Method of manufacturing a LED package structure for preventing lateral light leakage

This application is a divisional application of Ser. No. 14/490,212 filed on Sep. 18, 2014, and entitled “LED PACKAGE STRUCTURE FOR PREVENTING LATERAL LIGHT LEAKAGE AND METHOD OF MANUFACTURING THE SAME”, now pending, the entire disclosures of which are incorporated herein by reference.

1. Field of the Invention

The instant disclosure relates to a method of manufacturing a LED package structure, and more particularly to a method of manufacturing a LED package structure for preventing lateral light leakage.

2. Description of Related Art

Recently, with rapid development of information technology industry, a portable electronic device, such as a notebook computer, a smart phone and so on, can be used in various circumstances. As for using a notebook computer in the dark circumstances, it is hard for a user to operate a keyboard since characters marked on the keyswitch might not be visible. Moreover, it might damage the user's sight during the process of using the notebook computer in the dark circumstances. In the prior art, a specific keyswitch equipped with indication light can improve the aforementioned problem. In addition, by various disposals of specific keyswitch equipped with indication light, it makes the portable electronic device equipped with the specific keyboard be able to have different visual effects, so as to enhance the market.

In the prior art, a base plate module of the keyboard with the specific keyswitch capable of emitting indication light includes a circuit board, a light source and a mylar. The light source is disposed on the circuit board, and the mylar covers the light source and the circuit board. In addition, a hole is formed on the mylar and located in a position corresponding to the light source. The keyswitch module is disposed on the mylar, and a keycap of the keyswitch module includes a transparent structure located in a position corresponding to the hole. Accordingly, light emitted from the light source can pass through the hole on the mylar and the transparent structure of the keycap, so as to be detected by the user.

One aspect of the instant disclosure relates to a method of manufacturing a LED package structure for preventing lateral light leakage.

One of the embodiments of the instant disclosure provides a method of manufacturing a LED package structure for preventing lateral light leakage, comprising: placing a plurality of light-emitting units on a carrier substrate, wherein the light-emitting units are electrically connected to the carrier substrate; forming a plurality of light-transmitting gel bodies on the carrier substrate for respectively enclosing the light-emitting units, wherein the light-transmitting gel bodies are separated from each other to form a gel receiving space among the light-transmitting gel bodies; forming a light-shielding gel body to fill up the gel receiving space; and then cutting the carrier substrate and the light-shielding gel body to form the plurality of LED package structures separated from each other, wherein the carrier substrate is cut to form a plurality of circuit substrates for respectively carrying the light-emitting units.

Another one of the embodiments of the instant disclosure provides a method of manufacturing a LED package structure for preventing lateral light leakage, comprising: placing a plurality of light-emitting units on a carrier substrate, wherein the light-emitting units are electrically connected to the carrier substrate; forming a light-transmitting layer on the carrier substrate for enclosing the light-emitting units; cutting the light-transmitting layer to form a plurality of light-transmitting gel bodies, wherein the light-transmitting gel bodies are disposed on the carrier substrate for respectively enclosing the light-emitting units, and the light-transmitting gel bodies are separated from each other to form a gel receiving space among the light-transmitting gel bodies; forming a light-shielding gel body to fill up the gel receiving space; and then cutting the carrier substrate and the light-shielding gel body to form the plurality of LED package structures separated from each other, wherein the carrier substrate is cut to form a plurality of circuit substrates for respectively carrying the light-emitting units.

More precisely, the first light-transmitting portion is a first column body disposed on the corresponding circuit substrate for enclosing the at least one LED chip of the corresponding light-emitting unit, the at least one second light-transmitting portion is a second column body integrally and upwardly projected from the first light-transmitting portion and disposed right above the at least one LED chip of the corresponding light-emitting unit, and the diameter of the at least one second light-transmitting portion is increased or decreased gradually along a direction from the first light-transmitting portion to the light output surface of the at least one second light-transmitting portion.

More precisely, the circuit substrate has an outer perimeter, the light-shielding gel body has an outer perimeter, and the outer perimeter surface of the circuit substrate is substantially flush with the outer perimeter surface of the light-shielding gel body, wherein the light-transmitting gel body is formed by a transparent material only or by uniformly mixing the transparent material with phosphor particles and diffusion particles.

Therefore, the instant disclosure can provide a method of manufacturing a LED package structure for preventing lateral light leakage due to the design of “the light-shielding gel body disposed on the circuit substrate for exposing the light output surface of the at least one second light-transmitting portion” or “the light-shielding gel body disposed on the circuit substrate for exposing the light output surface of each second light-transmitting portion”.

