 into the aperture of thePWB 10. The knurls may be arranged such that they dig into thePWB 10 to form a fitted connection between the two components. - According to an embodiment of the present invention, the
heat sink stud 20 and the aperture of thePWB 10 are shaped and dimensioned such that theheat sink stud 20 may be pressed into thePWB 10 to form a tight friction fit. - According to another embodiment, the perimeter edges of the PWB aperture may be plated or lined with a solderable material. To form the
base assembly 30, theheat sink stud 20 may be pressed into the aperture and heated (to approximately 250° C.) causing the solder to flow and bond theheat sink stud 20 to thePWB 10. - According to yet another embodiment, the
heat sink stud 20 may be peened. The peenedheat sink stud 20 is fitted within the PWB aperture. Next, a peening tool may be used to mechanically stretch the perimeter of theheat sink stud 20 such that theheat sink stud 20 is forced into the sides of the aperture and locked in place. Optionally, theheat sink stud 20 may be pressed into thePWB 10 in panel form. - One having ordinary skill in the art will appreciate that the
heat sink stud 20 may be inserted and fixed within thePWB 10 using any combination of techniques described above or otherwise known in the art. - According to an embodiment of the present invention, the
heat sink stud 20 may be made of copper, aluminum, molybdenum copper, or other suitable high-thermal conductivity material. Optionally, theheat sink stud 20 may be fabricated using an electrically conductive material or an insulating material, such as, for example, aluminum nitride. - Referring to
FIG. 1 , theassembly 30 may be used as a substrate or base for a light source (or LED)package 100. According to an embodiment of the present invention, a light source, such as aLED die 40, may be placed directly on theheat sink stud 20 of theassembly 30. According to this arrangement, the heat generated by the LED die 40 is dissipated by theheat sink stud 20, thus allowing for high temperature operation of theLED package 100. Advantageously, in order to improve LED die performance reliability, aheat sink stud 20 material may be selected which has a thermal coefficient of expansion (TCE) that is closely matched to that of the LED die 40. For example, theheat sink stud 20 may comprise tungsten copper, copper molybdenum copper, aluminum nitride, copper, or boron nitride. - According to an embodiment of the present invention, one or
more conductors 50 may be provided on thePWB 10 for external electrical connections and for making electrical connections to the LED die 40, using, for example, wire-bonds 60. - The
LED package 100 may include areflector 70 for providing improved light extraction or for beam forming. Arrangement of thereflector 70 may, also provide a cavity surrounding the LED die 40, as shown inFIG. 1 , that protects the LED die 40 and provides a retention area for encapsulation of the LED die 40 with, for example, an epoxy resin or silicone. Thereflector 70 may be composed of any suitable material, such as a high-temperature plastic (e.g., a liquid crystal polymer, or other suitable plastic), ceramic, aluminum, or other optically reflective and electrically insulating material. Optionally, the reflector material may also compose electrically conductive materials, such as, for example, aluminum or nickel, provided an electrically insulating layer is disposed between thereflector 70 and each of the one ormore PWB conductors 50. Optionally, thereflector 70 may be attached to thePWB 10 using any suitable adhesive. - According to an embodiment of the present invention, the LED die 40 may be attached to the
heat sink stud 20 using any common chip-and-wire materials, such as an epoxy or solder. Encapsulation of the LED die 40 may be carried out by dispensing anencapsulant 80 into thereflector 70. Optionally, the optical element may be a transparent dome, disposed on and attached to theLED package 100 as a secondary component. The transparent dome may be attached in theLED package 100 using theencapsulant 80 as an adhesive, using a secondary adhesive, or by any suitable mechanical retention means. AlthoughFIG. 1 shows anLED package 100 including a single LED die 40, one having ordinary skill in the art will appreciate that the package may include any number of LED die 40. -
FIG. 2 shows a top view of anexemplary LED package 100, according to an embodiment of the present invention. As shown, external electrical connections may be made to the LED die 40 by attaching it to the one ormore PWB conductors 50. -
