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TWI765568B - Flip-chip light-emitting diode, manufacturing method and backlight module therefor - Google Patents

Flip-chip light-emitting diode, manufacturing method and backlight module therefor
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TWI765568B
TWI765568BTW110104719ATW110104719ATWI765568BTW I765568 BTWI765568 BTW I765568BTW 110104719 ATW110104719 ATW 110104719ATW 110104719 ATW110104719 ATW 110104719ATW I765568 BTWI765568 BTW I765568B
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light
photoresist
substrate
diodes
layer
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TW202232789A (en
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余海楊
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大陸商業成科技(成都)有限公司
大陸商業成光電(深圳)有限公司
英特盛科技股份有限公司
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Abstract

The present invention is a flip-chip light emitting diode, manufacturing method and backlight module therefor, comprising a substrate, a P-N diode, a first reflective layer, a light guide layer and a second reflective layer. The P-N diode is arranged on one side of the substrate. The light guide layer is arranged other side of the substrate. The light guide layer has an optical path adjustment surface. An angle is formed between the optical path adjustment surface and the substrate. The second reflection layer is disposed on the optical path adjustment surface. The first reflection layer is disposed on a side of the P-N diode relative to the substrate. The light emitted by the P-N diode is reflected between the first reflective layer and the second reflective layer, and emits light toward the two sides between the first reflective layer and the second reflective layer.

Description

Translated fromChinese
倒裝發光二極體及其製造方法與背光模組Flip-chip light-emitting diode and its manufacturing method and backlight module

本發明係有關於發光二極體,尤指一種倒裝發光二極體及其製造方法與背光模組。The present invention relates to light emitting diodes, in particular to a flip-chip light emitting diode, a manufacturing method thereof, and a backlight module.

傳統發光二極體(Light Emitting Diode,簡稱:LED)已經廣泛應用於照明或顯示面板的背光模組之中。以顯示面板的背光模組而言,又區分為側入式背光模組與直下式背光模組。Traditional light emitting diodes (Light Emitting Diode, LED for short) have been widely used in backlight modules for lighting or display panels. In terms of the backlight module of the display panel, it is further divided into an edge-type backlight module and a direct-type backlight module.

請參閱圖1所示,側入式背光模組係將正裝發光二極體10設置在顯示面板11的側面,使得正裝發光二極體10的光源由導光板12引導,同時由導光板12面對背面的反射片13,將發光二極體10的光源反射朝向背光膜材11。Referring to FIG. 1 , the side-illuminated backlight module sets the front-mounted light-emitting diode 10 on the side of thedisplay panel 11 , so that the light source of the front-mounted light-emitting diode 10 is guided by thelight guide plate 12 , and at the same time is guided by thelight guide plate 12 faces thereflective sheet 13 on the back, and reflects the light source of thelight emitting diode 10 toward thebacklight film 11 .

由於,側入式背光模組不具有區域調光之功能,使得對比度較差,而且在顯示面板的邊緣會有明顯的漏光,因此,許多的顯示面板採用直下式背光模組,尤其是使用倒裝發光二極體作為直下式背光模組的光源,請參閱圖2所示,直下式背光模組係在背光膜材20的下方設置反射片21,而倒裝發光二極體22設置在背光膜材20與反射片21之間,且倒裝發光二極體22由側面發出光源,再由反射片21將倒裝發光二極體22的光源反射朝向背光膜材20,藉以提高背光模組的亮度及色度的均勻性。Because the edge-type backlight module does not have the function of regional dimming, the contrast ratio is poor, and there will be obvious light leakage at the edge of the display panel. Therefore, many display panels use direct-type backlight modules, especially those using flip-chip The light emitting diode is used as the light source of the direct type backlight module. Please refer to FIG. 2. The direct type backlight module is provided with areflective sheet 21 under thebacklight film 20, and the flip-chiplight emitting diode 22 is disposed on the backlight film. between thematerial 20 and thereflective sheet 21, and the flip-chip light-emitting diode 22 emits light from the side, and thereflective sheet 21 reflects the light source of the flip-chip light-emitting diode 22 toward thebacklight film material 20, so as to improve the backlight module's light source. Uniformity of luminance and chromaticity.

請參閱圖3所示,前述的倒裝發光二極體22由上至下依序包括第一反射層220、基板221、N型半導體層222、發光層223、P型半導體層224、第二反射層225,並且在N型半導體層222底面於相鄰發光層223、P型半導體層224、第二反射層225的側邊設有負電極226,第二反射層225的底面設有正電極227,在且負電極226周圍延伸到第二反射層225接近正電極227的位置設有絕緣層228,當負電極226及正電極227導通時,N型半導體層222及P型半導體層224產生的電子及電洞,將在發光層223結合而產生出相應波長的光源。Referring to FIG. 3 , the aforementioned flip-chip light-emitting diode 22 includes a firstreflective layer 220 , asubstrate 221 , an N-type semiconductor layer 222 , a light-emitting layer 223 , a P-type semiconductor layer 224 , a second Thereflective layer 225 is provided with anegative electrode 226 on the bottom surface of the N-type semiconductor layer 222 on the sides of the adjacent light-emitting layer 223, the P-type semiconductor layer 224 and the secondreflective layer 225, and the bottom surface of the secondreflective layer 225 is provided with apositive electrode 227, aninsulating layer 228 is provided around thenegative electrode 226 and extends to the position where the secondreflective layer 225 is close to thepositive electrode 227. When thenegative electrode 226 and thepositive electrode 227 are turned on, the N-type semiconductor layer 222 and the P-type semiconductor layer 224 are formed. The electrons and holes generated will combine in the light-emittinglayer 223 to generate a light source with a corresponding wavelength.