To further understand the techniques, means and effects of the instant disclosure applied for achieving the prescribed objectives, the following detailed descriptions and appended drawings are hereby referred to, such that, and through which, the purposes, features and aspects of the instant disclosure can be thoroughly and concretely appreciated. However, the appended drawings are provided solely for reference and illustration, without any intention to limit the instant disclosure.

FIG. 1 shows a flowchart of the method of manufacturing a LED package structure for preventing lateral light leakage according to the first embodiment the instant disclosure;

FIG. 2 shows a lateral, schematic view of the two manufacture steps S 100 and S 102 of the method of manufacturing a LED package structure for preventing lateral light leakage according to the first embodiment the instant disclosure;

FIG. 3A shows a lateral, schematic view of the manufacture step S 104 of the method of manufacturing a LED package structure for preventing lateral light leakage according to the first embodiment the instant disclosure;

FIG. 3B shows a top, schematic view of the manufacture step S 104 of the method of manufacturing a LED package structure for preventing lateral light leakage according to the first embodiment the instant disclosure;

FIG. 4 shows a lateral, schematic view of the LED package structures for preventing lateral light leakage according to the first embodiment the instant disclosure;

FIG. 5 shows a flowchart of the method of manufacturing a LED package structure for preventing lateral light leakage according to the second embodiment the instant disclosure;

FIG. 6 shows a lateral, schematic view of the two manufacture steps S 200 and S 202 of the method of manufacturing a LED package structure for preventing lateral light leakage according to the second embodiment the instant disclosure;

FIG. 7 shows a lateral, schematic view of the LED package structures for preventing lateral light leakage according to the third embodiment the instant disclosure;

FIG. 8A shows a lateral, schematic view of the LED package structures providing a light output surface having a d 5 diameter according to the fourth embodiment the instant disclosure;

FIG. 8B shows a top, schematic view of the LED package structures providing a light output surface having a d 5 diameter according to the fourth embodiment the instant disclosure;

FIG. 9A shows a lateral, schematic view of the LED package structures providing a light output surface having a d 6 diameter according to the fourth embodiment the instant disclosure;

FIG. 9B shows a top, schematic view of the LED package structures providing a light output surface having a d 6 diameter according to the fourth embodiment the instant disclosure;

FIG. 10 shows a lateral, schematic view of the LED package structures for preventing lateral light leakage according to the fifth embodiment the instant disclosure;

FIG. 11 shows a lateral, schematic view of the LED package structures for preventing lateral light leakage according to the sixth embodiment the instant disclosure; and

FIG. 12 shows a top, schematic view of the LED package structures for preventing lateral light leakage disposed under a predetermined key cap according to the seventh embodiment the instant disclosure.

The embodiments of “a LED package structure for preventing lateral light leakage and a method of manufacturing the same” of the instant disclosure are described. Other advantages and objectives of the instant disclosure can be easily understood by one skilled in the art from the disclosure. The instant disclosure can be applied in different embodiments. Various modifications and variations can be made to various details in the description for different applications without departing from the scope of the instant disclosure. The drawings of the instant disclosure are provided only for simple illustrations, but are not drawn to scale and do not reflect the actual relative dimensions. The following embodiments are provided to describe in detail the concept of the instant disclosure, and are not intended to limit the scope thereof in any way.

First Embodiment

Referring to FIG. 1 to FIG. 4 , the first embodiment of the instant disclosure provides a method of manufacturing a LED package structure Z for preventing lateral light leakage, comprising the following steps:

Step S 100 is: referring to FIG. 1 and FIG. 2 , placing a plurality of light-emitting units 2 on a carrier substrate 1 ′, wherein the light-emitting units 2 are electrically connected to the carrier substrate 1 ′. For example, each light-emitting unit 2 includes at least one LED chip 20 , and the LED chip 20 is electrically connected to the carrier substrate 1 ′ through two conductive lines (not shown).

Step S 102 is: referring to FIG. 1 and FIG. 2 , forming a plurality of light-transmitting gel bodies 30 on the carrier substrate 1 ′ for respectively enclosing the light-emitting units 2 , wherein the light-transmitting gel bodies 30 are separated from each other to form a gel receiving space S among the light-transmitting gel bodies 30 . For example, the light-transmitting gel body 30 may be formed by a transparent material only or by uniformly mixing the transparent material with phosphor particles and/or diffusion particles. The light-transmitting gel bodies 30 are concurrently formed on the carrier substrate 1 ′ to respectively enclose the LED chips 20 by compression molding. More precisely, each light-transmitting gel body 30 has a first light-transmitting portion 30 A disposed on the carrier substrate 1 ′ to enclose the at least one LED chip 20 of the corresponding light-emitting unit 2 and at least one second light-transmitting portion 30 B projected upwardly from the first light-transmitting portion 30 A and corresponding to the at least one LED chip 20 of the corresponding light-emitting unit 2 .

