JP2014072309A - Light-emitting device for automobile headlamp and process of manufacturing the same - Google Patents

Light-emitting device for automobile headlamp and process of manufacturing the same Download PDF

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JP2014072309A
JP2014072309A JP2012216210A JP2012216210A JP2014072309A JP 2014072309 A JP2014072309 A JP 2014072309A JP 2012216210 A JP2012216210 A JP 2012216210A JP 2012216210 A JP2012216210 A JP 2012216210A JP 2014072309 A JP2014072309 A JP 2014072309A
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binder
phosphor
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JP5960565B2 (en
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Shogo Kirai
省吾 喜來
Takeshi Waragaya
剛司 藁谷
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Stanley Electric Co Ltd
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Abstract

PROBLEM TO BE SOLVED: To provide a light-emitting device for an automobile headlamp having a luminance gradient.SOLUTION: A phosphor layer 2, having a first thickness gradient, containing a phosphor particle 2a and a binder 2b, is provided on a light-emitting diode element 1. A scattering layer 3, having a second thickness gradient opposite the first thickness gradient, containing scattering particles 3a and a binder 3b, is provided on the phosphor layer 2.

Description

本発明は発光素子からの光を波長変換する蛍光体層を備える自動車ヘッドランプ用発光装置及びその製造方法に関する。   The present invention relates to an automotive headlamp light emitting device including a phosphor layer that converts the wavelength of light from a light emitting element, and a method for manufacturing the same.

発光装置として、発光素子からの光の一部分を蛍光体層で異なる波長の光に変換し、これと発光素子からの光の他の部分とを混合してたとえば白色光を発生するものがある。   As a light-emitting device, there is a device that converts part of light from a light-emitting element into light having a different wavelength in a phosphor layer and mixes this with another part of light from the light-emitting element to generate, for example, white light.

第1の従来の発光装置は、発光素子と、スプレー方式によって形成された蛍光体粒子含有液よりなる蛍光体部と、ガラスバインダ液によって蛍光体粒子間を埋めた含浸部とにより構成されている(参照:特許文献1)。   The first conventional light-emitting device includes a light-emitting element, a phosphor part made of a phosphor particle-containing liquid formed by a spray method, and an impregnation part in which the phosphor particles are filled with a glass binder liquid. (Reference: Patent Document 1).

第2の従来の発光装置は、発光素子と、スプレー方式によって形成された有機溶剤、蛍光体含有液、及び酸化物あるいは水酸化物よりなる微粒子よりなる蛍光体層により構成されている(参照:特許文献2)。   The second conventional light-emitting device is composed of a light-emitting element and a phosphor layer composed of organic solvent formed by a spray method, a phosphor-containing liquid, and fine particles made of oxide or hydroxide (see: Patent Document 2).

特開2004−88013号公報JP 2004-88013 A 特開2003−243727号公報JP 2003-243727 A

しかしながら、上述の第1、第2の従来の発光装置においては、スプレー方式によって形成された蛍光体部及び含浸部あるいは蛍光体層の膜厚がほぼ均一であるので、発光装置の輝度に勾配がない。従って、図9に示すように、この発光装置を自動車ヘッドランプ101に適用した場合にあってカットオフラインCLを形成した際に、路面照明領域102のカットオフラインCL側の遠方領域102aの照度が手前領域102bの照度より小さくなる。この結果、視認性が低下してしまうという課題がある。   However, in the above-described first and second conventional light emitting devices, the phosphor part and impregnated part or the phosphor layer formed by the spray method have almost uniform film thickness, so that the brightness of the light emitting apparatus has a gradient. Absent. Therefore, as shown in FIG. 9, when this light emitting device is applied to an automobile headlamp 101 and the cut-off line CL is formed, the illuminance of the distant area 102a on the cut-off line CL side of the road surface illumination area 102 is nearer. It becomes smaller than the illuminance of the region 102b. As a result, there exists a subject that visibility will fall.

上述の課題を解決するために、本発明に係る自動車ヘッドランプ用発光装置は、発光素子と、発光素子上に設けられ、蛍光体粒子及び第1のバインダを含む蛍光体層と、蛍光体層上に設けられ、散乱粒子及び第2のバインダを含む散乱層とを具備し、蛍光体層の厚さ勾配と散乱層の厚さ勾配とは逆の関係を有するものである。これにより、輝度勾配が生じる。   In order to solve the above-described problem, a light emitting device for an automobile headlamp according to the present invention includes a light emitting element, a phosphor layer provided on the light emitting element and including phosphor particles and a first binder, and a phosphor layer. And a scattering layer including scattering particles and a second binder, and the thickness gradient of the phosphor layer and the thickness gradient of the scattering layer have an inverse relationship. Thereby, a luminance gradient is generated.

また、本発明に係る第2の自動車ヘッドランプ用発光装置は、発光素子と、発光素子上に設けられ、蛍光体粒子、散乱粒子及びバインダを含む蛍光体/散乱層とを具備し、蛍光体/散乱層の厚さ勾配と散乱粒子の濃度勾配とは逆の関係を有するものである。これにより、輝度勾配が生じる。   A second automotive headlamp light emitting device according to the present invention includes a light emitting element, and a phosphor / scattering layer provided on the light emitting element and including phosphor particles, scattering particles, and a binder. The thickness gradient of the scattering layer and the concentration gradient of the scattering particles have an inverse relationship. Thereby, a luminance gradient is generated.