FIG. 3 shows an exemplary LED package including an array of LED assemblies, according to an embodiment of the present invention. As shown inFIG. 3 , pairs of LED die 40 are connected to separateheat sink studs 20 to form LED assemblies. The array of LED assemblies are packaged together into a singleLED array package 200. Spreading theheat sink studs 20 out over thePWB 10 reduces any stress that may result from a TCE mismatch between the materials of thePWB 10 and one or more of theheat sink studs 20. Mountingholes 11 are provided for part-mounting to ensure a mechanical connection and to minimize the resistance of the thermal connection both initially, and over time. -
FIG. 4 depicts an exemplaryLED array package 300 wherein thePWB 10 of theLED array package 300 includes terminals (e.g., metallized inset terminations), known ascastellations 310, adapted for making one or more external connections (e.g, physical and/or electrical connections). Thecastellations 310 are useful for assembling theLED array package 300 onto a secondary component, such as a larger PWB (not shown inFIG. 4 ), using, for example, Surface Mount Technology (SMT) techniques. Optionally, thecastellations 310 may be soldered or plated, to facilitate the mounting of theentire LED package 310 to another PWB or other secondary component. -
FIG. 5 shows a side view of theLED package 300 depicted inFIG. 4 (“daughter board”) mounted and/or soldered onto a larger PWB 400 (“mother board”) using common SMT techniques. The thermal connections to the heat sink studs may be made using any suitable material having a low thermal resistance, such as, for example, conductive epoxy, thermal grease, or solder. According to an embodiment of the present invention, solder orepoxy fillets 315 may be used to connect thedaughter board 300, at the sites of the one or more castellations, to aconductive region 320 of themother board 400. -
FIG. 6 shows yet another embodiment of the present invention wherein theLED package 500 includes a sheet-like heat sink which is formed with concavities which align or register with one or more apertures of thePWB 10, herein referred to as a formedheat sink 520. According to this embodiment of the present invention, at least a portion of the formed heat sink 520 (i.e., a concavity) is pressed into or otherwise inserted into the apertures of thePWB 10. The end portions of the formedheat sink 520 may extend out of the aperture and are attached to the surface of thePWB 10. One having ordinary skill in the art will appreciate that the ends of the formedheat sink 520 may be attached directly to the surface of thePWB 10, or attached to a PWB conductor 50 (as shown inFIG. 10 ). As shown, the formedheat sink 520 may be arranged such that it forms a pocket or cavity for disposal therein of one or more LED die 40. The formedheat sink 520 may be attached to thePWB 10 using any suitable adhesive or mechanical attachment technique. - Optionally, the cavity portion of the formed
heat sink 520 may be composed of, or coated with, a reflective material, such as for example aluminum or nickel, to provide areflective cavity 70 around the one or more LED die 40. The formed heat sink cavity may be filled with anencapsulant 80 to protect and manage the light extraction from the LED die 40. According to this embodiment of the present invention, the formedheat sink 520 may be composed of any suitable thermally conductive material, such as, for example, aluminum or copper. Optionally, the sheet-typeheat sink layer 520 may also be composed of a material that is both thermally conductive and has a TCE that is closely matched to the LED die 40, such as tungsten copper or copper-molybdenum-copper. -
FIG. 7 shows a top view of aLED array package 600 including a formedheat sink 520, as described in connection withFIG. 6 above. One having ordinary skill in the art will appreciate that, according to this embodiment of the present invention, the formedheat sink 520 may be isolated (i.e., one heat sink per LED die 40 or LED cluster 45). Alternatively, according to an embodiment of the present invention, there may be one solid, formedheat sink 520 upon which all LED die 40 andLED clusters 45 are arranged. As shown inFIG. 7 , the formedheat sink 520 may include one or more openings for allowing the connection of the one ormore wire bonds 60 to thePWB conductors 50. Optionally, a solder mask, or other electrically insulating layer, may be provided between the formedheat sink 520 and thePWB conductors 50 to prevent making an electrical connection between the electrical conductor and the formedheat sink 520. -