Step S 104 is: referring to FIG. 1 , FIG. 2 and FIG. 3A , forming a light-shielding gel body 40 to fill up the gel receiving space S. More precisely, the gel receiving space S is filled with the light-shielding gel body 40 , but the top side of each light-transmitting gel body 30 is exposed from the light-shielding gel body 40 . For example, referring to FIG. 3A and FIG. 3B , the first light-transmitting portion 30 A may be a first column body disposed on the carrier substrate 1 ′ to enclose the at least one LED chip 20 of the corresponding light-emitting unit 2 , and the at least one second light-transmitting portion 30 B may be a second column body integrally and upwardly projected from the first light-transmitting portion 30 A and disposed right above the at least one LED chip 20 of the corresponding light-emitting unit 2 . In addition, the top side 300 of the second light-transmitting portion 30 B may be a circular surface disposed right above the LED chip 20 , and the diameter d 2 of the at least one second light-transmitting portion 30 B is smaller than the diameter d 1 of the first light-transmitting portion 30 A. It is worth noting that both the first light-transmitting portion 30 A and the at least one second light-transmitting portion 30 B are cylinders for example in this embodiment, but it is not meant to limit the instant disclosure.

Step S 106 is: referring to FIG. 3A and FIG. 4 , cutting the carrier substrate 1 ′ and the light-shielding gel body 40 along the X-X cutting line of FIG. 3A to form the plurality of LED package structures Z separated from each other, wherein the carrier substrate 1 ′ is cut to form a plurality of circuit substrates 10 for respectively carrying the light-emitting units 2 .

In conclusion, due to the steps from S 100 to S 106 , the first embodiment of the instant disclosure provides a LED package structure Z for preventing lateral light leakage, comprising: a substrate unit 1 , a light-emitting unit 2 , a light-transmitting unit 3 and a light-shielding unit 4 . The substrate unit 1 includes a circuit substrate 10 . The light-emitting unit 2 includes at least one LED chip 20 disposed on the circuit substrate 10 and electrically connected to the circuit substrate 10 . The light-transmitting unit 3 includes a light-transmitting gel body 30 disposed on the circuit substrate 10 for enclosing the at least one LED chip 20 , and the light-transmitting gel body 30 has a first light-transmitting portion 30 A disposed on the circuit substrate 10 for enclosing the at least one LED chip 20 and at least one second light-transmitting portion 30 B projected upwardly from the first light-transmitting portion 30 A and corresponding to the at least one LED chip 20 , and the at least one second light-transmitting portion 30 B has a light output surface 300 B and an outer perimeter surface 301 B (such as an outer surrounding peripheral surface) connected between the light output surface 300 B and the first light-transmitting portion 30 A. The light-shielding unit 4 includes a light-shielding gel body 40 disposed on the circuit substrate 10 for exposing the light output surface 300 B of the at least one second light-transmitting portion 30 B. The first light-transmitting portion 30 A and the outer perimeter surface 301 B of the at least one second light-transmitting portion 30 B are enclosed by the light-shielding gel body 40 , and the light output surface 300 B of the at least one second light-transmitting portion 30 B is substantially flush with the top surface 400 of the light-shielding gel body 40 . In another embodiment, the light output surface 300 B of the at least one second light-transmitting portion 30 B may be higher or lower than the top surface 400 of the light-shielding gel body 40 , according to different requirements. It is worth mentioning that the outer perimeter surface 100 of the circuit substrate 10 may be substantially flush with the outer perimeter surface 401 of the light-shielding gel body 40 .

Second Embodiment

Referring to FIG. 5 and FIG. 6 , the second embodiment of the instant disclosure provides a method of manufacturing a LED package structure Z for preventing lateral light leakage comprising the steps from S 200 to S 208 , and the step S 200 and the steps from S 206 to S 208 are the same as the step S 100 and the steps from S 104 to S 106 . The difference between the second embodiment and the first embodiment is as follows:

Step S 202 is: referring to FIG. 5 and FIG. 6 , forming a light-transmitting layer (not labeled) on the carrier substrate 1 ′ for enclosing the light-emitting units 2 . For example, the light-transmitting layer may be formed by a transparent material only or by uniformly mixing the transparent material with phosphor particles and/or diffusion particles. The light-transmitting layer is formed on the carrier substrate 1 ′ to respectively enclose the LED chips 20 by compression molding.

