CN1825641A - 半导体发光器件及制造方法 - Google Patents

半导体发光器件及制造方法 Download PDF

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CN1825641A
CN1825641A CNA200510115051XA CN200510115051A CN1825641A CN 1825641 A CN1825641 A CN 1825641A CN A200510115051X A CNA200510115051X A CN A200510115051XA CN 200510115051 A CN200510115051 A CN 200510115051A CN 1825641 A CN1825641 A CN 1825641A
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周东发
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Abstract

本发明公开了一种半导体发光器件及其制造方法。发光二极管(“LED”)器件具有安装到衬底的LED芯片。LED芯片的端子电耦合到LED器件的引脚。LED器件的容器内的弹性体密封剂包围LED芯片。第二密封剂布置在弹性体密封剂上的容器孔内。

Description

半导体发光器件及制造方法
技术领域
本发明涉及半导体发光器件及制造方法。
背景技术
传统的发光二极管(“LED”)器件使用环氧树脂作为密封材料。密封过程经常是通过注射成型(injection molding)、转注成型(transfermolding)或铸造完成的。凝固的环氧密封剂具有相对高的硬度(这提供了抗擦伤和抗磨损的性能)、高刚度和高的初始透光率。传统的密封LED器件以多种尺寸和样式出现,例如4mm椭圆形LED灯、5mm圆形LED灯、贴片LED和塑封有引线芯片载体(“PLCC”)。
但是,基于环氧树脂的密封材料易受到热降解和光降解作用损害。如果LED芯片发射的波长在光谱的近紫外(UV)部分,降解特别严重。当经受高的光通量,特别是光波长在200nm到570nm范围内时,环氧密封材料发生降解。密封剂降解引起蓝色到绿色波长的光吸收增加,导致透明环氧密封剂的“黄化”效应并降低了通过密封剂的透光率,这使得LED器件的光输出严重下降。通常基于环氧树脂的5mm LED灯器件在使用1000小时后,光输出下降20%或更多,而在使用10000小时后下降50%或更多。
图1A示出传统LED灯102、104半成品构成的条100的一部分。LED灯102、104安装到制成一条LED灯的引线框106。通过剪断引脚108、110可以将LED灯与引线框106分离。“分离”表示将一个LED灯或一组相关联的LED灯从引线框或其他衬底分开,其他衬底例如陶瓷衬底或印刷电路板(“PCB”)衬底。
LED芯片114安装到第一衬底部分115上,该衬底部分将LED芯片114的第一端子(未示出)电耦合到引脚110。在一个特定实施例中,LED芯片使用导电环氧树脂安装在第一衬底部分的反射器杯(reflector cup)中。接合线112将LED芯片114的第二端子(未示出)电耦合到第二衬底部分117。接合线112、LED灯114、第一衬底部分115、第二衬底部分117以及部分引脚108、110密封在刚性的硬密封剂116(例如环氧密封剂)中。当LED灯从引线框106剪下时,刚性的硬密封剂116通过固定第一和第二衬底部分使之彼此不相对运动而防止接合线损坏。
图1B示出传统的单个LED灯102。引脚108、110已经从引线框切开(见图1A,标号106、108、110)。一个引脚108被切得比另一引脚110短,以指示LED芯片114的电极性。刚性的硬密封剂116将引脚相对于彼此固定,以免损坏接合线112。