FIG. 8 depicts aLED package 600 wherein thePWB 10 is mounted above the formedheat sink 520, which is formed with concavities in registration with the apertures of thePWB 10. As described above, the formedheat sink 520 may be shaped such that it forms acavity 70 in which the one or more LED die 40 may be disposed. By disposing the formedheat sink 520 below thePWB 10, an improved thermal connection may be made to an external heat sink. One having ordinary skill in the art will appreciate that the formedheat sink 520 may be attached to thePWB 10 using any suitable means, including an adhesive or a mechanical means. -
FIG. 9 shows anLED package 600 according to embodiment of the present invention in a typical connection arrangement with anexternal heat sink 720. Materials and construction for the embodiment depicted inFIGS. 8 and 9 are similar to the those depicted inFIG. 6 and described in detail above. Optionally, as shown inFIG. 9 , one or more holes, or eyelets 725, may be punched or otherwise formed in the formedheat sink 520. The eyelets are adapted to accept a securing mechanism, such as a screw or rivet, for connecting the formedheat sink 520. For example, one or more clamping screws 730 may be used to secure together the formedheat sink 520, thePWB 10, and theexternal heat sink 720. Optionally, theLED package 600 and theexternal heat sink 720 may be joined using a suitable adhesive, such as, for example,thermal grease 735. -
FIG. 10 illustrates an embodiment of the present invention wherein one or more grooves, notches, or holes are formed in the surface of anexternal heat sink 820. One or moreheat sink studs 20 are pressed into the grooves of theexternal heat sink 820. Once theheat sink studs 20 are pressed or attached in place, aPWB 10, having openings or apertures aligning with theheat sink studs 20 is laid over the protrudingheat sink studs 20 and attached to theexternal heat sink 820. TheLED dice 40 are then mounted on theheat sink studs 20. Optionally,reflectors 70 are arranged around each of theLED dice 40, using, for example, an adhesive. Further, theLED dice 40 may be electrically connected to thePWB conductor 50 using one ormore wire bonds 60, and may be encapsulated byencapsulant 80. - Optionally, the
LED package 800 may be attached to theexternal heat sink 820 by a low thermal resistance connection where theheat sink stud 20 is pressed into theexternal heat sink 820, and between the externalheat sink stud 820 and thePWB 10. The low thermal resistance attachment may be made using, for example, a thermally-conductive epoxy, thermal grease, solder, or other suitable material. Heat produced by each of the one or more LED die 40 during operation is carried away from the LED die 40 through theheat sink stud 20, and into theexternal heat sink 820. Advantageously, removing the heat generated by the LED die 40 increases both the LED die life and the light output. Another advantage of this arrangement is that it eliminates the additional expenses associated with adding the thermal resistance of a secondary assembly. AlthoughFIG. 10 depicts theLED package 800 attached to theexternal heat sink 820, one having ordinary skill in the art will appreciate that theLED package 800 may be attached to or mounted on any suitable component. -
FIG. 11 illustrates aLED package 900 according to an embodiment of the present invention, wherein ametal layer 920 is disposed underlying aPWB 930. Themetal layer 920 may be attached or laminated to thePWB 930 using any suitable PWB laminate (e.g., pressure sensitive adhesive or pre-punched pre-preg material) according to any suitable lamination process. Themetal layer 920 may be composed of any suitable material having a high thermal conductivity (TC) and a low TCE, such as, for example, copper. - The
LED package 900 further includes one or more LED die 40 arranged on anisolator 910. Theisolator 910 and LED die 40 assembly are disposed in an aperture or cavity formed in aPWB 930, as shown inFIG. 11 . The one or more LED die 40 may be attached to theisolator 910 using any suitable attachment means including, but not limited to, a conductive epoxy, a solder, etc. - As shown in
