JP2017149929A - Manufacturing method of phosphor-containing member - Google Patents

Abstract

PROBLEM TO BE SOLVED: To manufacture, relatively easily and with high reproducibility, a phosphor-containing member having a phosphor member 10 provided with a light reflection member 20 at the circumference.SOLUTION: Provided is a manufacturing method related to an embodiment of a phosphor-containing member 100 including: a process where prepared is a phosphor member 10 which includes a phosphor, and in which a plurality of projecting parts is provided at the side of a first main face; a process where a powdery light reflection member 20 is prepared; a process where the powdery light reflection member 20 is arranged between a plurality of projection parts in the phosphor member 10; a process where the powdery light reflection member 20 is sintered to obtain a sintered body in which the phosphor member 10 and the light reflection member 20 are integrally formed; and a process where a part of the sintered body is removed from at least either side of the first main face side or a second main face side in the phosphor member 10 so as to obtain the phosphor-containing member 100 in which the face of the first main face side is made of both of the phosphor member 10 and the light reflection member 20, and the face of the second main face side is made of the phosphor member 10 only or made of both of the phosphor member 10 and the light reflection member 20.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a method for producing a phosphor-containing member.

  In the light-emitting device described in Patent Document 1, a ceramic wavelength conversion member (corresponding to a “fluorescent member” in the present specification) is a through hole of a holder (corresponding to a “light reflecting member” in the present specification). It is fixed using an adhesive.

JP2014-67961A

  In order to manufacture such a member, a through hole is formed in the holder, the wavelength conversion member is processed according to the shape of the through hole, and then the processed wavelength conversion member is accurately fixed to the through hole of the holder. Must. That is, a complicated process is required, and the shape of the wavelength conversion member and the shape of the through hole in the holder need to be matched, so that it is difficult to manufacture with good reproducibility.

  The method for producing a phosphor-containing member according to one aspect of the present invention includes a step of preparing a phosphor member including a phosphor, in which a plurality of convex portions are provided on the first main surface side, and a powdery light reflecting member A step of arranging the powdery light reflecting member between a plurality of convex portions of the fluorescent member, and sintering the powdery light reflecting member to thereby provide the fluorescent member and the light reflecting member. A step of obtaining a sintered body integrally formed with the member, the surface on the first main surface side is composed of both the fluorescent member and the light reflecting member, and the surface on the second main surface side is At least on the first main surface side or the second main surface side of the fluorescent member so as to obtain a phosphor-containing member consisting of only the fluorescent member or both the fluorescent member and the light reflecting member. Removing a part of the sintered body from one side.

  The method for producing a phosphor-containing member according to another aspect of the present invention includes a step of preparing a light reflecting member in which a plurality of recesses are provided on the first main surface side, and a powdery phosphor member containing the phosphor. A step of preparing, a step of arranging the powdery fluorescent member in a plurality of recesses in the light reflecting member, and sintering the powdery fluorescent member so that the light reflecting member and the fluorescent member are integrated. A step of obtaining a formed sintered body, a surface of the light reflecting member on the side of the second principal surface opposite to the first principal surface is composed of both the fluorescent member and the light reflecting member, and At least the second main surface of the light reflecting member so that a phosphor-containing member can be obtained in which the surface on the first main surface side consists of only the fluorescent member or both the fluorescent member and the light reflecting member. And removing a part of the sintered body from the side.

  The manufacturing method of the fluorescent substance containing member which concerns on another form of this invention is a process of preparing the light reflection member provided with the several through-hole which penetrates the 1st main surface and 2nd main surface which are mutually opposite sides. And a step of preparing a powdery fluorescent member including a phosphor, a step of arranging the powdery fluorescent member in the plurality of through holes, and sintering the powdery fluorescent member to provide the light reflection A step of obtaining a sintered body in which the member and the fluorescent member are integrally formed, and one surface of the first main surface side or the second main surface side surface is the fluorescent member and the light. It consists of both reflecting members, and the other surface of the surface on the first main surface side or the second main surface side consists of only the fluorescent member or both the fluorescent member and the light reflecting member In order to obtain a phosphor-containing member comprising: the first main surface side of the fluorescent member or the first From at least one side of the side of the main surface and a step of removing a portion of the sintered body.

  Thereby, the fluorescent substance containing member by which the light reflection member is arrange | positioned around the fluorescent member can be manufactured comparatively easily and with good reproducibility.