但是傳統的第一反射層220與第二反射層225之間呈現平行,造成倒裝發光二極體22之光源在第一反射層220與第二反射層225之間反覆地繞射,進一步而言,光源在倒裝發光二極體的內部中繞射太久時間,導致出光效率太低,而且會產生高熱,故有必要針對此些問題進行改善。However, the conventional firstreflective layer 220 and the secondreflective layer 225 are parallel, so that the light source of the flip-chiplight emitting diode 22 is repeatedly diffracted between the firstreflective layer 220 and the secondreflective layer 225, and further, In other words, the light source is diffracted in the inside of the flip-chip light-emitting diode for too long, resulting in low light extraction efficiency and high heat generation. Therefore, it is necessary to improve these problems.

有鑑於先前技術的問題,本發明之目的係減少光源在倒裝發光二極體內部繞射時間,避免倒裝發光二極體產生高熱,並且達到讓光源快速地從側面出光之目的。In view of the problems of the prior art, the purpose of the present invention is to reduce the diffraction time of the light source inside the flip-chip light-emitting diode, avoid high heat generated by the flip-chip light-emitting diode, and achieve the purpose of allowing the light source to quickly emit light from the side.

根據本發明之目的,係提供一種倒裝發光二極體,包括基板、P-N二極管、第一反射層、導光層及第二反射層,P-N二極管設置在基板之一側,第一反射層設置在P-N二極管相對基板的一側,導光層設置在基板相對於P-N二極管層之一側,導光層背對基板的一面設有光路調整面,第二反射層設置在光路調整面上, P-N二極管所發出的光線在該第一反射層及該第二反射層之間反射,並朝向該倒裝發光二極體的側面出光。According to the purpose of the present invention, a flip-chip light-emitting diode is provided, which includes a substrate, a P-N diode, a first reflective layer, a light guide layer and a second reflective layer. The P-N diode is arranged on one side of the substrate, and the first reflective layer is arranged on one side. On the side of the P-N diode opposite to the substrate, the light guide layer is arranged on the side of the substrate opposite to the P-N diode layer, the side of the light guide layer facing away from the substrate is provided with an optical path adjustment surface, and the second reflection layer is arranged on the optical path adjustment surface, P-N The light emitted by the diode is reflected between the first reflection layer and the second reflection layer, and emits light toward the side of the flip-chip light emitting diode.

其中,P-N二極管自基板到第一反射層之間,係包括N型半導體層、P型半導體層及發光層,發光層在P型半導體層與N型半導體層的導電之狀態發出的光線,並在第一反射層及第二反射層之間反射,且朝向倒裝發光二極體的側面出光。The P-N diode from the substrate to the first reflective layer includes an N-type semiconductor layer, a P-type semiconductor layer and a light-emitting layer, and the light-emitting layer emits light in the conductive state of the P-type semiconductor layer and the N-type semiconductor layer, and It is reflected between the first reflective layer and the second reflective layer, and emits light toward the side of the flip-chip light emitting diode.

其中,倒裝發光二極體尚包括負電極、正電極及絕緣層,其中負電極設置在N型半導體層的底面相鄰發光層、P型半導體層、第一反射層的位置,正電極設在第一反射層的底部,絕緣層設在負電極的周圍,並沿著第一反射層的底部延伸到接近正電極的位置。The flip-chip light-emitting diode still includes a negative electrode, a positive electrode and an insulating layer, wherein the negative electrode is arranged on the bottom surface of the N-type semiconductor layer adjacent to the light-emitting layer, the P-type semiconductor layer, and the position of the first reflective layer, and the positive electrode is arranged At the bottom of the first reflective layer, an insulating layer is provided around the negative electrode and extends along the bottom of the first reflective layer to a position close to the positive electrode.

其中,基板係為藍寶石(sapphire)基板,組成為氧化鋁(Al2O3)。Among them, the substrate is a sapphire substrate, and the composition is aluminum oxide (Al2 O3 ).

其中,第一反射層係為分佈式布拉格反射器(Distributed Bragg Reflector)。The first reflection layer is a distributed Bragg reflector (Distributed Bragg Reflector).

其中,光路調整面為固定斜率的斜面,令導光層形成倒錐形體,或者光路調整面為漸變曲率的曲面,令導光層形成連續曲面體,且光路調整面的中央位置的切線之法線與光路調整面的任一位置的切線之法線具有夾角。Among them, the optical path adjustment surface is a slope with a fixed slope, so that the light guide layer forms an inverted cone, or the optical path adjustment surface is a curved surface with gradual curvature, so that the light guide layer forms a continuous curved surface, and the method of tangent to the central position of the optical path adjustment surface The line has an included angle with the normal of the tangent at any position of the light path adjustment surface.