Step S 204 is: referring to FIG. 5 , FIG. 6 and FIG. 2 , cutting the light-transmitting layer (not labeled) to form a plurality of light-transmitting gel bodies 30 , wherein the light-transmitting gel bodies 30 are disposed on the carrier substrate 1 ′ for respectively enclosing the light-emitting units 2 , and the light-transmitting gel bodies 30 are separated from each other to form a gel receiving space S among the light-transmitting gel bodies 30 . More precisely, each light-transmitting gel body 30 has a first light-transmitting portion 30 A disposed on the carrier substrate 1 ′ to enclose the at least one LED chip 20 of the corresponding light-emitting unit 2 and at least one second light-transmitting portion 30 B projected upwardly from the first light-transmitting portion 30 A and corresponding to the at least one LED chip 20 of the corresponding light-emitting unit 2 . It is worth mentioning that the width of each light-transmitting gel body 30 can be defined by the cutting step of S 204 .

Third Embodiment

Referring to FIG. 7 , the third embodiment of the instant disclosure provides a LED package structure Z for preventing lateral light leakage, comprising: a substrate unit 1 , a light-emitting unit 2 , a light-transmitting unit 3 and a light-shielding unit 4 . Comparing FIG. 7 with FIG. 4 , the difference between the third embodiment and the other embodiments is as follows: in the third embodiment, light-transmitting unit 3 further includes a plurality of phosphor particles 31 uniformly mixed with the light-transmitting gel body 30 and a plurality of diffusion particles 32 uniformly mixed with the light-transmitting gel body 30 , and the light-emitting efficiency of the instant disclosure is increased by using the diffusion particles 32 . In other words, the light-transmitting gel body 30 may be formed by a transparent material (such as epoxy or silicone) only or by uniformly mixing the transparent material with the phosphor particles 31 and the diffusion particles 32 .

Fourth Embodiment

Referring to FIG. 8A to FIG. 9B , the fourth embodiment of the instant disclosure provides a LED package structure Z for preventing lateral light leakage, comprising: a substrate unit 1 , a light-emitting unit 2 , a light-transmitting unit 3 and a light-shielding unit 4 . The difference between the fourth embodiment and the other embodiments is as follows: in the fourth embodiment, the diameter of the at least one second light-transmitting portion 30 B is decreased gradually along a direction from the first light-transmitting portion 30 A to the light output surface 300 B of the at least one second light-transmitting portion 30 B. The maximum diameter d 4 of the at least one second light-transmitting portion 30 B is smaller than the diameter d 3 of the first light-transmitting portion 30 A, and the minimum diameters (d 5 , d 6 ) of the light output surface 300 B of the at least one second light-transmitting portion 30 B varies inversely as the heights (H 1 , H 2 ) from the top surface 400 of the light-shielding gel body 40 to the first light-transmitting portion 30 A, respectively. For example, when the height from the top surface 400 of the light-shielding gel body 40 to the first light-transmitting portion 30 A is ground from H 1 (as shown in FIG. 8A ) into H 2 (as shown in FIG. 9A ), the diameter of the light output surface 300 B of the at least one second light-transmitting portion 30 B is increased from d 5 to d 6 . In other words, the minimum diameters (d 5 , d 6 ) of the light output surface 300 B of the at least one second light-transmitting portion 30 B can be adjusted or changed according to different requirements.

It is worth mentioning that the diameter of the at least one second light-transmitting portion 30 B can be increased gradually along a direction from the first light-transmitting portion 30 A to the light output surface 300 B of the at least one second light-transmitting portion 30 B, and the maximum diameter d 4 of the at least one second light-transmitting portion 30 B is bigger than the diameter d 3 of the first light-transmitting portion 30 A. In addition, for especial application, the diameter d 4 of the at least one second light-transmitting portion 30 B may be substantially the same as the diameter d 3 of the first light-transmitting portion 30 A. In other words, the light output angle and the light output range of the light-emitting unit 2 can be changed by adjusting the diameters (d 5 , d 6 ) of the light output surface 300 B of the at least one second light-transmitting portion 30 B.