图1C示出插入并钉牢在PCB 120中的传统单个LED灯102。在通常的自动装配工序中,LED灯102的引脚108、110通过PCB 120中的孔插入并弯曲,来将LED灯102固定到位以用于后续焊接步骤。刚性的坚固环氧密封剂固定引脚108、110以使其不彼此相对运动,否则这种运动可能损坏LED芯片114和/或接合线112。
图2示出现有技术的光源200。LED芯片214安装到PCB衬底201上。接合线212、213将LED芯片214上的端子(未示出)电耦合到PCB衬底201上的端子208、210。端子208、210是允许光源200在表面安装电路衬底上进行表面安装的镀覆通孔。在形成为圆盖形的密封剂216在LED芯片214和PCB衬底201顶部的上方成型之前,将镀覆通孔用例如阻焊剂的混合物211堵塞。关于这样的光源的更多信息可以在美国专利No.6806583中找到。
图3是另一种现有技术的LED器件300的简化剖视轴测图。LED芯片314安装到硅衬底构件301(形成通常所知“芯片堆叠(chip-on-chip)”组件),该衬底构件301安装到衬底构件303上。在具体实施例中,LED芯片314是高功率LED芯片,即工作于500mW或更高的LED芯片,并且衬底构件303是提供散热器来将热量经过硅衬底构件301传导离开LED芯片314的金属(例如金属“栓”)。引脚308从通常为模制聚合物的引脚支撑构件309伸出。此视图中未示出第二引脚,但其基本上从引脚308对面的引脚支撑构件伸出。
预先模制的热塑性罩316配合安装在LED芯片314上方以形成LED器件300内部的腔315。按照期望的LED器件300光强分布模式,罩316的外形形成为透镜。该罩形成内置了LED芯片314的腔315。随后,液体硅酮密封剂通过封装中的开口分配或注入而引入腔中,以填充封装内的腔315中的整个空间,然后将密封剂材料凝固。填充腔315的硅酮提供了光学透明的软材料,其具有大于1.3的折射率。
期望与高功率LED芯片(特别是工作于光谱的蓝色到绿色部分的那些芯片)同时使用硅酮材料,因为硅酮与LED灯(例如图1B中所示的LED灯102)中使用的环氧树脂相比更不易于黄化。但是,图3的LED器件300中使用的封装技术相对复杂精细,包括许多部分和装配步骤。
因此需要这样的LED器件,其既不像传统LED灯那样降解,又无需通常封装高功率LED芯片所用的那样多的部件和装配步骤。
发明内容
发光二极管(“LED”)器件具有安装到衬底的LED芯片。LED芯片的端子电耦合到LED器件的引脚。LED器件的容器内的弹性体密封剂包围LED芯片。第二密封剂布置在弹性体密封剂上的容器孔内。
附图说明
图1A示出一条传统半成品LED灯的一部分。
图1B示出单个传统LED灯。
图1C示出插入并钉牢在PCB中的传统单个LED灯。
图2示出现有技术的光源。
图3是另一种现有技术的LED器件的简化剖视轴测图。
图4示出根据本发明实施例的LED器件(“灯”)的简化截面图。
图5A-5C示出根据本发明的实施例的替代容器。
图6A是根据本发明的实施例,具有圆形凸缘和圆形边缘的容器的轴测图。
图6B是根据本发明的实施例,带有方形凸缘和方形边缘的容器的分解轴测图。
图7A-7C示出部分LED灯的截面图,以图示根据本发明实施例的制造顺序。
图8是根据本发明另一实施例的LED灯的截面图。
图9示出根据本发明另一实施例的LED灯的截面图。
图10示出根据本发明另一实施例的LED灯的截面图。
图11A示出根据本发明另一实施例的LED灯的截面图。
图11B是图11A的衬底的俯视图。
图12-14是构建来容纳多于一个LED芯片的容器的轴测图。