さらにまた、上述の第1の自動車ヘッドランプ用発光装置の製造方法は、発光素子上に蛍光体粒子を含む蛍光体粒子含有液を第1の非対称スプレ塗布をして第1の厚さ勾配を有する蛍光体粒子含有層を形成する蛍光体粒子含有液塗布工程と、蛍光体粒子含有層を乾燥せしめて発光素子上に蛍光体粒子を残存せしめる乾燥工程と、残存せしめた蛍光体粒子上に第1のバインダを含むバインダ含有液を第1の非対称スプレ塗布をして第1の厚さ勾配と同一の傾向の第2の厚さ勾配を有するバインダ含有層を形成し、バインダ含有層の第1のバインダは蛍光体粒子間の隙間に埋められてバインダ含有層は蛍光体粒子及び第1のバインダを含む蛍光体層となる、バインダ含有液塗布工程と、蛍光体層上に、散乱粒子及び第2のバインダを含む散乱粒子/バインダ含有液を第1の非対称スプレ塗布と異なる第2の非対称スプレ塗布をして第1の厚さ勾配と逆の第2の厚さ勾配を有する散乱粒子/バインダ含有層を形成し、散乱粒子/バインダ含有層は乾燥して散乱層となる、散乱粒子/バインダ含有液塗布工程とを具備するものである。尚、第1、第2の非対称スプレ塗布の代わりに、ジェットディスペンサによるドット塗布を用いることもできる。   Furthermore, in the first method for manufacturing a light emitting device for an automobile headlamp, the first asymmetric spray is applied to the phosphor particle-containing liquid containing the phosphor particles on the light emitting element, and the first thickness gradient is applied. A phosphor particle-containing liquid coating step for forming the phosphor particle-containing layer, a drying step for drying the phosphor particle-containing layer to leave the phosphor particles on the light-emitting element, and a step on the remaining phosphor particles. A binder-containing liquid containing one binder is applied with a first asymmetric spray to form a binder-containing layer having a second thickness gradient having the same tendency as the first thickness gradient. The binder is filled in the gaps between the phosphor particles, and the binder-containing layer becomes a phosphor layer containing the phosphor particles and the first binder. Scattered particles containing two binders / A scattering particle / binder-containing layer having a second thickness gradient opposite to the first thickness gradient is formed by applying a second asymmetric spray different from the first asymmetric spray coating to the binder-containing liquid, and the scattering particles The / binder-containing layer comprises a scattering particle / binder-containing liquid coating step that is dried to form a scattering layer. Note that dot application by a jet dispenser can be used instead of the first and second asymmetric spray applications.

さらにまた、上述の第2の自動車ヘッドランプ用発光装置の製造方法は、発光素子上に蛍光体粒子を含む蛍光体粒子含有液を第1の非対称スプレ塗布をして厚さ勾配を有する蛍光体粒子含有層を形成する蛍光体粒子含有液塗布工程と、蛍光体粒子含有層を乾燥せしめて発光素子上に蛍光体粒子を残存せしめる乾燥工程と、残存せしめた蛍光体粒子上に散乱粒子及びバインダを含む散乱粒子/バインダ含有液を第1の非対称スプレ塗布と異なる第2の非対称スプレ塗布をして厚さ勾配と逆の濃度勾配を有する散乱粒子/バインダ含有層を形成し、散乱粒子/バインダ含有層の散乱粒子及びバインダは蛍光体粒子間の隙間に埋められて散乱粒子/バインダ含有層は蛍光体粒子、散乱粒子及びバインダを含む蛍光体/散乱層となる、散乱粒子/バインダ含有液塗布工程とを具備するものである。尚、第1、第2の非対称スプレ塗布の代わりにジェットディスペンサによるドット塗布を用いることもできる。   Furthermore, in the second method for manufacturing a light emitting device for an automobile headlamp described above, the phosphor having a thickness gradient is obtained by applying the phosphor particle-containing liquid containing phosphor particles on the light emitting element to the first asymmetric spray. A phosphor particle-containing liquid coating step for forming a particle-containing layer, a drying step for drying the phosphor particle-containing layer to leave the phosphor particles on the light emitting device, and a scattering particle and a binder on the remaining phosphor particles A scattering particle / binder-containing layer having a concentration gradient opposite to the thickness gradient is formed by applying a second asymmetric spray different from the first asymmetric spray coating to the scattering particle / binder-containing liquid containing Scattered particles / binders in the containing layer are filled in the gaps between the phosphor particles, and the scattering particle / binder containing layer becomes a phosphor / scattering layer containing the phosphor particles, scattering particles and binder, containing the scattering particles / binder It is intended to and a coating step. Note that dot application by a jet dispenser can be used instead of the first and second asymmetric spray applications.

本発明によれば、輝度勾配を生じるようにしたので、図9において、カットオフラインCLを形成した際に、路面照明領域102のカットオフラインCL側の遠方領域102aの照度と手前領域102bの照度とを同等にすることができ、この結果、視認性を向上できる。   According to the present invention, since a luminance gradient is generated, in FIG. 9, when the cut-off line CL is formed, the illuminance of the distant area 102a on the cut-off line CL side of the road surface illumination area 102 and the illuminance of the front area 102b Can be made equivalent, and as a result, visibility can be improved.

本発明に係る自動車ヘッドランプ用発光装置の第1の実施の形態を示し、(A)は全体断面図、(B)は(A)のB−B線拡大断面図である。1 shows a first embodiment of a light emitting device for an automobile headlamp according to the present invention, in which (A) is an overall cross-sectional view, and (B) is an enlarged cross-sectional view along line BB of (A). 図1の自動車ヘッドランプ用発光装置の製造に用いられるスプレ塗布装置(シリンジディスペンサ型塗布装置)を示し、(A)はその平面図、(B)は塗布された塗布層の上面図、(C)は塗布層の厚さ分布を示すグラフである。The spray coating device (syringe dispenser type coating device) used for manufacture of the light-emitting device for automobile headlamps of FIG. 1 is shown, (A) is the top view, (B) is the top view of the coated coating layer, (C ) Is a graph showing the thickness distribution of the coating layer. 図1の自動車ヘッドランプ用発光装置の製造方法の蛍光体粒子含有液塗布工程を説明するためのものであって、(A)はスプレ塗布装置の正面図、(B)は蛍光体粒子含有層の上面図、(C)は発光素子上の蛍光体粒子含有層の部分断面図である。It is for demonstrating the fluorescent substance particle containing liquid application | coating process of the manufacturing method of the light-emitting device for motor vehicle headlamps of FIG. 1, Comprising: (A) is a front view of a spray application apparatus, (B) is a fluorescent substance particle content layer. FIG. 4C is a partial cross-sectional view of the phosphor particle-containing layer on the light-emitting element. 図1の自動車ヘッドランプ用発光装置の製造方法の乾燥工程を説明するための発光素子上の蛍光体粒子の部分断面図である。It is a fragmentary sectional view of the fluorescent substance particle on the light emitting element for demonstrating the drying process of the manufacturing method of the light-emitting device for motor vehicle headlamps of FIG. 図1の自動車ヘッドランプ用発光装置の製造方法のバインダ含有液塗布工程を説明するためのものであって、(A)はスプレ塗布装置の正面図、(B)はバインダ含有層の上面図、(C)は発光素子上の蛍光体層の部分断面図である。It is for demonstrating the binder containing liquid application | coating process of the manufacturing method of the light-emitting device for motor vehicle headlamps of FIG. 1, (A) is a front view of a spray coating apparatus, (B) is a top view of a binder containing layer, (C) is a fragmentary sectional view of the fluorescent substance layer on a light emitting element. 図1の自動車ヘッドランプ用発光装置の製造方法の散乱粒子/バインダ含有液塗布工程を説明するためのものであって、(A)はスプレ塗布装置の正面図、(B)は散乱粒子/バインダ含有層の上面図、(C)は発光素子上の蛍光体層及び散乱層の部分断面図である。It is for demonstrating the scattering particle / binder containing liquid application | coating process of the manufacturing method of the light-emitting device for motor vehicle headlamps of FIG. 1, Comprising: (A) is a front view of a spray coating apparatus, (B) is a scattering particle / binder. The top view of a content layer, (C) is a fragmentary sectional view of the fluorescent substance layer and scattering layer on a light emitting element. 本発明に係る自動車ヘッドランプ用発光装置の第2の実施の形態を示し、(A)は全体断面図、(B)は(A)のB−B線拡大断面図である。The 2nd Embodiment of the light-emitting device for motor vehicle headlamps which concerns on this invention is shown, (A) is whole sectional drawing, (B) is the BB expanded sectional view of (A). 図1、図7の自動車ヘッドランプ用発光装置の製造に用いられるジェットディスペンサ型塗布装置を示し、(A)その平面図、(B)は塗布された塗布層の上面図、(C)は塗布層の厚さ分布を示すグラフである。FIGS. 1 and 7 show a jet dispenser type coating device used for manufacturing a light emitting device for an automobile headlamp, wherein (A) a plan view thereof, (B) a top view of an applied coating layer, and (C) a coating. It is a graph which shows thickness distribution of a layer. 自動車ヘッドランプの路面照明領域の照度分布を説明する図である。It is a figure explaining the illumination intensity distribution of the road surface illumination area | region of a motor vehicle headlamp.