FIG. 11 , theisolator 910 may be attached directly to themetal layer 920, according to any suitable attachment means or material, such as conductive epoxy, solder, brazing, mechanical means, etc. One having ordinary skill in the art will appreciate that in fabrication, theisolator 910 and LED die 40 assembly may be disposed on themetal layer 920, followed by the disposition of thePWB 930 onto themetal layer 910 such that the aperture or cavity of thePWB 930 aligns with or corresponds to theisolator 910 and LED die 40 assembly. Alternatively, one having ordinary skill in the art will appreciate that thePWB 930 may be disposed on themetal layer 920, followed by the disposition of theisolator 910 and LED die 40 assembly in the aperture or cavity of thePWB 930. - The
PWB 930 may comprise one or more layers, and may include one or more PWB conductor layers 930A. The LED die 40 may be electrically connected to the PWB conductor layer(s) 930A using any suitable connection means, such as awire bond 940, as shown inFIG. 11 . In addition, asolder pad 950 may be disposed on thePWB 930. - According to an embodiment of the present invention, the
isolator 910 is composed of a material adapted to tolerate expansion excursions cause by the heat produced by the attached LED die 40. Preferably, theisolator 910 is composed of a material that has a TCE that approximately matches the TCE of the LED die 40. Suitable TCE-matching materials that may be used in accordance with the present invention include, but are not limited to, copper-molybdenum-copper (CuMoCu), tungsten-copper (WCu), aluminum-silicon-carbide (AlSiC), aluminum nitride (AlN), silicon (Si), beryllium oxide (BeO), diamond, or other material that has a TCE that is matched to that of the LED. - According to an embodiment of the present invention, the
LED package 900 may include areflector 960 disposed on a layer of thePWB 930 to provide improved light extraction and/or for efficient beam forming. As described above, thereflector 960 may be composed of any suitable high temperature plastic (e.g., liquid crystal polymer), a ceramic material, or other optically reflective and electrically insulating material. Thereflector 960 may be attached to thePWB 930 using any suitable adhesive. - According to an embodiment of the present invention, an
encapsulant 970 may be disposed in the cavity of thePWB 930 such that theencapsulant 970 covers all or a portion of the LED die 40. The encapsulant material may be composed of any suitable transparent optical material. Optionally, as shown inFIG. 12 and as described above in conjunction withFIG. 1 , a secondaryoptical element 980, such as a transparent dome, may be disposed over the LED die 40. According to an embodiment of the present invention, the optical element may be attached in theLED package 900 using anencapsulant 970 or other adhesive. Furthermore, as shown inFIG. 12 , a plurality ofLED dice 40 may be mounted on theisolator 910, to form an LED assembly including an array ofLED dice 40, included within asingle LED package 900. -
FIG. 13 illustrates anexemplary LED package 1000, according to an embodiment of the present invention, which is similar toLED package 900 described above in conjunction withFIG. 12 . In this embodiment, however, the one or more LED die 40 are attached directly to ametal layer 1020 composed of a material having a TCE that matches that of the LED die 40. Themetal layer 1020 is preferably a low TCE material, such as, for example, copper-molybdenum-copper (CuMoCu), tungsten-copper (WCu), aluminum-silicon-carbide (AlSiC), aluminum nitride (AlN), silicon (Si), beryllium oxide (BeO), diamond, or other material that has a TCE that is matched to that of the LED die 40. The LED die 40 may be attached or adhered to the TCE-matchingmetal layer 1020 using a conductive epoxy, solder, or other suitable attachment means or material. - Advantageously, the heat generated by the LED die 40 and the stresses associated with the thermal expansion of the LED die 40 and the
metal layer 1020 are efficiently managed by using the TCE-matchingmetal layer 1020. - The one or more LED die 40 are disposed within a cavity of a
PWB 1030. ThePWB 1030 may be comprised of one or more layers, and include aconductive layer 1030A that is electrically connected to the LED die 40 using any suitable connection means, such as, for example, awire bond 1040. - According to an embodiment of the present invention, the
LED package 1000 may include areflector 1060 attached to thePWB 1030 and at least partially surrounding the LED die 40. Optionally, theLED package 1000 may comprise anencapsulant 1070 dispensed in the cavity of thePWB 1030 and/or thereflector 1060, such that it at least partially covers the LED die 40. - According to yet another embodiment of the present invention, a method is provided for fabricating a multi-layer PWB assembly having a stepped cavity formed therein, particularly suited for housing light emitting devices, such as, for example, one or more LED die 40. According to an embodiment of the present invention, the stepped cavity is buried in the PWB assembly. The present invention further relates to a PWB assembly including a stepped cavity made according to the fabrication method. In addition, the present application describes a method for fabricating a LED package comprising a PWB assembly having a stepped cavity