其中,導光層於基板的投影面積大於基板,導光層中間位置的厚度為基板、P-N二極管及第一反射層的總和厚度的十分之一,進一步約為10~20微米(10~20μm),又導光層兩側邊緣的厚度與導光層中間位置的厚度之厚度差約為基板、P-N二極管及第一反射層的總和厚度的四分之一,進一步約為10~50微米(10~50μm)。The projected area of the light guide layer on the substrate is larger than that of the substrate, and the thickness of the middle position of the light guide layer is one-tenth of the total thickness of the substrate, the P-N diode and the first reflective layer, and is further about 10-20 μm (10-20 μm ), and the thickness difference between the thickness of the edge of the light guide layer and the thickness of the middle position of the light guide layer is about a quarter of the total thickness of the substrate, the P-N diode and the first reflective layer, and further about 10 to 50 microns ( 10~50μm).

根據本發明之目的,係一種背光模組,係包括複數個前述的倒裝發光二極體、電路板、背光膜材,各倒裝發光二極體係夾設在電路板與背光膜材之間,並在各倒裝發光二極體上設置保護層,且各倒裝發光二極體連接電路板。According to the purpose of the present invention, it is a backlight module, which includes a plurality of the aforementioned flip-chip light-emitting diodes, circuit boards, and backlight film materials, and each flip-chip light-emitting diode system is sandwiched between the circuit board and the backlight film material. , and a protective layer is arranged on each flip-chip light-emitting diode, and each flip-chip light-emitting diode is connected to the circuit board.

根據本發明之目的,係提供一種倒裝發光二極體之製造方法,包括下列步驟,提供一待製品,待製品包括一基板、複數個P-N二極管及複數個第一反射層,其中各P-N二極管設置在基板之一側,各第一反射層分別設置在其中一個P-N二極管相對於基板的一側,在基板相對於各P-N二極管之一側製作導光層,各導光層相對基板的一側為光路調整面,以及沿著光路調整面製作第二反射層,切割各導光層及其相對應的第二反射層直到基板面對各P-N二極管的一面為止,形成複數個倒裝發光二極體。According to the purpose of the present invention, a method for manufacturing flip-chip light-emitting diodes is provided, which includes the following steps, and provides a product to be prepared, the product to be prepared includes a substrate, a plurality of P-N diodes and a plurality of first reflective layers, wherein each P-N diode It is arranged on one side of the substrate, each first reflective layer is respectively arranged on one side of one of the P-N diodes opposite to the substrate, and a light guide layer is made on one side of the substrate opposite to each P-N diode, and each light guide layer is opposite to the side of the substrate. For the optical path adjustment surface and the second reflection layer along the optical path adjustment surface, each light guide layer and its corresponding second reflection layer are cut until the substrate faces the side of each P-N diode to form a plurality of flip-chip light emitting diodes body.

其中,製作導光層的步驟進一步包括:將光阻塗佈在基板相對於P-N二極管之一側,對光阻進行曝光,且對光阻的曝光強度分布係分別對應各P-N二極管的位置進行調整,對光阻進行顯影,完成顯影後光阻即形成導光層,並導光層在背對各P-N二極管分別形成光路調整面,且光路調整面與基板之間具有夾角。Wherein, the step of making the light guide layer further includes: coating a photoresist on one side of the substrate opposite to the P-N diode, exposing the photoresist, and adjusting the exposure intensity distribution of the photoresist corresponding to the position of each P-N diode respectively , develop the photoresist, and after the development is completed, the photoresist forms a light guide layer, and the light guide layer forms an optical path adjustment surface on the back of each P-N diode, and the optical path adjustment surface and the substrate have an included angle.

其中,在進行曝光的過程中,對光阻的曝光強度分布係針對各P-N二極管的中央往兩側漸變,對光阻進行顯影,完成顯影後光阻即形成導光層,且導光層在背對各P-N二極管形成光路調整面,各光路調整面的厚度以相對各P-N二極管中央到兩側逐漸增厚。Among them, in the process of exposure, the exposure intensity distribution of the photoresist is gradually changed from the center of each P-N diode to both sides, and the photoresist is developed. After the development is completed, the photoresist forms a light guide layer, and the light guide layer is in An optical path adjustment surface is formed facing away from each P-N diode, and the thickness of each optical path adjustment surface gradually increases relative to the center to both sides of each P-N diode.

其中,光阻為正型光刻膠,而當對光阻進行曝光時,係以半調色掩膜板設置在光源與光阻之間,利用半調色掩膜板調整光源的曝光強度從相對各P-N二極管的中央往兩側逐漸減弱。Among them, the photoresist is a positive type photoresist, and when the photoresist is exposed, a half-tone mask is set between the light source and the photoresist, and the half-tone mask is used to adjust the exposure intensity of the light source from Relative to the center of each P-N diode, it gradually weakens toward both sides.

其中,光阻為負型光刻膠,而當對光阻進行曝光時,係以半調色掩膜板設置在光源與光阻之間,利用半調色掩膜板調整光源的曝光強度從相對各P-N二極管的中央往兩側逐漸增強。Among them, the photoresist is a negative photoresist, and when the photoresist is exposed, a half-tone mask is set between the light source and the photoresist, and the half-tone mask is used to adjust the exposure intensity of the light source from Relative to the center of each P-N diode, it gradually increases toward both sides.

其中,切割為使用雷射切割機進行切割。Among them, the cutting is cutting using a laser cutting machine.