図1は本発明に係る自動車ヘッドランプ用発光装置の第1の実施の形態を示し、(A)は全体断面図、(B)は(A)のB−B線拡大断面図である。   1A and 1B show a first embodiment of a light emitting device for an automobile headlamp according to the present invention. FIG. 1A is an overall cross-sectional view, and FIG.

図1に示すように、発光素子たとえば発光ダイオード(LED)素子1上に、第1の厚さ勾配を有し平均粒径5〜50μmの蛍光体粒子2a及びバインダ2bを含む蛍光体層2を設ける。また、蛍光体層2上に、第1の厚さ勾配と逆の第2の厚さ勾配を有し散乱粒子3a及びバインダ3bを含む散乱層3を設ける。   As shown in FIG. 1, on a light emitting element, for example, a light emitting diode (LED) element 1, a phosphor layer 2 including a phosphor particle 2a having a first thickness gradient and an average particle diameter of 5 to 50 μm and a binder 2b. Provide. Further, on the phosphor layer 2, a scattering layer 3 having a second thickness gradient opposite to the first thickness gradient and including the scattering particles 3a and the binder 3b is provided.

たとえば、LED素子1を青色LED素子で構成し、蛍光体粒子2aを青色光を黄色光に変換するYAGで構成すれば、図1の自動車ヘッドランプ用発光装置は白色光を発生する。   For example, if the LED element 1 is composed of a blue LED element and the phosphor particles 2a are composed of YAG that converts blue light into yellow light, the automobile headlamp light emitting device of FIG. 1 generates white light.

散乱粒子3aは、酸化チタン、酸化亜鉛等の反射性フィラよりなる。また、バインダ2b、3bはエチルシリケート化合物等の無機ガラス系化合物、アルコール系、キシレン等の揮発性有機溶媒で低粘度に調整したジメチルシリコーン、フェニルシリコーン等の樹脂、あるいはこれらの2つ以上を混合したものよりなる。   The scattering particles 3a are made of a reflective filler such as titanium oxide or zinc oxide. The binders 2b and 3b are inorganic glass compounds such as ethyl silicate compounds, alcohols, resins such as dimethyl silicone and phenyl silicone adjusted to low viscosity with volatile organic solvents such as xylene, or a mixture of two or more of these. Made up of.

図1の(B)において、矢印L2に示すごとく、LED素子1からの光が蛍光体層2を色変換を受けながら通過すると、光は矢印L31、L32、L33、L34、L35に示すごとく、散乱層3の散乱粒子3aによって散乱される。このとき、蛍光体層2の厚さが大きくかつ散乱層3の厚さが小さいと、光は、たとえば、矢印L31、L32に示すごとく、小さく散乱するので、散乱層3を通過した光の輝度たとえばI1は大きくなる。他方、蛍光体層2の厚さが小さくかつ散乱層3の厚さが大きいと、光は、たとえば、矢印L33、L34、L35に示すごとく、大きく散乱するので、散乱層3を通過した光の輝度たとえばI3は小さくなる。この結果、図1の自動車ヘッドランプ用発光装置の光の輝度I1、I2、I3は勾配を有することになる。つまり、
I1>I2>I3
となる。このような輝度勾配は図9に示す自動車ヘッドランプの路面照明範囲102の照度分布を均一化することができる。
In FIG. 1B, as indicated by an arrow L2, when the light from the LED element 1 passes through the phosphor layer 2 while undergoing color conversion, the light is indicated by arrows L31, L32, L33, L34, and L35. Scattered by the scattering particles 3 a of the scattering layer 3. At this time, if the thickness of the phosphor layer 2 is large and the thickness of the scattering layer 3 is small, the light is scattered small as indicated by arrows L31 and L32, for example. For example, I1 increases. On the other hand, when the thickness of the phosphor layer 2 is small and the thickness of the scattering layer 3 is large, the light is greatly scattered as indicated by arrows L33, L34, and L35. The brightness, for example, I3 is reduced. As a result, the light intensities I1, I2, and I3 of the automobile headlamp light emitting device of FIG. 1 have a gradient. That means
I1>I2> I3
It becomes. Such a luminance gradient can make the illuminance distribution in the road illumination range 102 of the automobile headlamp shown in FIG. 9 uniform.