FIG. 1 is a top view of the phosphor-containing member according to the first embodiment. 2 is a cross-sectional view taken along line XX of FIG. FIG. 3A is a cross-sectional view for explaining the method for manufacturing the phosphor-containing member according to the first embodiment. FIG. 3B is a cross-sectional view for explaining the method for manufacturing the phosphor-containing member according to the first embodiment. FIG. 3C is a cross-sectional view for explaining the method for manufacturing the phosphor-containing member according to the first embodiment. FIG. 3D is a cross-sectional view for explaining the method for manufacturing the phosphor-containing member according to the first embodiment. FIG. 3E is a cross-sectional view for explaining the method for manufacturing the phosphor-containing member according to the first embodiment. FIG. 3F is a cross-sectional view for explaining the method for manufacturing the phosphor-containing member according to the first embodiment. FIG. 3G is a cross-sectional view for explaining the method for manufacturing the phosphor-containing member according to the first embodiment. FIG. 3H is a cross-sectional view for explaining the method for manufacturing the phosphor-containing member according to the first embodiment. FIG. 3I is a cross-sectional view for explaining the method for manufacturing the phosphor-containing member according to the first embodiment. FIG. 3J is a cross-sectional view for explaining the method for manufacturing the phosphor-containing member according to the first embodiment. FIG. 4A is a cross-sectional view for explaining another method of preparing a fluorescent member. FIG. 4B is a cross-sectional view for explaining another method for preparing the fluorescent member. FIG. 4C is a cross-sectional view for explaining another method for preparing the fluorescent member. FIG. 5 is a cross-sectional view for explaining another example of the step of removing a part of the sintered body. FIG. 6 is a schematic view of a light-emitting device that combines a phosphor-containing member after singulation and a light-emitting element according to the first embodiment. FIG. 7 is a top view of the phosphor-containing member according to the second embodiment. 8 is a cross-sectional view taken along line YY of FIG. FIG. 9A is a cross-sectional view for explaining the method for manufacturing the phosphor-containing member according to the second embodiment. FIG. 9B is a cross-sectional view for explaining the method for manufacturing the phosphor-containing member according to the second embodiment. FIG. 9C is a cross-sectional view for explaining the method for manufacturing the phosphor-containing member according to the second embodiment. FIG. 9D is a cross-sectional view for explaining the method for manufacturing the phosphor-containing member according to the second embodiment. FIG. 9E is a cross-sectional view for explaining the method for manufacturing the phosphor-containing member according to the second embodiment. FIG. 9F is a cross-sectional view for explaining the method for manufacturing the phosphor-containing member according to the second embodiment. FIG. 9G is a cross-sectional view for explaining the method for manufacturing the phosphor-containing member according to the second embodiment. FIG. 9H is a cross-sectional view for explaining the method for manufacturing the phosphor-containing member according to the second embodiment. FIG. 10 is a cross-sectional view of a light-emitting device that combines a phosphor-containing member and a light-emitting element according to the second embodiment. FIG. 11A is a cross-sectional view for explaining the method for manufacturing the phosphor-containing member according to the third embodiment. FIG. 11B is a cross-sectional view for explaining the method for manufacturing the phosphor-containing member according to the third embodiment. FIG. 11C is a cross-sectional view for explaining the method for manufacturing the phosphor-containing member according to the third embodiment. FIG. 11D is a cross-sectional view for explaining the method for manufacturing the phosphor-containing member according to the third embodiment. FIG. 11E is a cross-sectional view for explaining the method for manufacturing the phosphor-containing member according to the third embodiment. FIG. 11F is a cross-sectional view for explaining the method for manufacturing the phosphor-containing member according to the third embodiment. FIG. 11G is a cross-sectional view for explaining the method for manufacturing the phosphor-containing member according to the third embodiment. FIG. 12 is a cross-sectional view for explaining another example of the step of removing a part of the sintered body in the third embodiment.

  A mode for carrying out the present invention will be described below with reference to the drawings. However, the form shown below is for embodying the technical idea of the present invention, and does not limit the present invention. Note that the size, positional relationship, and the like of the members shown in each drawing may be exaggerated for clarity of explanation.

  In this specification, for example, the terms “powdered fluorescent member” and “sintered fluorescent member” are used, and the term “fluorescent member” is used regardless of the state of the fluorescent member. . Similarly, in this specification, for example, the terms “powdered light reflecting member” and “light reflecting member made of a sintered body” are used. Is used. Further, in this specification, the term “phosphor-containing member” is used regardless of the presence or absence of individualization.

<First Embodiment>
FIG. 1 shows a view (top view) of a phosphor-containing member 100 obtained by the manufacturing method according to the present embodiment as viewed from the first main surface side. 2 is a cross-sectional view taken along line XX in FIG. 3A to 3I are for explaining a method of manufacturing the phosphor-containing member 100. FIG. Further, FIG. 3J shows a process of obtaining the phosphor-containing member 100a by dividing the phosphor-containing member 100 into individual pieces.