-
FIG. 14 illustrates an exemplary process for fabricating a PWB assembly having a stepped cavity, according to an embodiment of the present invention.FIGS. 15A-15I depict an exemplary PWB assembly at different stages of the fabrication process illustrated inFIG. 14 and described in detail below.FIG. 15I depicts anexemplary PWB assembly 2000 including a steppedcavity 1900, fabricated according to an embodiment of the present invention. - In
step 1, a number of PWB layers 1500 to be assembled are provided. Although the exemplary embodiment described herein and illustrated inFIGS. 14 and 15 A-15I includes threePWB layers PWB assembly 2000 may include any suitable number of PWB layers 1500. One having ordinary skill in the art will appreciate that each of the PWB layers 1500A, 1500B, 1500C may comprise any suitable number of layers. - According to an exemplary embodiment of the present invention, each of the PWB layers 1500A, 1500B, 1500C comprises a double sided FR4 (or FR4-5) board, which includes a dielectric layer (e.g., a layer of FR4 material) 1502 disposed between a top metal layer 1501 and a bottom metal layer 1503, as shown in
FIG. 15A . The metal layers 1501, 1503 of the PWB layer 1500 may be composed of any suitable metal, including but not limited to copper. - The PWB layers 1500A, 1500B, 1500C may be of any suitable thickness (e.g., approximately 0.002 inches thick). According to an embodiment of the present invention, the bottom-most PWB layer (1500C in
FIG. 15A ) is thicker than the other PWB layers (e.g., approximately 0.004 inches thick). - In
step 2, one or more of metal layers 1501, 1503 are patterned with wiring traces appropriately to enable assembly of the PWB layers such that the metal portions of the individual PWB layers are properly aligned for desired interconnection. For example, as shown inFIG. 15B , thebottom metal layer 1503A ofPWB layer 1500A is patterned to include features adapted for assembly withadjacent PWB layer 1500B, and so on, as described in detail below. - Optionally, in
step 3, one or more of the metal layers 1501, 1503 may be plated with a suitable metal for electrical connectivity with a light emitting device. Any suitable material may be used for the plating, such as, for example, nickel or gold. - In
step 4, the process of forming a stepped cavity is initiated. Specifically, an aperture is formed in the dielectric layer 1502 of each of the one or more intermediate PWB layers. In the exemplary embodiment illustrated inFIG. 15C , the aperture or hole is formed in thedielectric layer 1502B ofPWB layer 1500B. One having ordinary skill in the art will appreciate that the aperture may be of any suitable size and/or shape, such as a circle, square, etc. In addition, the aperture may be formed according to any suitable method, such as, for example, punching, routing or drilling. - In
step 5, the plurality of PWB layers 1500A, 1500B, 1500C are laminated together, as shown inFIG. 15D to form a multi-layer PWB structure. To laminate the PWB layers together, asuitable adhesive layer 1600 is disposed in between each adjacent PWB layer, and the layers are pressed together. Theadhesive layer 1600 may be comprised of any suitable adhesive material. According to an embodiment of the present invention, theadhesive layer 1600 is composed of a suitable pressure sensitive adhesive (PSA), such as, for example, 3M™ High Tack Tape PSA 3794. According to another embodiment of the present invention, theadhesive layer 1600 may be composed of a pre-punched pre-preg material, such as, for example, Arlon 49N and Arlon 37N. - Optionally, via holes may be formed through the PWB layers 1500A, 1500B, 1500C according to any suitable method (e.g., drilling), as shown in
FIG. 15E . In addition, the via holes may be plated with a suitable metallization material 1700 (e.g., copper) for electrical continuity, as shown inFIG. 15F . - In
step 6, formation of the stepped cavity in the PWB assembly is finalized, by removing at least a portion of the top and bottomdielectric layers top dielectric layer 1502A is removed using any suitable technique or tool, such as, for example, a piercing tool, a routing tool or a flat bottom drill, as shown inFIG. 15G . Furthermore, instep 6, a portion of thebottom dielectric layer 1502C is removed, as shown inFIG. 15H . - As a result of the process described in detail above with reference to