據上所述,與第一反射層與第二反射層將發光層所發出的光源朝向側面,減少光源在與第一反射層與第二反射層之間來回繞射,使得光源快速地朝向倒裝發光二極體的側面出光。此外,本發明係在倒裝發光二極體增設一個導光層,其餘的製程皆與傳統的倒裝發光二極體,故本發明在較低程度的流程就可以達到最佳的側面出光效果。According to the above, with the first reflective layer and the second reflective layer, the light source emitted by the light-emitting layer is directed to the side, reducing the back and forth diffraction of the light source between the first reflective layer and the second reflective layer, so that the light source rapidly faces the opposite direction. The side where the light-emitting diode is installed emits light. In addition, in the present invention, a light guide layer is added to the flip-chip light-emitting diode, and the rest of the manufacturing process is the same as that of the traditional flip-chip light-emitting diode, so the present invention can achieve the best side light emitting effect with a relatively low level of process. .

為了使本發明的目的、技術方案及優點更加清楚明白,下面結合附圖及實施例,對本發明進行進一步詳細說明。應當理解,此處所描述的具體實施例僅用以解釋本發明,但並不用於限定本發明。In order to make the objectives, technical solutions and advantages of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention, but not to limit the present invention.

請參閱圖4所示,本發明係一種倒裝發光二極體,係包括基板30、P-N二極管31、第一反射層32、導光層33及第二反射層34,P-N二極管31設置在基板30之一側,第一反射層32設置在P-N二極管31相對基板30的一側,導光層33設置在基板30相對於P-N二極管31層之一側,導光層33背對基板30的一面設有光路調整面330,第二反射層34設置在光路調整面330上,即形成倒裝發光二極體3, P-N二極管31所發出的光線在該第一反射層32及該第二反射層34之間反射,並朝向倒裝發光二極體3的側面出光。如此,即可解決傳統倒裝發光二極體來回反覆繞射但是不易從側面出光的問題,由於可以快速地出光也進一步解決傳統倒裝發光二極體產生高熱的問題。Please refer to FIG. 4 , the present invention is a flip-chip light emitting diode, which includes asubstrate 30 , aP-N diode 31 , afirst reflection layer 32 , alight guide layer 33 and asecond reflection layer 34 , and theP-N diode 31 is disposed on the substrate On one side of 30, the firstreflective layer 32 is arranged on the side of theP-N diode 31 opposite to thesubstrate 30, thelight guide layer 33 is arranged on the side of thesubstrate 30 opposite to theP-N diode 31 layer, and thelight guide layer 33 is on the side opposite to thesubstrate 30 There is an opticalpath adjustment surface 330, and thesecond reflection layer 34 is arranged on the opticalpath adjustment surface 330, that is, the flip-chiplight emitting diode 3 is formed, and the light emitted by theP-N diode 31 is in thefirst reflection layer 32 and the second reflection layer. 34, and emit light toward the side of the flip-chip light-emittingdiode 3. In this way, the problem that the traditional flip-chip light-emitting diode is refracted back and forth but is not easy to emit light from the side can be solved, and the problem of high heat generated by the traditional flip-chip light-emitting diode can be further solved because the light can be quickly emitted.

在本發明中,請參閱圖5所示,P-N二極管31自基板30到第一反射層32之間,係包括N型半導體層310、P型半導體層311及發光層312,其中N型半導體層310與P型半導體層311之間夾設發光層312,發光層312在N型半導體層310與P型半導體層311的導電之狀態發出的光線,並在第一反射層32及第二反射層34之間反射,且朝向第一反射層32及第二反射層34之間的側面出光。In the present invention, please refer to FIG. 5, theP-N diode 31 from thesubstrate 30 to the firstreflective layer 32 includes an N-type semiconductor layer 310, a P-type semiconductor layer 311 and a light-emitting layer 312, wherein the N-type semiconductor layer The light-emitting layer 312 is sandwiched between the 310 and the P-type semiconductor layer 311. The light-emittinglayer 312 emits light in the conductive state of the N-type semiconductor layer 310 and the P-type semiconductor layer 311, and the firstreflective layer 32 and the second reflective layer emit light. 34 and emit light toward the side between the firstreflective layer 32 and the secondreflective layer 34 .

在本發明中,請參閱圖5所示,倒裝發光二極體3尚包括負電極35、正電極36及絕緣層37,其中負電極35設置在N型半導體層310的底面相鄰發光層312、P型半導體層311、第一反射層32的位置,正電極36設在第一反射層32的底部,絕緣層37設在負電極35的周圍,並沿著第一反射層32的底部延伸到接近正電極36的位置。In the present invention, please refer to FIG. 5 , the flip-chip light-emitting diode 3 further includes anegative electrode 35 , apositive electrode 36 and aninsulating layer 37 , wherein thenegative electrode 35 is disposed on the bottom surface of the N-type semiconductor layer 310 adjacent to the light-emittinglayer 312, the position of the P-type semiconductor layer 311 and the firstreflective layer 32, thepositive electrode 36 is arranged at the bottom of the firstreflective layer 32, theinsulating layer 37 is arranged around thenegative electrode 35, and along the bottom of the firstreflective layer 32 extends to a position close to thepositive electrode 36 .

據上所述,當導通負電極35及正電極36時,N型半導體層310及P型半導體層311產生的電子及電洞,電子及電洞將在發光層312結合,而在發光層312產生出相應波長的光源,此光源將在第一反射層32與第二反射層34之間反射,並朝向倒裝發光二極體3的側面出光。According to the above, when thenegative electrode 35 and thepositive electrode 36 are turned on, the electrons and holes generated by the N-type semiconductor layer 310 and the P-type semiconductor layer 311 will combine in the light-emitting layer 312 , and the electrons and holes will be combined in the light-emitting layer 312 . A light source with a corresponding wavelength is generated, which is reflected between thefirst reflection layer 32 and thesecond reflection layer 34 and emits light toward the side of the flip-chiplight emitting diode 3 .