  The method for manufacturing the phosphor-containing member 100 includes a step of preparing a fluorescent member 10 including a phosphor, in which a plurality of convex portions are provided on the first main surface side, and a step of preparing a powdery light reflecting member 20. And the step of disposing the powdery light reflecting member 20 between the plurality of convex portions in the fluorescent member 10, and sintering the powdery light reflecting member 20 so that the fluorescent member 10 and the light reflecting member 20 are integrated. A step of obtaining the sintered body formed on the first main surface, the surface on the first main surface side is composed of both the fluorescent member 10 and the light reflecting member 20, and the surface on the second main surface side is composed of only the fluorescent member 10. Alternatively, the sintered body is formed from at least one of the first main surface side and the second main surface side of the fluorescent member 10 so that the phosphor-containing member 100 including both the fluorescent member 10 and the light reflecting member 20 is obtained. A step of removing a part thereof.

  Thereby, the phosphor-containing member 100 having the fluorescent member 10 and the light reflecting member 20 surrounding the fluorescent member 10 can be manufactured relatively easily and with good reproducibility.

  In the conventional method for producing a phosphor-containing member, a through hole is formed in a light reflecting member, the sintered fluorescent member is processed into a shape of a through hole, and then the processed fluorescent member is optically bonded using an adhesive. It fixes to the inner wall of a reflective member. However, this method requires a step of forming a through hole in the light reflecting member, a step of sintering the fluorescent member, a step of processing the fluorescent member, and a step of fixing the fluorescent member to the light reflecting member. The process becomes complicated and it takes time to manufacture the phosphor-containing member. Moreover, since it is necessary to match | combine the shape of the through-hole of a light reflection member with the shape of a fluorescent member accurately, it is difficult to manufacture a fluorescent substance containing member with sufficient reproducibility.

  On the other hand, in the manufacturing method of the present embodiment, the powdery light reflecting member 20 is sintered after the powdery light reflecting member 20 is disposed between the plurality of convex portions in the fluorescent member 10, The phosphor-containing member 100 is manufactured by forming a sintered body in which the fluorescent member 10 and the light reflecting member 20 are integrally formed, and further removing a part of the sintered body. That is, by using the powdery light reflecting member 20, the phosphor-containing member 100 can be manufactured without processing the light reflecting member 20 into a specific shape, so that the process can be simplified. Furthermore, since the powdery light reflecting member 20 is used, it is not necessary to align the fluorescent member 10 and the light reflecting member 20, so that the phosphor-containing member can be manufactured with good reproducibility. In particular, in the manufacturing method of the present embodiment, since the powdery light reflecting member 20 is used for sintering, the fluorescent member 10 and the light reflecting member 20 are directly joined in the phosphor-containing member 100 obtained thereby. Yes. That is, no member (for example, adhesive) other than the fluorescent member 10 and the light reflecting member 20 is interposed between the fluorescent member 10 and the light reflecting member 20. Thereby, the heat generated when light hits the fluorescent member 10 can be efficiently released to the light reflecting member 20.

(Process before preparing the fluorescent member 10)
In this embodiment, as shown to FIG. 3A, before the process of preparing the fluorescent member 10, a powdery material (for example, material similar to the light reflection member 20) is arrange | positioned as the buffer member 30 in a container. In the present embodiment, the sintered die 40 and the lower punch 50 are used as containers. Although the buffer member 30 is not essential, even if the fluorescent member 10 made of a sintered body is used, the pressure applied to the fluorescent member 10 can be reduced when the light reflecting member 20 is sintered later. Since it can be made substantially uniform, cracks and the like of the fluorescent member 10 made of a sintered body can be reduced.

  Next, in order to make it easier to take out the sintered body composed of the fluorescent member 10 and the light reflecting member 20 from the container in the subsequent process, as shown in FIG. 3B, the release sheet 60 is disposed above the buffer member 30. . As the release sheet 60, for example, a polyethylene sheet or a carbon sheet can be used.

(Process of preparing fluorescent member 10)
Next, as shown in FIG. 3E, a fluorescent member 10 having a plurality of convex portions provided on the first main surface side is prepared.

In the present embodiment, in the step of preparing the fluorescent member 10, the powdered phosphor and the powdery sintering aid containing the same material as the light reflecting member are mixed and then sintered, The fluorescent member 10 made of a sintered body having a convex portion provided on the first main surface side is obtained. In the present embodiment, a sintering aid made of Y ₃ Al ₅ O ₁₂ : Ce (yttrium, aluminum, garnet (YAG)) phosphor and aluminum oxide is used as the fluorescent member 10, and the light reflecting member 20 is oxidized. Aluminum is used.