尚、蛍光体層2の厚さ勾配は色度角度依存性の低下を招く。しかし、蛍光体層2の厚さ分布(勾配)と散乱層3の厚さ分布(勾配)とを逆にすることにより、蛍光体層2が厚い領域程、蛍光体励起が多くなって黄色光が増加すると共に、蛍光体層2が薄い領域でも散乱層3の散乱で青色光が蛍光体励起を起こす。従って、色度むらが減少し、この結果、色度角度依存性の低下を抑制できる。   In addition, the thickness gradient of the phosphor layer 2 causes a decrease in chromaticity angle dependency. However, by reversing the thickness distribution (gradient) of the phosphor layer 2 and the thickness distribution (gradient) of the scattering layer 3, the thicker the phosphor layer 2 is, the more phosphor excitation occurs and the yellow light And the blue light causes phosphor excitation due to scattering of the scattering layer 3 even in a region where the phosphor layer 2 is thin. Therefore, the chromaticity unevenness is reduced, and as a result, a decrease in chromaticity angle dependency can be suppressed.

次に、図1の自動車ヘッドランプ用発光装置の製造に用いられるスプレ塗布装置(シリンジディスペンサ型塗布装置とも言う)を図2を参照して説明する。   Next, a spray coating device (also referred to as a syringe dispenser type coating device) used for manufacturing the light emitting device for an automobile headlamp shown in FIG. 1 will be described with reference to FIG.

図2の(A)に示すように、塗布液を貯蔵するシリンジ(図示せず)の下端部に設けられたノズル201から塗布液202が逆円錐状に吐出される。このとき、吐出角が0°より大きくなる程、吐出量が低下するので、吐出円の中心の塗布液202の量が大きく、中心から離れる程、塗布液202の量が小さくなる。この結果、図2の(B)の矢印に示すごとく、ノズル201をたとえばLED素子に対して相対的に1次元的に移動させると、ストライプ状の塗布層203が得られる。この塗布層203の厚さは、図2の(C)に示すごとく、中央で大きく、中央を離れる程小さくなる。つまり、塗布層203が上方に凸状となるように、塗布層203には、中央より図2の左側で左下り厚さ勾配が生じ、中央より図2の右側で右下り厚さ勾配が生じている。従って、このスプレ塗布をLED素子に対して非対称に行うことにより図1の自動車ヘッドランプ用発光装置の蛍光体層2及び散乱層3に互いに逆の厚さ勾配を実現することができる。尚、塗布層203の勾配は、ノズル201の吐出角が適切なものを適宜選択し、また、吐出量を適切に選択すれば制御できる。勾配は、好ましくはLED素子1の表面とノズル201を動かす方向に垂直な断面から見て扇型か、直線状がよい。   As shown in FIG. 2A, the coating liquid 202 is discharged in an inverted conical shape from a nozzle 201 provided at the lower end of a syringe (not shown) that stores the coating liquid. At this time, since the discharge amount decreases as the discharge angle becomes larger than 0 °, the amount of the coating liquid 202 at the center of the discharge circle increases, and as the distance from the center increases, the amount of the coating liquid 202 decreases. As a result, as shown by the arrow in FIG. 2B, when the nozzle 201 is moved one-dimensionally relative to the LED element, for example, a stripe-shaped coating layer 203 is obtained. As shown in FIG. 2C, the thickness of the coating layer 203 increases at the center and decreases as the distance from the center increases. That is, the coating layer 203 has a left-down thickness gradient on the left side of FIG. 2 from the center, and a right-down thickness gradient on the right side of FIG. 2 from the center so that the coating layer 203 is convex upward. ing. Therefore, by performing this spray coating asymmetrically with respect to the LED element, it is possible to realize thickness gradients opposite to each other in the phosphor layer 2 and the scattering layer 3 of the automobile headlamp light emitting device of FIG. Note that the gradient of the coating layer 203 can be controlled by appropriately selecting an appropriate discharge angle of the nozzle 201 and appropriately selecting the discharge amount. The gradient is preferably fan-shaped or linear when viewed from the cross section perpendicular to the surface of the LED element 1 and the direction in which the nozzle 201 is moved.

次に、図1の自動車ヘッドランプ用発光装置の製造方法を図3、図4、図5、図6を参照して説明する。尚、LED素子1としては、たとえばGaN系のエピ層の発光層をシリコン基板に金属接合したメタルボンディング型である。   Next, a method for manufacturing the automotive headlamp light emitting device of FIG. 1 will be described with reference to FIGS. 3, 4, 5, and 6. FIG. The LED element 1 is, for example, a metal bonding type in which a light emitting layer of a GaN-based epi layer is metal-bonded to a silicon substrate.

始めに、蛍光体粒子含有液塗布工程を図3を参照して説明する。すなわち、図3の(A)に示すように、ノズル201より平均粒径5〜50μmの蛍光体粒子2aをたとえば約10〜80wt%好ましくは50wt%で粘度20〜500mPa・sたとえば100mPa・sの有機溶媒2c内に分散した蛍光体粒子含有液301をスプレ塗布して図3の(B)に示すストライプ状の蛍光体粒子含有層302を形成する。この場合、LED素子1を図3の(B)の蛍光体粒子含有層302の中心より右側にずらして配置して第1の非対称スプレ塗布を行う。この結果、図3の(C)に示すように、LED素子1上の蛍光体粒子含有層302は右下がりの厚さ勾配を有することになる。   First, the phosphor particle-containing liquid application process will be described with reference to FIG. That is, as shown in FIG. 3A, the phosphor particles 2a having an average particle diameter of 5 to 50 μm are, for example, about 10 to 80 wt%, preferably 50 wt%, and a viscosity of 20 to 500 mPa · s, for example, 100 mPa · s. The phosphor particle-containing liquid 301 dispersed in the organic solvent 2c is spray-coated to form a stripe-shaped phosphor particle-containing layer 302 shown in FIG. In this case, the first asymmetric spray coating is performed with the LED element 1 being shifted from the center of the phosphor particle-containing layer 302 of FIG. As a result, as shown in FIG. 3C, the phosphor particle-containing layer 302 on the LED element 1 has a thickness gradient that descends to the right.

次に、乾燥工程を図4を参照して説明する。すなわち、乾燥工程により有機溶媒2cを蒸発させることにより右下がりの厚さ勾配を有する蛍光体粒子2aのみがLED素子1上に残存することになる。   Next, the drying process will be described with reference to FIG. That is, by evaporating the organic solvent 2c in the drying process, only the phosphor particles 2a having a thickness gradient that is descending to the right remain on the LED element 1.