在本發明中,倒裝發光二極體3係為迷你發光二極體(Mini LED),其厚度約為200微米(200μm),基板30係為藍寶石(sapphire)基板30,組成為氧化鋁(Al2O3),N型半導體層310為N型氮化鎵(N-GaN)半導體層,P型半導體層311為P型氮化鎵(P-GaN)半導體層。第二反射層34係為分佈式布拉格反射器(Distributed Bragg Reflector),發光層312係為多量子井(Multiple Quantum Well,簡稱:MQW)。In the present invention, the flip-chip light-emitting diode 3 is a mini light-emitting diode (Mini LED) with a thickness of about 200 μm (200 μm), and thesubstrate 30 is asapphire substrate 30 composed of aluminum oxide ( Al2 O3 ), the N-type semiconductor layer 310 is an N-type gallium nitride (N-GaN) semiconductor layer, and the P-type semiconductor layer 311 is a P-type gallium nitride (P-GaN) semiconductor layer. Thesecond reflection layer 34 is a distributed Bragg reflector (Distributed Bragg Reflector), and thelight emitting layer 312 is a multiple quantum well (Multiple Quantum Well, MQW for short).

在本發明中,請參閱圖6所示,光路調整面330為固定斜率的斜面,令導光層33形成倒錐形體,或者光路調整面330為漸變曲率的曲面,令導光層33形成連續曲面體(如圖5所示),且光路調整面330的中央位置的切線之法線與光路調整面330的任一位置的切線之法線具有夾角θ(如圖4所示),但本發明在實際實施時,並不限於此,舉凡光路調整面330之形狀可以使得光源快速被反射出光者,皆屬於本發明所稱之光路調整面330。第二反射層34可為銀薄膜、鋁薄膜、銀化合物薄膜或鋁化合物薄膜,但本發明於實際實施時,並不限於此,舉凡可以將光源反射到第一反射層3231之任一種具有反射能力之薄膜,皆屬於本發明所稱之第二反射層34。In the present invention, please refer to FIG. 6 , the opticalpath adjustment surface 330 is a slope with a fixed slope, so that thelight guide layer 33 forms an inverted cone, or the opticalpath adjustment surface 330 is a curved surface with a gradual curvature, so that thelight guide layer 33 forms a continuous A curved body (as shown in FIG. 5 ), and the normal of the tangent at the central position of the opticalpath adjustment surface 330 and the normal of the tangent at any position of the opticalpath adjustment surface 330 have an included angle θ (as shown in FIG. 4 ), but this When the invention is actually implemented, it is not limited to this. For example, the shape of the opticalpath adjustment surface 330 can make the light source reflect light quickly, all belong to the opticalpath adjustment surface 330 in the present invention. Thesecond reflection layer 34 can be a silver film, an aluminum film, a silver compound film or an aluminum compound film, but the present invention is not limited to this in actual implementation. Capable thin films belong to the secondreflective layer 34 referred to in the present invention.

由於,若導光層33於基板30的投影面積與基板30相等,光源可能會由基板30與導光層33的位置漏光,甚至於導光層33於基板30的投影面積小於基板30,光源會朝向基板30的方向直接出光,因此,在本發明中,導光層33於基板30的投影面積大於基板30,將使得導光層33完全遮住基板30,而且導光層33突出基板的部分就如同帽子的帽沿,使得倒裝發光二極體3朝向基板30的方向出光的部分,可以被導光層33上所設置的第二反射層34反側,而可以減少或完全解決漏光或直接出光的問題。又,導光層33兩側邊緣的厚度(H1)與導光層33中間位置的厚度(H2)之厚度差約為基板30、P-N二極管31及第一反射層32的總和厚度的四分之一(意即約小於倒裝發光二極體3的四分之一),進一步約為10~50微米(10~20μm),導光層33中間位置的厚度(H2)為基板30、P-N二極管31及第一反射層32的總和厚度的十分之一(意即約為倒裝發光二極體3的十分之一),進一步約為10~20微米(10~20μm)。Because, if the projected area of thelight guide layer 33 on thesubstrate 30 is equal to that of thesubstrate 30, the light source may leak light from the position of thesubstrate 30 and thelight guide layer 33, even if the projected area of thelight guide layer 33 on thesubstrate 30 is smaller than that of thesubstrate 30, the light source Therefore, in the present invention, the projected area of thelight guide layer 33 on thesubstrate 30 is larger than that of thesubstrate 30, so that thelight guide layer 33 completely covers thesubstrate 30, and thelight guide layer 33 protrudes from thesubstrate 30. The part is like the brim of a hat, so that the part of the flip-chip light-emitting diode 3 that emits light toward thesubstrate 30 can be on the opposite side of the secondreflective layer 34 provided on thelight guide layer 33, thereby reducing or completely solving light leakage Or the problem of direct light. In addition, the thickness difference between the thickness ( H1 ) of the two edges of thelight guide layer 33 and the thickness ( H2 ) of the middle position of thelight guide layer 33 is about a quarter of the total thickness of thesubstrate 30 , theP-N diode 31 and the firstreflective layer 32 One (meaning less than a quarter of the flip-chip light-emitting diode 3), further about 10-50 microns (10-20 μm), the thickness (H2) at the middle position of thelight guide layer 33 is thesubstrate 30, the P-N diode The total thickness of 31 and the firstreflective layer 32 is one-tenth of the total thickness (that is, about one-tenth of the flip-chip light emitting diode 3), and further about 10-20 microns (10-20 μm).