  In the present embodiment, in the step of preparing the fluorescent member 10, the plurality of convex portions are formed on the first main surface side by forming the plurality of convex portions on the fluorescent member 10 made of a sintered body. 10 is earned. That is, first, a plate-like fluorescent member 10 made of a sintered body is produced as shown in FIG. 3C, and then a plurality of convex portions are formed on the plate-like sintered body as shown in FIG. 3D. Thereby, the shape of a convex part can be designed comparatively freely. In addition, sintering a powdery fluorescent member using a predetermined shape of a sintering die (upper punch 50, lower punch 50, and sintering die 40) so that a plurality of convex portions are formed. Thus, the fluorescent member 10 made of a sintered body provided with a plurality of convex portions may be formed.

  The shortest distance between the side surface of one convex portion of the fluorescent member 10 and the side surface of the adjacent convex portion is preferably 0.7 mm or more. Thereby, in the process of arrange | positioning the powdery light reflection member 20, it can be made easy to fill the light reflection member 20 between adjacent convex parts.

  The shape of the convex portion can be a circle, an ellipse, a rectangle, or the like when viewed from above, and is a circle in this embodiment. At this time, the width at the top of the convex portion is smaller than the width at the bottom (base) of the convex portion. That is, the side surface of the convex portion is inclined so that the width of the convex portion becomes smaller from the lower portion that becomes the bottom portion toward the upper portion that becomes the top portion. For example, the width of the top of the convex portion can be in the range of 0.1 mm to 1.2 mm. Moreover, the width | variety of the bottom part of a convex part can be made into the range of 0.5 mm or more and 10 mm or less. The convex portion is preferably formed using a machining center. Thereby, the thing with the comparatively small width | variety of a convex part and the thing in which the side surface of a convex part inclines can be processed with high precision.

  In the present embodiment, in the step of preparing the fluorescent member 10, the fluorescent member 10 made of a sintered body is prepared. However, as shown in FIGS. 4A to 4C, the powdered fluorescent member 10 may be prepared. it can. In this case, the step of preparing the fluorescent member 10 includes the step of filling the container with the powdered fluorescent member 10 containing the phosphor (FIG. 4A) and the pressing member 51 provided with a plurality of recesses. A step of manufacturing the fluorescent member 10 provided with a plurality of convex portions by pressing the member 10 (FIGS. 4B and 4C), and obtaining a sintered body. In the step of obtaining the sintered body, the fluorescent member 10 and the light reflecting member Both 20 are sintered. By using the pressing member 51 provided with a plurality of recesses, it is possible to form the fluorescent member 10 that is in a powder form but retains a constant shape (a shape provided with a plurality of protrusions) as a whole. Thereby, a process can be simplified compared with the case where the plate-shaped fluorescent member 10 which consists of a sintered compact is used.

  The opening shape of the concave portion of the pressing member 51 can be a circle, an ellipse, a rectangle, or the like. It is preferable that the opening of the concave portion of the pressing member 51 is formed so as to become wider as the distance from the bottom surface of the concave portion increases. That is, it is preferable that the width of the concave portion increases as the distance from the surface on the side pressing the fluorescent member 10 increases. Thereby, the fluorescent member 10 and the pressing member 51 are easily separated. A release sheet may be interposed between the pressing member 51 and the powdery fluorescent member 10. Thereby, when the fluorescent member 10 and the pressing member 51 are separated, the fluorescent member 10 hardly remains in the recess.

  The phosphor contained in the fluorescent member 10 can be appropriately selected according to the required fluorescent color. For example, it comprises at least one element selected from the group consisting of Y, Lu, Sc, La, Tb and Gd and at least one element selected from the group consisting of Al, Ga and In, and includes Ce, Cr A garnet-based phosphor combined with at least one element selected from the group consisting of Nd, Eu can be used. When the light reflecting member 20 contains aluminum oxide, the fluorescent member 10 preferably contains an oxide phosphor containing Al. Thereby, since the same material is contained in the fluorescent member 10 and the light reflecting member 20, the bonding strength between them can be increased. Examples of oxide phosphors containing Al include YAG phosphors.

  The fluorescent member 10 may be composed of only a phosphor, or may be composed of a phosphor and other members. As the other member, for example, a sintering aid can be used. In this case, the sintering aid preferably contains the same material as that contained in the light reflecting member 20. Thereby, the joint strength between the fluorescent member 10 and the light reflecting member 20 can be further increased.

(Step of preparing the light reflecting member 20)
Next, a powdery light reflecting member 20 is prepared. The light reflecting member 20 can include an additive. When an additive is included, it is preferable to use a material having a refractive index higher than that of a base material (for example, aluminum oxide) that is a main component of the light reflecting member. Thereby, the reflectance (the reflectance with respect to the fluorescence from the fluorescent member and / or the light from the light emitting element) of the light reflecting member 20 can be improved, and the transmittance can be suppressed. As a material having a high refractive index, for example, boron nitride, yttrium oxide, lutetium oxide, zirconium oxide, or lanthanum oxide can be used. However, since these are hardly sinterable materials, the strength of the light reflecting member 20 may be reduced. In this case, a glass material having a lower melting point than that of the base material (for example, a glass material containing boron oxide) can be used as the additive. As a result, the glass material becomes a liquid phase and enters between the base material in the light reflecting member 20 and the additive material excluding the glass material, so that the coupling between the two can be strengthened. When a glass material having a low melting point is used as an additive, it is added at 2% by mass or less of the light reflecting member. In this specification, even if the glass material contains 2% by mass or less, “sintered body” That's it.