图15是根据本发明的实施例制造LED器件的方法的流程图。
具体实施方式
硅酮弹性体提供了作为密封材料的良好特性。硅酮弹性体提供了较高的热稳定性、较低的光降解、较低的透光损耗特性、较宽的折射率范围、密封凝固后应力较低、以及较低的成本。其无毒并对高湿度高温环境不敏感。由于其透光损耗低,硅酮密封剂用于波长范围从200nm到570nm的发光特别理想,用于高温操作(即高达100℃)时更是特别理想。
但是,凝固的硅酮密封剂的硬度通常小于邵氏硬度计值70A。硅酮聚合物在不同制造阶段可以是液体、凝胶状或固态。但是,硅酮聚合物的低硬度具有抗刮擦、擦伤和磨损性低的缺点。此外,由硅酮聚合物形成的封装不具有高刚度,并且在经受机械处理时不提供很好的尺寸稳定性,从而减小了其易装配程度并限制了其在各种优选LED封装外形设计中的使用范围。
如果图1A中所示LED灯102的环氧密封剂116用硅酮密封剂代替,则当LED灯从引线框分离或通过PCB插入之后弯曲引脚(见图1C)时,引脚108、110以及第一和第二衬底部分115、117可能不能保持足够刚度以避免接合线损坏。具有硅酮密封剂的LED灯外表面也可能更容易发生降低光学性能的刮擦、擦伤和磨损。于是,由于一般硅酮材料的低硬度和低刚度,使用硅酮作为密封剂不能获得类似于图1B的现有技术器件的可靠LED灯。
如果在使用硅酮-荧光波长转换层的LED灯中用硅酮类密封剂代替环氧密封剂,会出现另一个问题。与硅酮-荧光涂层和环氧密封剂之间的粘接强度相比,硅酮-荧光涂层到LED芯片的粘接强度相对较弱,这使得硅酮-荧光层从LED芯片表面剥离。
与更加凝固硬化的聚合物相比,在凝固后,硅酮在封装中的LED芯片上产生的压应力或拉应力通常较低。LED芯片上的应力降低可使LED器件更可靠、更长寿。已知硅酮用于具有薄且均匀的波长转换材料层(例如荧光颗粒和/或散布在硅酮基体中的量子点颗粒)的LED芯片特别理想。可选地添加硅石的小颗粒作为扩散剂。这样的“荧光层”通常小于LED结构厚度的约10%,并能够使从LED芯片发射的光穿过均匀的路径长度,从而使均匀比例的光在荧光层中转化。这导致从LED器件输出的颜色相对于光的空间分布是均匀的。荧光层和硅酮密封剂之间的硅酮-硅酮界面已知在热漂移中受化学不相容性和机械不相容性的影响极小。
图4示出根据本发明实施例的LED器件(“灯”)400的简化截面图。LED灯400竖着看是圆形的,并具有容器402,具有高硬度、高刚度和高透光性的该容器402通常是透明的,但也可以是漫射的,弹性体密封剂404布置在容器402中。容器402可以用例如具有高刚度、高抗刮擦性的基本透明的材料,例如但不限于如聚碳酸酯、环烯聚合物或共聚物、聚酰胺、聚甲基丙烯酸甲酯(PMMA)、液晶聚合物(“LCP”)、环氧树脂和聚砜的材料,通过注射成型或转注成型形成。此处使用的“透明”表示清澈的或淡色的。在一些实施例中,LED芯片发射约200nm和约700nm之间的波长。
LED芯片408机械安装到可选的反射器杯410中的第一衬底部分406。LED芯片的第一端子(未示出)用导电胶电耦合到第一衬底部分406。LED芯片的第二端子(未示出)用接合线416电耦合到第二衬底部分407。弹性体密封剂404分配到容器402中,并且LED芯片408、第一和第二衬底部分406、407以及接合线416插入弹性体密封剂404中,之后使弹性体密封剂404凝固。
容器402起模杯(mold-cup)的作用,该模杯形成LED灯400成品的一部分。容器402成为LED灯400成品的一部分,这样防止了在从模子上除去弹性体密封剂时可能出现的剥离问题。合适的弹性体密封剂包括硅酮、氟硅酮、全氟聚合物以及无定形氟塑料。合适的密封剂包括Young等人的题为“Optically clear high temperature resistant silicone polymers of highrefractive index”的美国专利申请公开No.US 2004/0198924A1中描述的密封剂,其可从加利福尼亚州Carpenteria的NUSIL TECHNOLOGY得到。