請參閱圖7所示,本發明係一種背光模組,係包括複數個前述的倒裝發光二極體3、電路板4、背光膜材5,各倒裝發光二極體3係夾設在電路板4與背光膜材5之間,其中倒裝發光二極體3係為裸晶,為了避免損壞,各倒裝發光二極體3上設置保護層38,且各倒裝發光二極體3連接電路板4。如此,當電路板4可以傳送電力及輸出驅動訊號到各倒裝發光二極體3,使得各倒裝發光二極體3朝向背光膜材5發光,並且倒裝發光二極體3的光源可以有效地且均勻地朝向背光膜材5的方向發光。Referring to FIG. 7, the present invention is a backlight module, which includes a plurality of the aforementioned flip-chip light-emitting diodes 3,circuit boards 4, andbacklight films 5, and each flip-chip light-emitting diode 3 is sandwiched between Between thecircuit board 4 and thebacklight film 5, the flip-chip light-emitting diodes 3 are bare chips. In order to avoid damage, aprotective layer 38 is provided on each flip-chip light-emitting diode 3, and each flip-chip light-emitting diode 3 Connect thecircuit board 4. In this way, when thecircuit board 4 can transmit power and output driving signals to each flip-chip light-emitting diode 3, so that each flip-chip light-emitting diode 3 emits light toward thebacklight film 5, and the light source of the flip-chip light-emitting diode 3 can be It emits light efficiently and uniformly toward the direction of thebacklight film material 5 .

請參閱圖8所示,本發明係一種倒裝發光二極體之製造方法,包括下列步驟: (S101) 提供一待製品6,待製品包括一基板30、複數個P-N二極管31及複數個第一反射層32,其中各P-N二極管31設置在基板30之一側,各第一反射層32分別設置在其中一個P-N二極管31相對於基板30的一側; (S102) 在基板30相對於各P-N二極管31之一側製作導光層33,各導光層33相對基板30的一側為光路調整面330; (S103) 沿著光路調整面330製作第二反射層34;以及 (S104)切割各導光層33及其相對應的第二反射層34直到基板30面對各P-N二極管31的一面為止,形成複數個倒裝發光二極體。Please refer to FIG. 8 , the present invention is a manufacturing method of a flip-chip light-emitting diode, comprising the following steps: (S101) Provide aproduct 6 to be prepared, which includes asubstrate 30, a plurality ofP-N diodes 31 and a plurality of firstreflective layers 32, wherein each of theP-N diodes 31 is disposed on one side of thesubstrate 30, and each of the firstreflective layers 32 respectively arranged on one side of one of theP-N diodes 31 relative to thesubstrate 30; (S102) Alight guide layer 33 is formed on one side of thesubstrate 30 opposite to each of theP-N diodes 31, and the side of eachlight guide layer 33 opposite to thesubstrate 30 is an opticalpath adjustment surface 330; (S103) forming the secondreflective layer 34 along the opticalpath adjustment surface 330; and (S104) Cutting eachlight guide layer 33 and its corresponding secondreflective layer 34 until one side of thesubstrate 30 facing eachP-N diode 31, to form a plurality of flip-chip light emitting diodes.

綜上所述,本發明的倒裝發光二極體係在原本的傳統製程上增加製作導光層33,並未增加太多額外的製程及生產時間,但是可以大幅提高倒裝發光二極體從側面出光的效率。To sum up, the flip-chip light-emitting diode system of the present invention adds the fabrication of thelight guide layer 33 to the original traditional process, without adding too much extra process and production time, but can greatly improve the flip-chip light-emitting diode from Efficiency of side light extraction.

在本發明中,製作導光層33的步驟進一步包括: (S1021)將光阻7塗佈在基板30相對於P-N二極管31之一側; (S1022)對光阻7進行曝光,且對光阻7的曝光強度分布係分別對應各P-N二極管31的位置進行調整; (S1023)對光阻7進行顯影,完成顯影後光阻7即形成導光層33,並導光層33在背對各P-N二極管31分別形成光路調整面330,且光路調整面330與基板30之間具有夾角。In the present invention, the step of making thelight guide layer 33 further includes: (S1021) Coating thephotoresist 7 on one side of thesubstrate 30 opposite to theP-N diode 31; (S1022) exposing thephotoresist 7, and adjusting the exposure intensity distribution of thephotoresist 7 respectively corresponding to the position of eachP-N diode 31; ( S1023 ) Thephotoresist 7 is developed. After the development is completed, thephotoresist 7 forms alight guide layer 33 , and thelight guide layer 33 forms an opticalpath adjustment surface 330 on the back of eachP-N diode 31 , and the opticalpath adjustment surface 330 and thesubstrate 30 . There is an angle between them.