次に、バインダ含有液塗布工程を図5を参照して説明する。すなわち、図5の(A)に示すように、ノズル201よりバインダ2bを含む有機溶媒液であるバインダ含有液501をスプレ塗布すると、図5の(B)に示すストライプ状のバインダ含有層502が形成される。この場合も、LED素子1を図5の(B)の蛍光体層2の中心より右側にずらして配置して第1の非対称スプレ塗布を行う。従って、LED素子1上のバインダ含有層502も右下がりの厚さ勾配を有する。この結果、図5の(C)に示すように、バインダ2bが蛍光体粒子2a間の空隙を埋めることになり、蛍光体粒子2a及びバインダ2bを含む蛍光体層2がLED素子1上に形成されることになる。尚、図5の(C)の蛍光体層2には有機溶媒が含まれるが、この有機溶媒は乾燥工程により蒸発して消滅するものとし、図示省略してある。このようにして、LED素子1上に右下がりの厚さ勾配を有する蛍光体層2が形成される。この場合、蛍光体層2の厚さは、最も厚い領域で40〜60μmであり、最も薄い領域で5〜30μmである。   Next, the binder-containing liquid application process will be described with reference to FIG. That is, as shown in FIG. 5A, when the binder-containing liquid 501 that is an organic solvent liquid containing the binder 2b is sprayed from the nozzle 201, the stripe-shaped binder-containing layer 502 shown in FIG. It is formed. Also in this case, the first asymmetric spray coating is performed with the LED element 1 being shifted to the right side from the center of the phosphor layer 2 in FIG. Accordingly, the binder-containing layer 502 on the LED element 1 also has a thickness gradient that descends to the right. As a result, as shown in FIG. 5C, the binder 2b fills the space between the phosphor particles 2a, and the phosphor layer 2 including the phosphor particles 2a and the binder 2b is formed on the LED element 1. Will be. In addition, although the organic solvent is contained in the fluorescent substance layer 2 of FIG.5 (C), this organic solvent shall evaporate and lose | disappear by a drying process and is abbreviate | omitting illustration. In this way, the phosphor layer 2 having a thickness gradient that descends to the right is formed on the LED element 1. In this case, the thickness of the phosphor layer 2 is 40 to 60 μm in the thickest region and 5 to 30 μm in the thinnest region.

最後に、散乱粒子/バインダ含有液塗布工程を図6を参照して説明する。すなわち、図6の(A)に示すように、ノズル201より散乱粒子3a及びバインダ3bを含む有機溶媒液である散乱粒子/バインダ含有液601をスプレ塗布すると、図6の(B)に示すストライプ状の散乱粒子3a及びバインダ3bを含む散乱粒子/バインダ含有層602が形成される。この場合は、LED素子1を図6の(B)の散乱粒子/バインダ含有層602の中心より左側にずらして配置する。従って、蛍光体層2上の散乱粒子/バインダ含有層602は左下がりの厚さ勾配を有する。この結果、散乱粒子/バインダ含有層602の有機溶媒が図示しない乾燥工程で蒸発すると、図6の(C)に示すごとく、蛍光体層2上に左下がりの厚さ勾配を有する散乱粒子3a及びバインダ3bを含む散乱層3が形成されることになる。   Finally, the scattering particle / binder-containing liquid coating step will be described with reference to FIG. That is, as shown in FIG. 6A, when the scattering particles / binder-containing liquid 601 that is an organic solvent liquid containing the scattering particles 3a and the binder 3b is spray-applied from the nozzle 201, the stripes shown in FIG. A scattering particle / binder-containing layer 602 including the scattering particles 3a and the binder 3b is formed. In this case, the LED element 1 is arranged so as to be shifted to the left side from the center of the scattering particle / binder-containing layer 602 in FIG. Therefore, the scattering particle / binder-containing layer 602 on the phosphor layer 2 has a thickness gradient that decreases to the left. As a result, when the organic solvent of the scattering particle / binder-containing layer 602 evaporates in a drying step (not shown), as shown in FIG. 6C, the scattering particles 3a having a thickness gradient that descends to the left on the phosphor layer 2 and The scattering layer 3 including the binder 3b is formed.

これにより、図1の自動車ヘッドランプ用発光装置は完成する。尚、必要に応じて、図1の自動車ヘッドランプ用発光装置はパッケージ化される。   As a result, the automobile headlamp light emitting device of FIG. 1 is completed. If necessary, the automobile headlamp light emitting device of FIG. 1 is packaged.

図7は本発明に係る自動車ヘッドランプ用発光装置の第2の実施の形態を示し、(A)は全体断面図、(B)は(A)のB−B線拡大断面図である。   7A and 7B show a second embodiment of a light emitting device for an automobile headlamp according to the present invention. FIG. 7A is an overall cross-sectional view, and FIG. 7B is an enlarged cross-sectional view taken along line BB in FIG.

図7においては、図1の蛍光体層2及び散乱層3の代りに、厚さ勾配を有する1つの蛍光体/散乱層4を設けてある。蛍光体/散乱層4は図1の蛍光体粒子2a、散乱粒子3a及びバインダ3bを有する。つまり、図1のバインダ2bは存在しない。この場合、散乱粒子3aの濃度勾配は蛍光体/散乱層4の厚さ勾配と逆になっている。つまり、蛍光体/散乱層4の厚さが大きい領域では、散乱粒子3aの濃度が小さく、他方、蛍光体/散乱層4の厚さが小さい領域では、散乱粒子3aの濃度が大きくなっている。   In FIG. 7, instead of the phosphor layer 2 and the scattering layer 3 of FIG. 1, one phosphor / scattering layer 4 having a thickness gradient is provided. The phosphor / scattering layer 4 includes the phosphor particles 2a, the scattering particles 3a, and the binder 3b shown in FIG. That is, the binder 2b in FIG. 1 does not exist. In this case, the concentration gradient of the scattering particles 3 a is opposite to the thickness gradient of the phosphor / scattering layer 4. That is, in the region where the phosphor / scattering layer 4 is thick, the concentration of the scattering particles 3a is small. On the other hand, in the region where the phosphor / scattering layer 4 is thin, the concentration of the scattering particles 3a is large. .