以前是金属引线框带一部分的第一引脚412从第一衬底部分406伸出。以前也是金属引线框带一部分的第二引脚414从第二衬底部分407伸出。
容器402具有实际上不均匀的厚度,这就形成透镜以对来自LED芯片408的光进行导向。另一透镜由弹性体密封剂404根据容器402的内部曲率形成。容器形成的透镜和弹性体密封剂形成的透镜的组合在获得用传统LED密封剂(例如,图1A标号116)不能实现的光分布模式方面特别理想。在具体实施例中,选择弹性体密封剂和容器材料来使弹性体密封剂材料的折射率大于容器材料的折射率,以使光的菲涅耳透射损耗最小化。更高的弹性体密封剂材料折射率提供改进的效率。
在弹性体密封剂404凝固后,在弹性体密封剂404之上回填第二密封剂418。第二密封剂凝固后是刚性的,在具体实施例中具有大于D70的邵氏硬度,这在分离和将LED灯组装到电路的过程中对于保护引脚是理想的。回填是通过分配处于液态或凝胶态的未凝固的第二密封剂完成的。第二密封剂418凝固后在弹性体密封剂404顶部形成导热、坚硬的刚性层,将LED芯片408和弹性体密封剂404密封在容器402内。在具体实施例中,第二密封剂418包括散布在环氧基体中的导热填料,例如陶瓷(例如硅-氧化铝)粉末。在具体实施例中,第二密封材料的导热率大于0.5W/m°K。
第二密封剂418层为引脚412、414提供了更坚固、更高刚度的基座,减小了分离、处理和装配操作过程中对LED芯片408和接合线416的潜在损坏。第二密封剂418也有助于通过沿着引脚412、414以及向着容器402将热量导离衬底406而耗散LED芯片408在操作中产生的热。
图5A-5C示出根据本发明实施例的替代容器。图5A示出与图4的容器402类似,并外加了凸缘504的容器502的截面图。凸缘方便了用户在一些应用中制造和装配LED灯。图5B示出根据本发明另一实施例的壁厚基本均匀的容器506的截面图。图5C示出带有凸缘510且壁厚基本均匀的容器508的截面图。替代实施例使用其他形状。在具体实施例中,选择容器的壁厚以便在用弹性体密封剂填充时提供来自LED器件的光强的理想空间分布。
图6A是根据本发明实施例具有圆形凸缘602和圆形边缘604的容器600的轴测图。边缘在LED灯穿过PCB插入以限制LED灯的高度时是有用的。图6B是具有容器608和衬底610的LED灯606的分解轴测图。在具体实施例中,衬底610是PCB衬底,其具有阴极电触盘613、中心盘612以及位于衬底610背面的阳极电触盘614,其中中心盘612在一些实施例中作为散热盘并在替代实施例中作为第二阴极盘。LED芯片(未示出)安装在衬底610相对侧的反射器杯中并电耦合到触盘。容器608具有方形凸缘616和方形边缘618。
衬底610中的对准孔620与容器608上的对准销622配合来使衬底对准容器,并因此使LED芯片(未示出)对准容器。将弹性体密封剂(未示出)分配到容器608的模杯624中,衬底610与容器608装配,并使弹性体密封剂凝固。在此实施例中,刚性的第二密封剂是可选的。(多个)阴极电触盘和阳极电触盘没有用密封剂覆盖,并可用于将LED灯表面安装到表面安装电路板上。在替代实施例中使用其他形状和形式的容器。特别地,替代实施例使用设置成容纳几个LED的容器,例如图12-14所示的那些。