FIG. 14 , thePWB assembly 2000 including a steppedcavity 1900 is formed, as shown inFIG. 15I . - According to an embodiment of the present invention, the
PWB assembly 2000 with steppedcavity 1900 may be used to fabricate a LED package, particularly those suited for high temperature operation. -
FIG. 16 illustrates an exemplary process for the fabrication of a LED package 5000 (shown inFIG. 17D ) including a stepped-cavity PWB assembly 2000. One having ordinary skill in the art will appreciate that the steps set forth in the process illustrated inFIG. 16 , and described in detail below, do not necessarily need to be performed in the order provided. - In step S1, as shown in
FIG. 17A , a layer is provided which acts to electrically isolate the electrical connections of thePWB assembly 2000 from ametal base 3000. One having ordinary skill in the art will appreciate that the “insulating layer” 2500 may be composed of any suitable dielectric material. According to an embodiment of the present invention, the insulatinglayer 2500 may be comprised of a PWB layer. The PWB layer may be composed of any suitable material, such as for example, a fiberglass reinforced material (e.g., FR4 board) or a high temperature fiberglass reinforced material (e.g., FR4-5 board). The insulatinglayer 2500 includes an aperture or hole 2510 adapted to correspond to the bottommost opening of the stepped cavity of thePWB assembly 2000, as shown inFIG. 17A . According to another embodiment of the present invention, the insulatinglayer 2500 may be comprised of one or more pre-preg layers having a desired voltage breakdown. Preferably, a breakdown voltage of greater than or equal to 250 Volts is maintained. The insulatinglayer 2500 may be of any suitable thickness. Preferably, the insulatinglayer 2500 is at least approximately 0.002 inches thick. - The
metal base 3000 is provided which serves as a heat sink in theLED package 5000. According to an embodiment of the present invention, themetal base 3000 may be composed of any suitable metal, such as, for example, copper. In addition, themetal base 3000 may be of any suitable thickness sufficient to manage the heat generated by the one or more LED die of theLED package 5000. The insulatinglayer 2500 advantageously isolates the plated vias of thePWB assembly 2000 from themetal base 3000. - In step S2, the
PWB assembly 2000, the insulatinglayer 2500, and themetal base 3000 are laminated together, as shown inFIG. 17B . According to an embodiment of the present invention, one or morelaminate layers 2800 are disposed between thePWB assembly 2000 and the insulatinglayer 2500, and the insulatinglayer 2500 and themetal base 3000. Thelaminate layers 2800 include an aperture or opening which corresponds to the bottommost opening of the stepped cavity of thePWB assembly 2000 and the aperture of the insulatinglayer 2500, as shown inFIG. 17A . One having ordinary skill in the art will appreciate that thelaminate layers 2800 may be composed of any suitable laminate material, including, but not limited to, a pressure sensitive adhesive, a pre-punched pre-preg material, or a combination of both. - Optionally, the
top dielectric layer 1502A may be left in place until after thePWB assembly 2000 is laminated to themetal base 3000. By so doing, thePWB assembly 2000 is a more robust and stronger assembly, able to withstand process variations experienced during the lamination process. For example, leaving thetop dielectric layer 1502A intact during integration of thePWB assembly 2000 into theLED package 5000 may result in less pre-punched pre-preg material running out onto the PWB layers and/or the metal base, and less deformation of the steppedcavity 1900 due to the stresses of the lamination process. - Optionally, according to an embodiment of the present invention, in step S3, in order to block the flow of the laminate material into the stepped cavity or onto one or more portions of an adjacent PWB layer, one or more dams may be applied to the laminate layers 2800. The
dams 2900, shown inFIG. 17C , may be fabricated according to any suitable technique, including, but not limited to, a photo-imageable solder mask technique, a screen printed maskant technique, or by pre-scoring thelaminate layers 2800 to include the one or more dams. Thedams 2900 may be composed of any suitable material, such as, for example, DuPont Vacrel® 8100 Series Photopolymer Dry Film Solder Mask. - In step S4, one or more LED die 40 are introduced into the stepped cavity of the