図7の(B)において、矢印L41、L42、…、L45に示すごとく、LED素子1からの光が蛍光体粒子2aを色変換を受けながら通過すると共に、光は矢印L51、L52、L53、L54、L55に示すごとく、散乱粒子3aによって散乱される。このとき、蛍光体/散乱層4の厚さが大きくかつ散乱粒子3aの濃度が小さいと、光はたとえば、矢印L51、L52に示すごとく、小さく散乱するので、蛍光体/散乱層4を通過した光の輝度たとえばI1’は大きくなる。他方、蛍光体/散乱層4の厚さが小さくかつ散乱粒子3aの濃度が大きいと、光はたとえば、矢印L53、L54、L55に示すごとく、大きく散乱するので、蛍光体/散乱層4を通過した光の輝度たとえばI3’は小さくなる。この結果、図7の自動車ヘッドランプ用発光装置の光の輝度I1’、I2’、I3’は勾配を有することになる。つまり、
I1’>I2’>I3’
となる。このような輝度勾配は図9に示す自動車ヘッドランプの路面照明範囲102の照度分布を均一化することができる。
In FIG. 7B, as indicated by arrows L41, L42,..., L45, the light from the LED element 1 passes through the phosphor particles 2a while undergoing color conversion, and the light passes through the arrows L51, L52, L53, As indicated by L54 and L55, the light is scattered by the scattering particles 3a. At this time, if the thickness of the phosphor / scattering layer 4 is large and the concentration of the scattering particles 3a is small, the light scatters small as indicated by arrows L51 and L52, for example, so that it passes through the phosphor / scattering layer 4. The brightness of light, for example, I1 ′ increases. On the other hand, when the thickness of the phosphor / scattering layer 4 is small and the concentration of the scattering particles 3a is large, the light is greatly scattered as indicated by arrows L53, L54, and L55. The brightness of the light, for example, I3 ′ is reduced. As a result, the light intensities I1 ′, I2 ′, and I3 ′ of the light emitting device for an automobile headlamp in FIG. 7 have a gradient. That means
I1 '>I2'> I3 '
It becomes. Such a luminance gradient can make the illuminance distribution in the road illumination range 102 of the automobile headlamp shown in FIG. 9 uniform.

尚、図7においても、蛍光体/散乱層4の厚さ勾配は色度角度依存性の低下を招く。しかし、蛍光体/散乱層4の厚さ分布(勾配)と散乱粒子3aの濃度分布(勾配)とを逆にすることにより、蛍光体/散乱層4が厚い領域程、蛍光体励起が多くなって黄色光が増加すると共に、蛍光体/散乱層4が薄い領域でも散乱粒子3aの散乱で青色光が蛍光体励起を起こす。従って、色度むらが減少し、この結果、色度角度依存性の低下を抑制できる。   Also in FIG. 7, the thickness gradient of the phosphor / scattering layer 4 causes a decrease in chromaticity angle dependency. However, by reversing the thickness distribution (gradient) of the phosphor / scattering layer 4 and the concentration distribution (gradient) of the scattering particles 3a, the phosphor excitation increases in the thicker region of the phosphor / scattering layer 4. As the yellow light increases, even when the phosphor / scattering layer 4 is thin, the blue light causes phosphor excitation due to scattering of the scattering particles 3a. Therefore, the chromaticity unevenness is reduced, and as a result, a decrease in chromaticity angle dependency can be suppressed.

図7の自動車ヘッドランプ用発光装置の製造方法は、図3、図4、図5、図6に示す図1の自動車ヘッドランプ用発光装置の製造方法において、図5に示すバインダ含有液塗布工程を省略した点を除き、同一である。   The manufacturing method of the light emitting device for the automobile headlamp of FIG. 7 is the same as the manufacturing method of the light emitting device for the automotive headlamp of FIG. 1 shown in FIG. 3, FIG. 4, FIG. It is the same except that is omitted.

すなわち、図4に示す乾燥工程の直後に図6に示す散乱粒子/バインダ含有液塗布工程を行うと、図6の(A)に示すように、ノズル201より散乱粒子3a及びバインダ3bを含む有機溶媒液である散乱粒子/バインダ含有液601がスプレ塗布され、図6の(B)に示すストライプ状の散乱粒子3a及びバインダ3bを含む散乱粒子/バインダ含有層602が形成される。この場合、LED素子を図6の(B)の散乱粒子/バインダ含有層602の中心より左側にずらして配置する。従って、散乱粒子3a及びバインダ3bの量は左下りの勾配を有する。この状態で、散乱粒子3a及びバインダ3bが残存した蛍光体粒子2a間の空隙を埋めることになる。この結果、有機溶媒が図示しない乾燥工程で蒸発すると、図7に示す蛍光体粒子2a、散乱粒子3a及びバインダ3bよりなる蛍光体/散乱層4が形成されることになる。   That is, when the scattering particle / binder-containing liquid coating step shown in FIG. 6 is performed immediately after the drying step shown in FIG. 4, an organic containing the scattering particles 3a and the binder 3b from the nozzle 201 as shown in FIG. A scattering particle / binder-containing liquid 601 that is a solvent liquid is applied by spraying to form a scattering particle / binder-containing layer 602 including stripe-shaped scattering particles 3a and a binder 3b shown in FIG. In this case, the LED element is arranged so as to be shifted to the left side from the center of the scattering particle / binder-containing layer 602 in FIG. Therefore, the amount of the scattering particles 3a and the binder 3b has a leftward and downward gradient. In this state, the gap between the phosphor particles 2a where the scattering particles 3a and the binder 3b remain is filled. As a result, when the organic solvent evaporates in a drying step (not shown), the phosphor / scattering layer 4 composed of the phosphor particles 2a, the scattering particles 3a, and the binder 3b shown in FIG. 7 is formed.

上述の自動車ヘッドランプ用発光装置の製造にはスプレ塗布装置(シリンジディスペンサ型塗布装置)による非対称スプレ塗布を用いたが、図8に示すジェットディスペンサ型塗布装置によるドット塗布を用いることもできる。   Although the asymmetric spray coating by the spray coating device (syringe dispenser type coating device) is used for manufacturing the above-described automobile headlamp light emitting device, dot coating by the jet dispenser type coating device shown in FIG. 8 can also be used.