(Process of arranging the light reflecting member 20)
Next, the powdery light reflecting member 20 is disposed between the plurality of convex portions in the fluorescent member 10. By using the powdery light reflecting member 20, the fluorescent member 10 can be easily filled between the adjacent convex portions, and the gap between the fluorescent member 10 and the light reflecting member 20 can be substantially eliminated. In the present embodiment, as shown in FIG. 3F, the fluorescent member 10 is arranged so that the convex portion faces upward, and the powdery light reflecting member 20 is arranged from above, so that the convex portion of the fluorescent member 10 is located between the convex portions. The light reflecting member 20 is disposed on the surface.

  In FIG. 3F, the fluorescent member 10 made of a sintered body is disposed below and the powdery light reflecting member 20 is disposed above, but the arrangement order can be reversed. That is, the powdery light reflecting member 20 is first arranged in the container, and then the fluorescent member 10 made of a sintered body is arranged above the convex member so that the convex portion faces downward, and is pressed as necessary. You can also. Even in this case, the light reflecting member 20 can be disposed between the plurality of convex portions of the fluorescent member 10.

(Step of obtaining a sintered body)
Next, as shown in FIG. 3G, the powdery light reflecting member 20 is sintered to obtain a sintered body in which the fluorescent member 10 and the light reflecting member 20 are integrally formed. In general, a sintered body refers to a powdered material that is solidified by heating at a temperature lower than the melting point. However, even in the case where the fluorescent member 10 that has already been sintered and the powdery light reflecting member 20 that has not been sintered are heat-treated as in the present embodiment, it is made of a sintered body. It is considered that the same phenomenon occurs on the surface of the fluorescent member 10 and the surface of the powdery light reflecting member 20. Therefore, in the present embodiment, the one in which the fluorescent member 10 made of a sintered body and the powdery light reflecting member 20 are integrally formed is also called a sintered body.

  It is preferable to sinter the fluorescent member 10 and the light reflecting member 20 while applying pressure. Thereby, the joint strength between the fluorescent member 10 and the light reflecting member 20 can be improved. As the sintering method, for example, a discharge plasma sintering method (SPS method: spark plasma sintering method) or a hot press sintering method (HP method: hot pressing method) can be used, and the SPS method is preferably used. The SPS method is a method of heating by pulse energization while applying pressure using the upper and lower punches 50. According to the SPS method, rapid temperature rise is possible in a relatively short time by applying a pulse, so that the grain growth of the light reflecting member 20 can be easily controlled. When sintering while applying pressure, for example, the pressure can be set in a range of 10 MPa to 50 MPa. By setting it to the above lower limit value or more, the bonding strength between the fluorescent member 10 and the light reflecting member 20 can be improved, and by setting it to the above upper limit value or less, grain growth of the light reflecting member 20 can be easily controlled. Further, it becomes easy to suppress an increase in the particle size of the light reflecting member 20 (that is, the transmittance increases and the light reflectivity is impaired).

  In this embodiment, the powdery fluorescent member and the powdery light reflecting member are not sintered in one step, but the fluorescent member 10 made of a sintered body is prepared in advance, and then the convexity of the fluorescent member 10 is prepared. The powdery light reflecting member disposed between the parts is sintered. The sintering aid and at least a part of the light reflecting member are made of the same material (aluminum oxide), and the sintering temperature for sintering the powdery light reflecting member 20 is set to the sintering temperature for obtaining the fluorescent member 10. The sintering temperature is lower than the sintering temperature (sintering temperature when the powdered phosphor and the powdery sintering aid are mixed and sintered). The reason will be described below.