图7A-7C示出LED灯的多个部分的截面图,以图示根据本发明的实施例的制造顺序。在图7A中,容器702填充有未凝固的弹性体密封剂材料704,例如液态或凝胶状态的硅酮密封剂材料。LED芯片708已管芯安装(die-attach)到作为引线框条710一部分的衬底706。夹具712在凝固步骤中夹持容器。或者,空容器置于夹具712中,然后将其用弹性体密封剂填充。边缘714将容器702支撑在夹具712中。
图7B示出衬底706和插入流体弹性体密封剂并随后凝固的LED芯片708。图7C示出分配到凝固的弹性体密封剂704上并围绕引脚718、720的第二密封剂716。之后第二密封剂被凝固。凝固后,第二密封剂716比凝固的弹性体密封剂704更硬、更坚固。第二密封剂材料的厚度仅仅是示例性的。在具体实施例中,第二密封剂材料比示出的更厚,并进一步向衬底表面延伸,这可以增强导热性能并为引脚和衬底提供更多支撑。
图8是根据本发明另一实施例的LED灯800的截面图。LED芯片808是具有硅制副底座(未单独示出)的倒装芯片(flip-chip)LED。倒装芯片LED在美国专利No.6521914和6646292中有进一步讨论。LED芯片808在器件的同一侧既有阳极结合盘(未示出),也有阴极结合盘(未示出)。接合线816、817将LED芯片808的端子电连接到引脚412、414。
回填第二密封剂818来基本包围衬底406直到接近LED芯片808,以提供从倒装芯片LED到第二密封剂818的更短的热路径。更厚的第二密封剂还为衬底406和引脚412、414提供了更坚固、更有刚性的基座。其他实施例在单个LED封装中包括许多LED芯片。
图9示出根据本发明另一实施例的LED灯900的截面图。衬底906是带有管脚(引脚)912、914的PCB衬底,这些管脚配置为符合双列直插封装(“DIP”)标准的引脚。此实施例对于通孔安装特别理想。容器902中的弹性体密封剂904覆盖LED芯片908和关联的接合线。凝固的第二密封剂918比弹性体密封剂904更硬、更有刚性,提供了可靠的密封,可靠地将衬底906紧固在容器902内,并进一步支撑管脚912、914。
图10示出根据本发明另一实施例的LED灯1000的截面图。衬底1006是PCB,其带有背面端子1012、1014以形成用于表面安装技术(“SMT”)应用的LED部件。衬底1006的厚度足以允许将衬底1006定位成使得安装在衬底1006一侧的LED芯片1008被弹性体密封剂1004密封,而背面端子1012、1014暴露在衬底1006的相反一侧。适合于SMT应用的LED在Koay等人题为“Light source”的美国专利No.6806583中有进一步描述。衬底1006部分由弹性体密封剂1004密封,部分由第二密封剂层1018密封,后者硬度更高,刚度更高,而且比弹性体密封剂更易导热。替代实施例使用带反射器杯的陶瓷衬底(例如氧化铝或氮化铝),该反射器杯镀有如银、镍、金或铝的反射性材料。
图11A示出根据本发明另一实施例的LED灯1100的截面图。衬底1106是“鸥翼(gull-wing)”型衬底。“J形引脚”衬底在提供用于LED灯表面安装的外部引脚方面与鸥翼型衬底相似。鸥翼型衬底是形成为鸥翼型SMT结构的金属引线框。金属引线框可以包括形成于其上并镀有反射性表面的反射器杯1110。衬底1106可以配置为具有2个或更多引脚1112、1114用于其电端子,且不限于图11A中所示例子。在本发明实现方式的一个方面,形成金属引线框或PCB中反射器杯的反射性表面的镀层材料可以包括但不限于银、镍或金。图11B是图11A的衬底的俯视图。
图12-14是配置为容纳多于一个LED芯片的容器1200、1300、1400的轴测图。容器1200有三个模杯1202、1204、1206和包围三个模杯1202、1204、1206的周围边缘1208。分配弹性体密封剂以将容器填充到希望的高度。安装在衬底上的LED或衬底插入弹性体密封剂中。在具体实施例中,三个LED安装在单个矩形衬底上并由弹性体密封剂包围,该衬底插入容器中以使LED将光发送到模杯中。边缘1208对准容器中的衬底,该衬底将LED定位在模杯中。