図8の(A)に示すように、ノズル801から微少量の塗布ドット802が高精度に吐出される。従って、図8の(B)に示すごとく、ノズル801をたとえばLED素子1に対して相対的に2次元的に移動させると、LED素子1上のみに塗布層803が形成される。また、図8の(C)に示すごとく、塗布ドット数を計数することにより塗布層803の厚さ勾配を任意の勾配とすることができる。たとえば、直線状勾配、曲線状勾配、右下り勾配、左下り勾配のいずれにもすることができる。尚、ジェットディスペンサー塗布方法で使用する液はスプレー塗布方法と同様の液でなく、より高粘度の蛍光体、散乱剤含有液を使用してもよい。その場合の粘度は0.5〜10Pa・sで、好ましくは2Pa・s以下のものがよい。   As shown in FIG. 8A, a very small amount of application dots 802 are ejected from the nozzle 801 with high accuracy. Therefore, as shown in FIG. 8B, when the nozzle 801 is moved two-dimensionally relative to the LED element 1, for example, the coating layer 803 is formed only on the LED element 1. Further, as shown in FIG. 8C, the thickness gradient of the coating layer 803 can be set to an arbitrary gradient by counting the number of coating dots. For example, it can be any of a linear gradient, a curved gradient, a right downward gradient, and a left downward gradient. The liquid used in the jet dispenser coating method is not the same as that used in the spray coating method, but a higher viscosity phosphor or scattering agent-containing liquid may be used. In this case, the viscosity is 0.5 to 10 Pa · s, preferably 2 Pa · s or less.

上述の実施の形態においては、発光素子としてLED素子を用いたが、本発明はレーザダイオード(LD)素子等の他の発光素子にも適用し得る。   In the above-described embodiment, the LED element is used as the light emitting element, but the present invention can also be applied to other light emitting elements such as a laser diode (LD) element.

また、本発明は上述の実施の形態の自明の範囲内でのいかなる変更に適用し得る。   The present invention can be applied to any changes within the obvious range of the above-described embodiment.

1:LED素子
2:蛍光体層
2a:蛍光体粒子
2b:バインダ
2c:有機溶媒
3:散乱層
3a:散乱粒子
3b:バインダ
4:蛍光体/散乱層
101:自動車ヘッドランプ
102:路面照明領域
102a:遠方領域
102b:手前領域
201:ノズル
202:塗布液
203:塗布層
301:蛍光体粒子含有液
302:蛍光体粒子含有層
801:ノズル
802:塗布ドット


1: LED element 2: phosphor layer 2a: phosphor particle 2b: binder 2c: organic solvent 3: scattering layer 3a: scattering particle 3b: binder 4: phosphor / scattering layer 101: automobile headlamp 102: road illumination region 102a : Distant area 102b: Front area 201: Nozzle 202: Coating liquid 203: Coating layer 301: Phosphor particle-containing liquid 302: Phosphor particle-containing layer 801: Nozzle 802: Coating dot


Claims (6)