  Since the fluorescent member 10 needs to make it easy to extract light, a certain level of transmittance (transmittance with respect to fluorescence from the fluorescent member 10 and / or light from the light emitting element) is required. For example, the transmittance of the fluorescent member can be increased by sintering at a high temperature and promoting the grain growth of the sintering aid contained in the fluorescent member 10. On the other hand, since the light reflecting member 20 needs to make it easy to reflect light, the reflectance of a certain level or more is required. For example, the reflectance of the light reflecting member 20 can be increased by sintering the light reflecting member 20 at a certain low temperature to suppress the grain growth of the light reflecting member 20. For these reasons, when the powdered fluorescent member 10 and the powdered light reflecting member 20 are sintered in one step, the transmittance of the light reflecting member 20 is increased by sintering at a high temperature in order to increase the transmittance of the fluorescent member 10. Will go down. On the other hand, if the light reflecting member 20 is sintered at a low temperature in order to increase the reflectance, the transmittance of the fluorescent member is lowered. Therefore, in the present embodiment, first, a fluorescent member 10 made of a sintered body obtained by sintering a powdered phosphor and a powdery sintering aid at a high temperature is obtained, and thereafter, between the convex portions of the fluorescent member 10. The powdery light reflecting member 20 arranged in the above is sintered at a low temperature. That is, when the fluorescent member 10 is sintered, the fluorescent member 10 can be sintered at a high temperature without considering a decrease in the reflectance of the light reflecting member 20, and when the light reflecting member 20 is sintered, It can be sintered at a low temperature while maintaining the transmittance. Thereby, it becomes possible to achieve both the improvement of the transmittance of the fluorescent member 10 and the improvement of the reflectance of the light reflecting member 20.

  The powdery light reflecting member 20 can be sintered in the range of 1100 ° C. or higher and 1400 ° C. or lower. When using the fluorescent member 10 made of a sintered body, it is preferable to sinter in the range of 1100 ° C. or more and 1200 ° C. or less in the step of obtaining the sintered body (step of sintering the powdery light reflecting member 20). It is more preferable to sinter in the range of 1130 ° C or higher and 1170 ° C or lower. The strength of the light reflecting member 20 can be improved by setting it to the above lower limit value or more, and the decrease in reflectance due to excessive grain growth of the light reflecting member 20 can be reduced by setting it to the above upper limit value or less. be able to.

  In the present embodiment, after the step of obtaining the sintered body, the sintered body is heat-treated in an oxidizing atmosphere (for example, an air atmosphere). Generally, carbon is contained in the sintering mold used for the SPS method and the HP method. When the light reflecting member 20 includes an oxide, the sintered carbon may cause carburization or reduction reaction of the oxide included in the light reflecting member 20, and the reflectance of the light reflecting member 20 may be reduced. Therefore, by heat-treating the sintered body in an oxidizing atmosphere, the carbon contained in the oxide can be easily removed and the lost oxygen can be returned, so that the reflectance of the light reflecting member 20 can be improved.

  In the heat treatment step, the heat treatment can be performed in the range of 1000 ° C. to 1500 ° C. When the fluorescent member 10 made of a sintered body is used, the heat treatment is preferably performed in the range of 1000 ° C. or more and 1200 ° C. or less, more preferably in the range of 1050 ° C. or more and 1150 ° C. or less. Oxygen can be easily returned to the oxide contained in the light reflecting member 20 by setting it to the above lower limit value or more, and lowering the reflectance of the light reflecting member 20 can be reduced by setting it to the above upper limit value or less.

(Step of removing part of the sintered body)
Next, the surface on the first main surface side is composed of both the fluorescent member 10 and the light reflecting member 20, and the surface on the second main surface side is composed only of the fluorescent member 10, or the fluorescent member and the light reflecting member A part of the sintered body is removed from at least one of the first main surface side and the second main surface side of the fluorescent member 10 so that a phosphor-containing member composed of both is obtained.

  In the present embodiment, in the sintered body obtained in FIG. 3G, the surface on the first main surface side is composed only of the light reflecting member 20, and the surface on the second main surface side is composed only of the fluorescent member 10. That is, the top of the convex portion of the fluorescent member 10 is buried in the light reflecting member 20. In this case, as shown in FIG. 3H, at least a part of the sintered body is removed from the side of the first main surface of the sintered body to the top of the convex portion of the fluorescent member 10 to thereby reflect the fluorescent member 10 and the light reflection. The member 20 is exposed. Thereby, it can be set as the fluorescent substance containing member which the surface by the side of the 1st main surface consists of both the fluorescent member 10 and the light reflection member 20. FIG. In the present embodiment, as shown in FIG. 3I, a part of the sintered body is removed from the side of the second main surface of the sintered body to the bottom of the convex portion of the fluorescent member 10. Thus, the phosphor-containing member 100 is obtained in which the first main surface side surface and the second main surface side surface are both the fluorescent member 10 and the light reflecting member 20.

  In addition, as shown in FIG. 5, you may remove a part of sintered compact so that it may not reach the bottom part of the convex part of the fluorescent member 10 from the 2nd main surface side of the fluorescent member 10. FIG. That is, a part of the sintered body may be removed so that the surface on the second main surface side is made only of the fluorescent member 10. As a result, the light reflecting member 20 is disposed around the fluorescent member 10 when viewed from the first main surface side, and the phosphor-containing member includes only the fluorescent member 10 when viewed from the second main surface side. it can. For example, such a phosphor-containing member is arranged on the upper surface side of the light-emitting element 70 so that the upper surface of the light-emitting element 70 and the second main surface of the phosphor-containing member face each other. Accordingly, light from the light emitting element 70 can be incident on the second main surface side of the fluorescent member 10 and can be extracted from the first main surface side having a smaller area than the second main surface. It becomes easy to improve the brightness.