图13示出具有单个模杯/透镜1302的容器1300,弹性体密封剂分配到其中。之后多个衬底上的多个LED芯片或单个衬底上的多个LED芯片通过椭圆形孔1304插入弹性体密封剂中。图14示出具有六个模杯/透镜和周围边缘1402的另一个容器1400。
可以将一个或更多LED芯片安装到衬底上,并且衬底可以有两个或更多电端子。容器的形状和透镜轮廓的数量可以配置为与LED和LED所在的衬底轮廓的数量相符。图中示出的配置是所用的透明容器形状的代表,本发明不限于这些形状。
图15是根据本发明实施例的制造LED器件1500的方法的流程图。LED芯片被管芯安装到衬底(步骤1502)并电连接到引脚(步骤1504)。在一种实施例中,衬底用导电管芯安装技术连接到LED芯片的第一端子,并用接合线连接到LED芯片的第二端子。在替代实施例中,第一接合线将LED芯片的第一端子耦合到第一引脚(例如与第一引脚集成的衬底),第二接合线将LED芯片的第二端子连接到第二引脚。在具体实施例中,第一和第二引脚从引线框带伸出。在替代实施例中,衬底是PCB衬底或分离时形成单独LED器件的PCB衬底阵列。在具体实施例中,散布在基体(例如硅酮、其他弹性体材料或溶胶-凝胶)中的荧光颗粒波长转换层布置在LED芯片上。
未凝固的弹性体密封剂分配到容器中(步骤1506),LED芯片和衬底插入未凝固的弹性体密封剂中(步骤1508)。之后弹性体密封剂被凝固(步骤1510)。在具体实施例中,包括任何对准夹具在内的整个LED器件或LED引线框带在传送带式加热炉或箱式加热炉中被凝固。
容器由比凝固的弹性体密封剂材料更硬、更有刚性的材料制成,通常是塑料。在一种实施例中,将LED芯片插入未凝固的弹性体密封剂中,以用未凝固的弹性体密封剂包围LED芯片。容器的体积一般是已知的,并将选定量的密封剂分配到容器中。LED-衬底子组件插入未凝固的弹性体密封剂中直到选定的深度,以使未凝固的弹性体密封剂填充容器到希望的水平。
在具体实施例中,将LED芯片、(多根)接合线、衬底和部分引脚插入未凝固的弹性体密封剂中。在具体实施例中,LED芯片平放在反射器杯内,且该方法包括在LED芯片和衬底插入分配到容器中的弹性体密封剂之前用未凝固的弹性体密封剂预填充反射器杯的可选步骤。对反射器杯进行预填充避免了可能在LED芯片附近形成(多个)气泡的捕集气体,这可能干扰LED器件的发光和LED芯片的散热。
在进一步的实施例中,将第二密封剂分配到容器中弹性体密封剂之上(步骤1512)然后凝固(步骤1514)。在具体实施例中,凝固的第二密封剂比弹性体密封剂更有刚性,并包围和固定引脚。在一些实施例中,第二密封剂提供了横跨孔的第二密封,其比弹性体密封剂提供的第一密封更坚固、更持久。在更进一步的实施例中,切断引脚以将LED器件从引线框带分离(步骤1516),或者从PCB衬底阵列将具有PCB衬底的LED器件分离。
坚硬的外部容器与内部弹性体材料的结合提供了超越传统LED灯的一些优点。参考图1A,如果环氧树脂用于密封剂116,凝固引起的应力可能损坏接合线。在热冲击(例如回流焊接工艺)过程中,环氧树脂和衬底之间热膨胀系数的差异还造成热应力。在灯加热和冷却时,过度的应力可能使LED芯片翘起或裂开。弹性体密封剂在封装中提供了更小的应力,以及如回流焊接的热冲击后更好的可靠性和成品率。类似地,弹性体密封剂防止了光输出的降解(黄化),特别是对于发射短波长光(即小于570nm)的中功率到低功率LED芯片(即小于500mW)。容器为弹性体密封剂提供刚性和抗磨损性。但是,实施例也适用于以大于500mW的功率发射大于570nm波长的LED器件。本发明的实施例易于适用到引线框LED制造技术,其用很少的零件提供了简单的构造,并方便了大批量生产的制造。