発光素子と、
該発光素子上に設けられ、蛍光体粒子及び第1のバインダを含む蛍光体層と、
該蛍光体層上に設けられ、散乱粒子及び第2のバインダを含む散乱層と
を具備し、
前記蛍光体層の厚さ勾配と前記散乱層の厚さ勾配とは逆の関係を有する自動車ヘッドランプ用発光装置。
A light emitting element;
A phosphor layer provided on the light emitting element and including phosphor particles and a first binder;
A scattering layer provided on the phosphor layer and including scattering particles and a second binder;
A light emitting device for an automobile headlamp, wherein the thickness gradient of the phosphor layer and the thickness gradient of the scattering layer have an inverse relationship.
発光素子と、
該発光素子上に設けられ、蛍光体粒子、散乱粒子及びバインダを含む蛍光体/散乱層と
を具備し、
前記蛍光体/散乱層の厚さ勾配と前記散乱粒子の濃度勾配とは逆の関係を有する自動車ヘッドランプ用発光装置。
A light emitting element;
Provided on the light emitting element, comprising a phosphor / scattering layer containing phosphor particles, scattering particles and a binder,
A light emitting device for an automobile headlamp, wherein a thickness gradient of the phosphor / scattering layer and a concentration gradient of the scattering particles have an inverse relationship.
発光素子上に蛍光体粒子を含む蛍光体粒子含有液を第1の非対称スプレ塗布をして第1の厚さ勾配を有する蛍光体粒子含有層を形成する蛍光体粒子含有液塗布工程と、
前記蛍光体粒子含有層を乾燥せしめて前記発光素子上に前記蛍光体粒子を残存せしめる乾燥工程と、
該残存せしめた蛍光体粒子上に第1のバインダを含むバインダ含有液を前記第1の非対称スプレ塗布をして前記第1の厚さ勾配と同一の傾向の第2の厚さ勾配を有するバインダ含有層を形成し、該バインダ含有層の前記第1のバインダは前記蛍光体粒子間の隙間に埋められて前記バインダ含有層は前記蛍光体粒子及び前記第1のバインダを含む蛍光体層となる、バインダ含有液塗布工程と、
前記蛍光体層上に、散乱粒子及び第2のバインダを含む散乱粒子/バインダ含有液を前記第1の非対称スプレ塗布と異なる第2の非対称スプレ塗布をして前記第1の厚さ勾配と逆の第2の厚さ勾配を有する散乱粒子/バインダ含有層を形成し、該散乱粒子/バインダ含有層は乾燥して散乱層となる、散乱粒子/バインダ含有液塗布工程と
を具備する自動車ヘッドランプ用発光装置の製造方法。
A phosphor particle-containing liquid coating step of forming a phosphor particle-containing layer having a first thickness gradient by applying a phosphor particle-containing liquid containing phosphor particles on a light-emitting element to the first asymmetric spray;
A drying step of drying the phosphor particle-containing layer to leave the phosphor particles on the light emitting element;
A binder having a second thickness gradient having the same tendency as the first thickness gradient by applying the first asymmetric spray on the remaining phosphor particles to the binder-containing liquid containing the first binder. Forming a containing layer, wherein the first binder of the binder containing layer is buried in a gap between the phosphor particles, and the binder containing layer becomes a phosphor layer including the phosphor particles and the first binder. A binder-containing liquid coating process;
On the phosphor layer, a scattering particle / binder-containing liquid containing scattering particles and a second binder is applied with a second asymmetric spray coating different from the first asymmetric spray coating to reverse the first thickness gradient. An automotive headlamp comprising: a scattering particle / binder-containing layer having a second thickness gradient, wherein the scattering particle / binder-containing layer is dried to form a scattering layer. For manufacturing a light emitting device for an automobile.
発光素子上に蛍光体粒子を含む蛍光体粒子含有液を第1の非対称スプレ塗布をして厚さ勾配を有する蛍光体粒子含有層を形成する蛍光体粒子含有液塗布工程と、
前記蛍光体粒子含有層を乾燥せしめて前記発光素子上に前記蛍光体粒子を残存せしめる乾燥工程と、
該残存せしめた蛍光体粒子上に散乱粒子及びバインダを含む散乱粒子/バインダ含有液を前記第1の非対称スプレ塗布と異なる第2の非対称スプレ塗布をして前記厚さ勾配と逆の濃度勾配を有する散乱粒子/バインダ含有層を形成し、該散乱粒子/バインダ含有層の前記散乱粒子及び前記バインダは前記蛍光体粒子間の隙間に埋められて前記散乱粒子/バインダ含有層は蛍光体粒子、前記散乱粒子及び前記バインダを含む蛍光体/散乱層となる、散乱粒子/バインダ含有液塗布工程と
を具備する自動車ヘッドランプ用発光装置の製造方法。
A phosphor particle-containing liquid coating step of forming a phosphor particle-containing layer having a thickness gradient by applying a first asymmetric spray on a phosphor particle-containing liquid containing phosphor particles on a light-emitting element;
A drying step of drying the phosphor particle-containing layer to leave the phosphor particles on the light emitting element;
A scattering particle / binder-containing liquid containing scattering particles and a binder is applied onto the remaining phosphor particles, and a second asymmetric spray coating different from the first asymmetric spray coating is performed to obtain a concentration gradient opposite to the thickness gradient. The scattering particles / binder-containing layer is formed, and the scattering particles and the binder of the scattering particles / binder-containing layer are filled in gaps between the phosphor particles, and the scattering particles / binder-containing layer is phosphor particles, A method for producing a light-emitting device for an automotive headlamp, comprising: a scattering particle / binder-containing liquid coating step that becomes a phosphor / scattering layer containing scattering particles and the binder.
発光素子上に蛍光体粒子を含む蛍光体粒子含有液をジェットディスペンサによるドット塗布をして第1の厚さ勾配を有する蛍光体粒子含有層を形成する蛍光体粒子含有液塗布工程と、
前記蛍光体粒子含有層を乾燥せしめて前記発光素子上に前記蛍光体粒子を残存せしめる乾燥工程と、
該残存せしめた蛍光体粒子上に第1のバインダを含むバインダ含有液を前記ジェットディスペンサによるドット塗布して前記第1の厚さ勾配と同一の傾向の第2の厚さ勾配を有するバインダ含有層を形成し、該バインダ含有層の前記第1のバインダは前記蛍光体粒子間の隙間に埋められて前記バインダ含有層は前記蛍光体粒子及び前記第1のバインダを含む蛍光体層となる、バインダ含有液塗布工程と、
前記蛍光体層上に、散乱粒子及び第2のバインダを含む散乱粒子及びバインダ含有液を前記ジェットディスペンサによるドット塗布をして前記第1の厚さ勾配と逆の第2の厚さ勾配を有する散乱粒子/バインダ含有層を形成し、該散乱粒子/バインダ含有層は乾燥して散乱層となる、散乱粒子/バインダ含有液塗布工程と
を具備する自動車ヘッドランプ用発光装置の製造方法。
A phosphor particle-containing liquid coating step of forming a phosphor particle-containing layer having a first thickness gradient by performing dot coating with a jet dispenser on a phosphor particle-containing liquid containing phosphor particles on a light emitting element;
A drying step of drying the phosphor particle-containing layer to leave the phosphor particles on the light emitting element;
A binder-containing layer having a second thickness gradient having the same tendency as the first thickness gradient by applying a dot-containing liquid containing the first binder onto the remaining phosphor particles using the jet dispenser. The binder-containing layer is filled with a gap between the phosphor particles, and the binder-containing layer becomes a phosphor layer containing the phosphor particles and the first binder. Containing liquid coating process;
On the phosphor layer, the scattering particles containing the scattering particles and the second binder and the binder-containing liquid are applied with dots by the jet dispenser to have a second thickness gradient opposite to the first thickness gradient. A method for producing a light-emitting device for an automotive headlamp comprising a scattering particle / binder-containing liquid coating step, wherein a scattering particle / binder-containing layer is formed, and the scattering particle / binder-containing layer is dried to form a scattering layer.
発光素子上に蛍光体粒子を含む蛍光体粒子含有液をジェットディスペンサドット塗布をして厚さ勾配を有する蛍光体粒子含有層を形成する蛍光体粒子含有液塗布工程と、
前記蛍光体粒子含有層を乾燥せしめて前記発光素子上に前記蛍光体粒子を残存せしめる乾燥工程と、
該残存せしめた蛍光体粒子上に散乱粒子及びバインダを含む散乱粒子/バインダ含有液を前記ジェットディスペンサによるドット塗布をして前記厚さ勾配と逆の濃度勾配を有する散乱粒子/バインダ含有層を形成し、該散乱粒子/バインダ含有層の前記散乱粒子及び前記バインダは前記蛍光体粒子間の隙間に埋められて前記散乱粒子/バインダ含有層は前記蛍光体粒子、前記散乱粒子及び前記バインダを含む蛍光体/散乱層となる、散乱粒子/バインダ含有液塗布工程と
を具備する自動車ヘッドランプ用発光装置の製造方法。

A phosphor particle-containing liquid application step of forming a phosphor particle-containing layer having a thickness gradient by applying a jet dispenser dot to a phosphor particle-containing liquid containing phosphor particles on a light-emitting element;
A drying step of drying the phosphor particle-containing layer to leave the phosphor particles on the light emitting element;
A scattering particle / binder-containing layer having a concentration gradient opposite to the thickness gradient is formed on the remaining phosphor particles by applying a scattering particle / binder-containing liquid containing scattering particles and a binder with the jet dispenser. The scattering particles and the binder of the scattering particle / binder-containing layer are buried in a gap between the phosphor particles, and the scattering particle / binder-containing layer is a fluorescent light containing the phosphor particles, the scattering particles, and the binder. A method for producing a light-emitting device for an automotive headlamp, comprising a scattering particle / binder-containing liquid coating step that becomes a body / scattering layer.

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