  In the present embodiment, the sintered body obtained in FIG. 3G has the top of the convex portion of the fluorescent member 10 buried in the light reflecting member 20, but in the step of arranging the light reflecting member, the convex portion as shown in FIG. 3H. It is also possible to obtain a sintered body in which the light reflecting member exists only between the convex portions in the step of arranging the light reflecting member only between them and obtaining the sintered body. That is, it is possible to obtain a sintered body in which the surface on the first surface side is composed of both the fluorescent member and the light reflecting member. At this time, when a part of the sintered body is removed from the first main surface side, a part of the sintered body is removed so as not to reach the bottom of the convex portion. Moreover, when removing a part of sintered compact from the 2nd main surface side, you may remove a part of sintered compact until it reaches the bottom part of a convex part, and the extent which does not reach the bottom part of a convex part A part of the sintered body may be removed.

  In the step of preparing the fluorescent member 10, when the fluorescent member 10 made of a sintered body is used, it is preferable that the first main surface and the second main surface be substantially parallel. And it is preferable to make a 2nd main surface of the fluorescent member 10 into an installation surface, and to remove a part of sintered compact from the light reflection member 20 side (above FIG. 3H). Thereby, if it removes in parallel with the lower surface of a sintered compact, since all the fluorescent members 10 can be exposed, removal can be performed easily.

  As a method for removing a part of the sintered body, for example, grinding or chemical mechanical polishing (CMP) can be used. When a part of the sintered body is removed from above and below, it is preferable that the surfaces after the removal have different roughnesses. For example, it is preferable that one of the upper surface and the lower surface of the phosphor-containing member 100 is a rough surface and the other is substantially a mirror surface. As shown in FIG. 6, when the light emitting device is combined with the light emitting element 70, the mirror surface side is preferably a light incident surface from the light emitting element 70 and the rough surface side is a light extraction surface of the light emitting device. Thereby, since the total reflection of the light which goes outside from the fluorescent member 10 can be reduced, reducing the light which returns from the fluorescent member 10 to the light emitting element 70, the light extraction efficiency fall as a light-emitting device can be suppressed.

(Process to divide into pieces)
As shown in FIG. 3J, after the step of removing a part of the sintered body, the sintered body includes at least one fluorescent member 10 surrounded by the light reflecting member 20 when viewed from the first main surface side. Can be singulated. Thereby, the fluorescent substance containing member 100a of the desired magnitude | size by which the light reflection member 20 is arrange | positioned around the fluorescent member 10 can be obtained. For example, the sintered body can be separated into pieces by scribing, dicing, or breaking. Although the working efficiency can be improved by separating the fluorescent member 10 after being exposed, the fluorescent member 10 may be exposed after the sintered body is separated.

(Other)
The phosphor-containing member 100 can be combined with the light emitting element 70 to form a light emitting device. In FIG. 6, an LD (laser diode) is used as the light emitting element 70, and the light emitting device 400 is formed by combining the LD and the individual phosphor-containing member 100 a. In the case of using the LD, it is preferable to dispose both of them separately as shown in FIG. 6 in consideration of the exhaust heat property between the heat generated from the LD and the heat generated from the fluorescent member 10. For example, the LD and the fluorescent member 10 can be separated by using an optical fiber. Note that the phosphor-containing member 100 may be placed on the upper surface of the light reflector so that the light incident on the fluorescent member 10 from the LD is reflected by the light reflector.

Second Embodiment
In FIG. 7, the top view of the fluorescent substance containing member 200 obtained by the manufacturing method which concerns on this embodiment is shown. 8 is a cross-sectional view taken along line YY of FIG. Furthermore, FIGS. 9A to 9H are views for explaining a method of manufacturing the phosphor-containing member 200. FIG.

  The method for manufacturing the phosphor-containing member 200 includes a step of preparing the light reflecting member 20 in which a plurality of concave portions are provided on the first main surface side (FIGS. 9A to 9D), and a powdery phosphor member containing the phosphor. 10, a step of arranging the powdery fluorescent member 10 in a plurality of recesses in the light reflecting member 20 (FIG. 9E), a sintering of the powdery fluorescent member 10, and the light reflecting member 20 and the fluorescent member The step of obtaining a sintered body integrally formed with the member 10 (FIG. 9F), and the surface on the second main surface side opposite to the first main surface are from both the fluorescent member 10 and the light reflecting member 20. And at least the first reflecting surface of the light reflecting member 20 so that the phosphor-containing member 100 composed of only the fluorescent member 10 or both the fluorescent member 10 and the light reflecting member 20 is obtained. (2) removing a part of the sintered body from the principal surface side (FIG. 9G); Obtain.