Fifth Embodiment

Referring to FIG. 10 , the fifth embodiment of the instant disclosure provides a LED package structure Z for preventing lateral light leakage, comprising: a substrate unit 1 , a light-emitting unit 2 , a light-transmitting unit 3 and a light-shielding unit 4 . The difference between the fifth embodiment and the other embodiments is as follows: in the fifth embodiment, the light-emitting unit 2 includes a plurality of LED chips 20 disposed on the circuit substrate 10 and electrically connected to the circuit substrate 10 . Hence, the single LED package structure Z is composed of the circuit substrate 10 , the LED chips 20 disposed on the circuit substrate 10 and electrically connected to the circuit substrate 10 , the light-transmitting gel body 30 disposed on the circuit substrate 10 for enclosing the plurality of LED chips 20 (the light-transmitting gel body 30 has a first light-transmitting portion 30 A and a second light-transmitting portion 30 B), and the light-shielding gel body 40 disposed on the circuit substrate 10 for exposing the light output surface 300 B of the second light-transmitting portion 30 B. It is worth mentioning that when the single LED package structure Z is applied to an LED display using a RGB LED chip array, the light-transmitting gel body 30 is mixed with the phosphor particles, thus the light-emitting unit 2 can generate white light through the light-transmitting gel body 30 with the phosphor particles. In another embodiment, the light output surface 300 B of the at least one second light-transmitting portion 30 B may be higher or lower than the top surface 400 of the light-shielding gel body 40 , according to different requirements.

Sixth Embodiment

Referring to FIG. 11 , the sixth embodiment of the instant disclosure provides a LED package structure Z for preventing lateral light leakage, comprising: a substrate unit 1 , a light-emitting unit 2 , a light-transmitting unit 3 and a light-shielding unit 4 . The substrate unit 1 includes a circuit substrate 10 . The light-emitting unit 2 includes a plurality of LED chips 20 disposed on the circuit substrate 10 and electrically connected to the circuit substrate 10 . The light-transmitting unit 3 includes a light-transmitting gel body 30 disposed on the circuit substrate 10 for enclosing the plurality of LED chips 20 , and the light-transmitting gel body 30 has a first light-transmitting portion 30 A disposed on the circuit substrate 10 for enclosing the plurality of LED chip 20 and a plurality of second light-transmitting portions 30 B projected upwardly from the first light-transmitting portion 30 A and respectively corresponding to the LED chips 20 , and each of the second light-transmitting portions 30 B has a light output surface 300 B and an outer perimeter surface 301 B (such as an outer surrounding peripheral surface) connected between the light output surface 300 B and the first light-transmitting portion 30 A. The light-shielding unit 4 includes a light-shielding gel body 40 disposed on the circuit substrate 10 for exposing the light output surface 300 B of each second light-transmitting portion 30 B. The first light-transmitting portion 30 A and the outer perimeter surface 301 B of each second light-transmitting portion 30 B are enclosed by the light-shielding gel body 40 , and the light output surface 300 B of each second light-transmitting portion 30 B is substantially flush with the top surface 400 of the light-shielding gel body 40 . In another embodiment, the light output surface 300 B of each second light-transmitting portion 30 B may be higher or lower than the top surface 400 of the light-shielding gel body 40 , according to different requirements.

Seventh Embodiment

Referring to FIG. 4 and FIG. 12 , the seventh embodiment of the instant disclosure provides a LED package structure Z applied to a predetermined key cap K. The LED package structure Z is disposed under the predetermined key cap K, and the predetermined key cap K has at least one light-transmitting opening K 100 (such as a solid transparent body or an empty hole) corresponding to the light output surface 300 B of the second light-transmitting portion 30 B. For example, the predetermined key cap K may be a Caps Lock key. When the user presses the predetermined key cap K, light beams generated by the LED chip 20 of the LED package structure Z pass through the at least one light-transmitting opening K 100 and project out of the predetermined key cap K to form an indication light for the user. Hence, it is convenient for the user to determine that whether the function of the predetermined key cap K is turned on or not.

In conclusion, the instant disclosure can provide a LED package structure Z for preventing lateral light leakage and a method of manufacturing the same due to the design of “the light-shielding gel body 40 disposed on the circuit substrate 10 for exposing the light output surface 300 B of the at least one second light-transmitting portion 30 B” or “the light-shielding gel body 40 disposed on the circuit substrate 10 for exposing the light output surface 300 B of each second light-transmitting portion 30 B”.

The aforementioned descriptions merely represent the preferred embodiments of the instant disclosure, without any intention to limit the scope of the instant disclosure which is fully described only within the following claims. Various equivalent changes, alterations or modifications based on the claims of the instant disclosure are all, consequently, viewed as being embraced by the scope of the instant disclosure.