尽管已经详细图示了本发明的优选实施例,但显然,在不脱离如所附权利要求中所阐述本发明范围的情况下,本领域技术人员可以想到对这些实施例进行的变更和修改。

Claims (20)

1.一种发光二极管灯,包括:
衬底;
发光二极管芯片,其具有安装到所述衬底的第一端子和第二端子;
第一引脚,其电耦合到所述发光二极管的所述第一端子;
第二引脚,其电耦合到所述发光二极管的所述第二端子;
具有孔的容器,所述衬底的至少一部分和所述发光二极管芯片通过所述孔被插入所述容器中;
弹性体密封剂,其在所述容器内至少包围所述发光二极管芯片;以及
刚性密封剂,其位于所述容器的所述孔内所述弹性体密封剂上。
2.根据权利要求1所述的发光二极管灯,其中所述弹性体密封剂包括硅酮密封剂。
3.根据权利要求1所述的发光二极管灯,其中所述第一引脚用接合线电耦合到所述发光二极管的所述第一端子。
4.根据权利要求1所述的发光二极管灯,其中所述发光二极管芯片是倒装芯片发光二极管。
5.根据权利要求1所述的发光二极管灯,其中所述发光二极管芯片包括波长转换覆盖层。
6.根据权利要求5所述的发光二极管灯,其中所述波长转换覆盖层包括散布在弹性体基体中的波长转换颗粒。
7.根据权利要求5所述的发光二极管灯,其中所述波长转换覆盖层包括散布在硅酮基体中的荧光颗粒。
8.根据权利要求1所述的发光二极管灯,其中所述发光二极管芯片发射波长在200nm和570nm之间的光。
9.根据权利要求1所述的发光二极管灯,其中所述第二密封剂包括邵氏硬度大于D70的刚性聚合物。
10.根据权利要求1所述的发光二极管灯,其中所述第二密封剂包括散布在刚性聚合物中的导热填料。
11.根据权利要求1所述的发光二极管灯,其中所述第二密封剂具有大于0.5W/m°K的导热率。
12.根据权利要求1所述的发光二极管灯,其中所述第一引脚和所述第二引脚被切开以便将所述发光二极管灯从引线框带分离。
13.根据权利要求12所述的发光二极管灯,其中所述衬底是与所述第二引脚集成的金属衬底,并且所述发光二极管芯片可导电地安装到所述金属衬底。
14.根据权利要求1所述的发光二极管灯,其中所述衬底是印刷电路板衬底。
15.根据权利要求1所述的发光二极管灯,其中所述第一引脚是所述衬底的第一背面端子,所述第二引脚是所述衬底的第二背面机端子,所述第二密封剂将所述衬底部分密封,以便密封所述容器内的所述弹性体密封剂同时允许到所述第一背面端子和到所述第二背面端子的电连接。
16.根据权利要求1所述的发光二极管灯,其中所述衬底是鸥翼型衬底或J形引脚衬底。
17.根据权利要求1所述的发光二极管灯,还包括多个发光二极管芯片,其中所述容器具有多个模杯,至少一个发光二极管芯片将光发射入所述多个模杯中的每一个,所述弹性体密封剂包围每个所述发光二极管芯片。
18.根据权利要求1所述的发光二极管灯,其中所述弹性体密封剂具有第一折射率并形成初级透镜,所述容器具有第二折射率并形成次级透镜,所述第一折射率选择为大于所述第二折射率。
19.一种制造发光二极管器件的方法,包括:
将发光二极管芯片管芯安装到衬底;
将所述发光二极管芯片电连接到所述发光二极管器件的引脚;
将未凝固的弹性体密封剂通过所述发光二极管器件的容器的孔分配到所述容器中;
通过所述孔插入所述发光二极管芯片和衬底以便用弹性体密封剂包围所述发光二极管芯片;以及
使所述弹性体密封剂凝固。
20.根据权利要求19所述的方法,在通过所述孔插入所述发光二极管芯片和衬底的所述步骤之后,还包括:
将第二密封剂分配到所述容器中所述凝固的弹性体密封剂之上;以及
使所述第二密封剂凝固。
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