LED package 5000. As described in detail above, the one or more LED die 40 may be disposed directly on themetal base 3000, or, alternatively, the LED die 40 may be disposed on aninterposer 3100, as shown inFIG. 17D . If theinterposer 3100 is not included, one having ordinary skill in the art will appreciate that themetal base 3000 may be advantageously composed of CuMoCu, WCu, or other suitable TCE-matching material. - According to an embodiment of the present invention, the one or more LED die 40 may be electrically connected to a metal layer of the
PWB assembly 2000 by any suitable means, including, but not limited to,wire bonds 3120. - Optionally, the
LED package 5000 may include areflector 3130 which reflects at least a portion of the light emitted by the one or more LED die 40. Thereflector 3130 may be composed of any suitable reflective material, including, but not limited to, aluminum, polycarbonate, and liquid crystal polymer (LCP). - Optionally, the
LED package 5000 may include anoptical element 3140, such as a lens. Theoptical element 3140 may be composed of any suitable material, including but not limited to, glass, silicone and polycarbonate. - According to an embodiment of the present invention, the
reflector 3130 and theoptical element 3140 may be adapted to produce a desired radiation pattern, such as, for example, a focused, narrow light beam. Thepattern forming reflector 3130 may be molded or machined plastic (metallized or un-metallized), molded or machined aluminum, other suitable reflective material, or a stamped metal part with a reflective surface. Thereflector 3130 or reflective surface may be roughened to improve color mixing and avoid creating undesirable, non-uniform light output. - It is to be understood that the exemplary embodiments are merely illustrative of the present invention and that many variations of the above-described embodiments can be devised by one skilled in the art without departing from the scope of the invention. It is therefore intended that all such variations be included within the scope of the invention.
Claims (61)
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
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US11/475,292 US20070007558A1 (en) | 2005-06-27 | 2006-06-27 | Light emitting diode package and method for making same |
US12/135,042 US8129734B2 (en) | 2005-06-27 | 2008-06-06 | LED package with stepped aperture |
US13/354,684 US20120110842A1 (en) | 2005-06-27 | 2012-01-20 | Led package with stepped aperture |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
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US69478805P | 2005-06-27 | 2005-06-27 | |
US73847805P | 2005-11-21 | 2005-11-21 | |
US76382806P | 2006-01-31 | 2006-01-31 | |
US11/475,292 US20070007558A1 (en) | 2005-06-27 | 2006-06-27 | Light emitting diode package and method for making same |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US12/135,042 Division US8129734B2 (en) | 2005-06-27 | 2008-06-06 | LED package with stepped aperture |
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US20070007558A1 true US20070007558A1 (en) | 2007-01-11 |
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US12/135,042 Expired - Fee Related US8129734B2 (en) | 2005-06-27 | 2008-06-06 | LED package with stepped aperture |
US13/354,684 Abandoned US20120110842A1 (en) | 2005-06-27 | 2012-01-20 | Led package with stepped aperture |
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US12/135,042 Expired - Fee Related US8129734B2 (en) | 2005-06-27 | 2008-06-06 | LED package with stepped aperture |
US13/354,684 Abandoned US20120110842A1 (en) | 2005-06-27 | 2012-01-20 | Led package with stepped aperture |
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EP (1) | EP1897146A2 (en) |
JP (2) | JP2009502024A (en) |
KR (1) | KR20080042798A (en) |
TW (1) | TW200709475A (en) |
WO (1) | WO2007002644A2 (en) |
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Also Published As
Publication number | Publication date |
---|---|
KR20080042798A (en) | 2008-05-15 |
US20120110842A1 (en) | 2012-05-10 |
JP2009502024A (en) | 2009-01-22 |
TW200709475A (en) | 2007-03-01 |
JP5600699B2 (en) | 2014-10-01 |
WO2007002644A2 (en) | 2007-01-04 |
US20080296599A1 (en) | 2008-12-04 |
WO2007002644A3 (en) | 2009-04-16 |
JP2012114470A (en) | 2012-06-14 |
EP1897146A2 (en) | 2008-03-12 |
US8129734B2 (en) | 2012-03-06 |
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