在本發明中,在進行曝光的過程中,對光阻7的曝光強度分布係針對各P-N二極管31的中央往兩側漸變,對光阻7進行顯影,完成顯影後光阻7即形成導光層33,且導光層33在背對各P-N二極管31形成光路調整面330,各光路調整面330的厚度以相對各P-N二極管31中央到兩側逐漸增厚。In the present invention, during the exposure process, the exposure intensity distribution of thephotoresist 7 is gradually changed from the center of eachP-N diode 31 to both sides, and thephotoresist 7 is developed. After the development is completed, thephotoresist 7 forms a light guide. Thelight guide layer 33 forms an opticalpath adjustment surface 330 opposite to eachP-N diode 31 .

在本發明中,光阻7為正型光刻膠,而當對光阻7進行曝光時,係以半調色掩膜板8設置在光源與光阻7之間,利用半調色掩膜板8調整光源的曝光強度從相對各P-N二極管31的中央往兩側逐漸減弱。光阻7為負型光刻膠,而當對光阻7進行曝光時,係以半調色掩膜板8設置在光源與光阻7之間,利用半調色掩膜板8調整光源的曝光強度從相對各P-N二極管31的中央往兩側逐漸增強。其中切割為使用雷射切割機9進行切割。In the present invention, thephotoresist 7 is a positive type photoresist, and when exposing thephotoresist 7, ahalftone mask 8 is arranged between the light source and thephotoresist 7, and the halftone mask is used. Theplate 8 adjusts the exposure intensity of the light source to gradually decrease from the center to both sides of eachP-N diode 31 . Thephotoresist 7 is a negative-type photoresist, and when thephotoresist 7 is exposed, a half-tone mask 8 is arranged between the light source and thephotoresist 7, and the half-tone mask 8 is used to adjust the light source. The exposure intensity gradually increases from the center to both sides of each of theP-N diodes 31 . The cutting is performed by using a laser cutting machine 9 .

綜上所述,發光層312所發出的光源從第一反射層31與第二反射層34之間反射直到從倒裝發光二極體3的側面出光,減少光源在倒裝發光二極體3內部來回繞射,進而可以增加發光效率,同時減少產生熱能。再者,本發明僅增設一個導光層33的製作流程,其餘的製程皆與傳統的倒裝發光二極體3雷同,故本發明在較低程度的流程就可以達到最佳的側面出光效果。To sum up, the light source emitted by the light-emittinglayer 312 is reflected from thefirst reflection layer 31 and thesecond reflection layer 34 until the light is emitted from the side of the flip-chip light-emittingdiode 3 , reducing the amount of light emitted by the light source in the flip-chip light-emittingdiode 3 . Internal back-and-forth diffraction, which in turn can increase the luminous efficiency, while reducing the generation of heat energy. Furthermore, the present invention only adds a manufacturing process of thelight guide layer 33 , and the rest of the manufacturing processes are similar to the traditional flip-chip light-emittingdiode 3 , so the present invention can achieve the best side light output effect at a relatively low level of process. .

上列詳細說明係針對本發明的可行實施例之具體說明,惟前述的實施例並非用以限制本發明之專利範圍,凡未脫離本發明技藝精神所為之等效實施或變更,均應包含於本案之專利範圍中。The above detailed descriptions are specific descriptions of feasible embodiments of the present invention, but the foregoing embodiments are not intended to limit the patent scope of the present invention. Any equivalent implementation or modification that does not depart from the technical spirit of the present invention shall be included in the within the scope of the patent in this case.

10:正裝發光二極體 11、20、5:背光膜材 12:導光板 13、21:反射片 22、3:倒裝發光二極體 220、34:第二反射層 221、30:基板 31:P-N二極管 222、310:N型半導體層 223、312:發光層 224、311:P型半導體層 225、32:第一反射層 33:導光層 330:光路調整面 226、35:負電極 227、36:正電極 228、37:絕緣層 38:保護層 4:電路板 5:背光膜材 6:待製品 7:光阻 8:半調色掩膜板 9:雷射切割器 θ:夾角 H1:導光層兩側邊緣的厚度 H2:導光層中間位置的厚度 S101~S104:步驟 S1021~S1023:步驟10: formal installation of light-emittingdiodes 11, 20, 5: Backlight film 12:Light guide plate 13, 21:Reflector 22, 3: Flip-chip light-emittingdiodes 220, 34: The secondreflective layer 221, 30: substrate 31:P-N diode 222, 310: N-type semiconductor layer 223, 312: light-emittinglayer 224, 311: P-type semiconductor layer 225, 32: the first reflective layer 33: light guide layer 330: Opticalpath adjustment surface 226, 35:negative electrode 227, 36:positive electrode 228, 37: insulating layer 38: Protective layer 4: circuit board 5: Backlight film 6: Products to be prepared 7: Photoresist 8: Halftone mask 9: Laser cutter θ: included angle H1: The thickness of the edges on both sides of the light guide layer H2: Thickness at the middle of the light guide layer S101~S104: Steps S1021~S1023: Steps

圖1係傳統側入式背光模組之示意圖。 圖2係傳統直下式背光模組之示意圖。 圖3係傳統倒裝發光二極體之示意圖。 圖4係本發明之倒裝發光二極體之示意圖。 圖5係本發明之第一實施例的倒裝發光二極體之示意圖。 圖6係本發明之第二實施例的倒裝發光二極體之示意圖。 圖7係本發明之背光模組之示意圖。 圖8係本發明之側光式倒裝發光二極體之製作流程示意圖。FIG. 1 is a schematic diagram of a conventional edge-lit backlight module. FIG. 2 is a schematic diagram of a conventional direct type backlight module. FIG. 3 is a schematic diagram of a conventional flip-chip light emitting diode. FIG. 4 is a schematic diagram of the flip-chip light emitting diode of the present invention. FIG. 5 is a schematic diagram of a flip-chip light emitting diode according to the first embodiment of the present invention. FIG. 6 is a schematic diagram of a flip-chip light emitting diode according to a second embodiment of the present invention. FIG. 7 is a schematic diagram of the backlight module of the present invention. FIG. 8 is a schematic diagram of the manufacturing process of the edge-lit flip-chip light emitting diode of the present invention.

3:倒裝發光二極體3: Flip chip light-emitting diode

30:基板30: Substrate

31:P-N二極管31: P-N diode

32:第一反射層32: The first reflective layer

33:導光層33: light guide layer

330:光路調整面330: Optical path adjustment surface

34:第二反射層34: Second reflective layer

θ:夾角θ: included angle

H1:導光層兩側邊緣的厚度H1: The thickness of the edges on both sides of the light guide layer

H2:導光層中間位置的厚度H2: Thickness at the middle of the light guide layer

Claims (4)

Translated fromChinese
一種倒裝發光二極體之製造方法,包括下列步驟:提供一待製品,待製品包括一基板、複數個P-N二極管及複數個第一反射層,其中各該P-N二極管設置在該基板之一側,各該第一反射層分別設置在其中一個該P-N二極管相對於該基板的一側;在該基板相對於各該P-N二極管之一側製作一導光層,各導光層相對基板的一側為一光路調整面,其中製作該導光層的步驟進一步包括:將一光阻塗佈在該基板相對於該P-N二極管之一側,對該光阻進行曝光,且對該光阻的曝光強度分布係分別對應各該P-N二極管的位置進行調整;以及對該光阻進行顯影,完成顯影後該光阻即形成該導光層,且該導光層在背對各該P-N二極管分別形成該光路調整面,又該光路調整面與基板之間具有夾角;沿著該光路調整面製作一第二反射層;以及切割各該導光層及其相對應的該第二反射層直到該基板面對各該P-N二極管的一面為止,分別形成一倒裝發光二極體。A method for manufacturing flip-chip light-emitting diodes, comprising the steps of: providing a product to be prepared, the product to be prepared includes a substrate, a plurality of P-N diodes and a plurality of first reflective layers, wherein each of the P-N diodes is arranged on one side of the substrate , each of the first reflective layers is respectively arranged on one side of the P-N diode relative to the substrate; a light guide layer is made on one side of the substrate relative to each of the P-N diodes, and each light guide layer is opposite to the side of the substrate It is an optical path adjustment surface, wherein the step of making the light guide layer further includes: coating a photoresist on one side of the substrate opposite to the P-N diode, exposing the photoresist, and exposing the photoresist to an exposure intensity The distribution system is adjusted respectively corresponding to the position of each of the P-N diodes; and the photoresist is developed, and the light guide layer is formed on the photoresist after the development is completed, and the light guide layer is facing away from each of the P-N diodes. The light path is formed respectively an adjustment surface, and an angle between the optical path adjustment surface and the substrate; making a second reflective layer along the optical path adjustment surface; and cutting each of the light guide layers and their corresponding second reflective layers until the substrate faces A flip-chip light-emitting diode is formed up to one side of each of the P-N diodes.如請求項1所述的倒裝發光二極體之製造方法,其中在進行曝光的過程中,對該光阻的曝光強度分布係針對各該P-N二極管的中央往兩側漸變,完成顯影後該導光層在背對各該P-N二極管的一側形成該光路調整面,各該光路調整面的厚度以相對各該P-N二極管中央到兩側逐漸增厚。The method for manufacturing flip-chip light-emitting diodes as claimed in claim 1, wherein in the process of exposing, the exposure intensity distribution of the photoresist is gradually changed from the center of each of the P-N diodes to both sides. The light guide layer forms the optical path adjustment surface on the side facing away from each of the P-N diodes, and the thickness of each of the optical path adjustment surfaces gradually increases relative to the center to both sides of each of the P-N diodes.如請求項2所述的倒裝發光二極體之製造方法,其中該光阻為正型光刻膠,而當對該正型光刻膠進行曝光時,係以一半調色掩膜板設置在一光源與該正型光刻膠之間,利用該半調色掩膜板調整該光源的曝光強度從相對各該P-N二極管的中央往兩側逐漸減弱。The method for manufacturing flip-chip light-emitting diodes as claimed in claim 2, wherein the photoresist is a positive type photoresist, and when the positive type photoresist is exposed, a half-tone mask is set Between a light source and the positive photoresist, the halftone mask is used to adjust the exposure intensity of the light source to gradually decrease from the center to the two sides relative to each of the P-N diodes.如請求項2所述的倒裝發光二極體之製造方法,其中該光阻為負型光刻膠,而當對負型光刻膠進行曝光時,係以半調色掩膜板設置在一光源與該負型光刻膠之間,利用一半調色掩膜板調整該光源的曝光強度從相對各該P-N二極管的中央往兩側逐漸增強。The method for manufacturing flip-chip light-emitting diodes as claimed in claim 2, wherein the photoresist is a negative-type photoresist, and when exposing the negative-type photoresist, a half-tone mask is set on the Between a light source and the negative photoresist, a half-tone mask is used to adjust the exposure intensity of the light source to gradually increase from the center to the two sides of each of the P-N diodes.
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