  In this embodiment, the same effect as that of the first embodiment can be obtained. The manufacturing method of the phosphor-containing member 200 is substantially the same as that described in the first embodiment, except for the items described below.

  First, the light reflecting member 20 provided with a plurality of recesses on the first main surface is prepared. In the present embodiment, the step of preparing the light reflecting member 20 includes a step of filling the powdery light reflecting member 20 into a sintered container (FIG. 9A), and a pressing member 52 provided with a plurality of convex portions. Thus, the step of producing the light reflecting member 20 provided with a plurality of recesses by pressing the powdery light reflecting member 20 (FIGS. 9B to 9D) is included. Thereby, although it is powdery, the light reflection member 20 holding a fixed shape (a shape provided with a plurality of recesses) can be formed by a relatively simple method. In this step, a light reflecting member 20 made of a sintered body may be prepared.

  In the present embodiment, the opening shape of the recess is a square when viewed from above. The size of the recess can be appropriately changed according to the light emitting element 70 to be combined. For example, when an LED chip is used as the light emitting element 70, the length of one side of the bottom of the recess is preferably in the range of 0.1 mm to 3 mm, and more preferably 0.5 mm to 2 mm. By setting it to the above lower limit value or more, the fluorescent member 10 can be easily filled in the concave portion, and by setting it to the above upper limit value or less, the fluorescent member 10 included in the phosphor-containing member before being singulated is made. You can increase the number.

  Next, a powdery fluorescent member 10 containing a phosphor is prepared. And the powdery fluorescent member 10 is arrange | positioned to the several recessed part in the light reflection member 20 (FIG. 9E). That is, in the present embodiment, the powdery fluorescent member 10 is disposed above the powdery light reflecting member 20. In addition, when preparing the light reflection member 20 which consists of a sintered compact, the order of arrangement | positioning of the light reflection member 20 and the fluorescence member 10 is not limited. That is, the light reflecting member 20 made of a sintered body may be disposed below, the powdery fluorescent member 10 may be disposed above, or the order of arrangement may be reversed.

  In this embodiment, in one step, both the powdery fluorescent member 10 and the powdery light reflecting member 20 are sintered, and a sintered body in which the fluorescent member 10 and the light reflecting member 20 are integrally formed is obtained. It has gained. At this time, since it is necessary to increase the transmittance of the sintering aid contained in the fluorescent member 10, the sintering temperature is set higher than that in the first embodiment. For example, the sintering is preferably performed in the range of 1100 ° C. or higher and 1400 ° C. or lower, and more preferably sintered in the range of 1200 ° C. or higher and 1350 ° C. or lower. By setting it to the above lower limit or higher, the transmittance of the sintering aid can be increased, and by setting it to the upper limit or lower, reduction of the reflectance of the light reflecting member 20 can be suppressed to some extent.

  In the heat treatment step, the heat treatment can be performed in the range of 1200 ° C. or higher and 1500 ° C. or lower. At this time, when improving the transmittance | permeability of a sintering auxiliary agent, it is preferable to heat-process in the range of 1350 degreeC or more and 1450 degrees C or less. In addition, when giving priority to improving the reflectance of the light reflecting member 20, heat treatment is preferably performed within the range described in the first embodiment.

  In the present embodiment, the buffer member 30 may be disposed via the release sheet 60 after the step of arranging the fluorescent member 10. At this time, it is preferable to arrange the buffer member 30 so as to have the same thickness as the light reflecting member 20.

  In the present embodiment, as shown in FIG. 9H, a part of the sintered body is removed so that the surface on the first main surface side of the light reflecting member 20 includes the fluorescent member 10 and the light reflecting member 20. . Not limited to this, a part of the sintered body may be removed from the first main surface side of the light reflecting member 20 so that the light reflecting member 20 is not exposed. That is, you may remove a part of sintered compact so that the surface by the side of the 1st main surface after removing from the 1st main surface side may consist only of the fluorescent member 10. FIG. When the phosphor-containing member whose surface on the first main surface side is composed of only the fluorescent member 10 is separated, at least one fluorescent member surrounded by the light reflecting member as viewed from the second main surface side is included. Thus, the sintered body is separated into pieces.

(Other)
In this embodiment, an LED chip is used as the light emitting element 70, and a plurality of LED chips arranged on the upper surface of the substrate 90 and the phosphor-containing member 200 are combined to form the light emitting device 500 (FIG. 10). At this time, it is preferable to provide the phosphor-containing member 200 so that light from one LED chip is incident on one fluorescent member 10. As a method of providing the phosphor-containing member 200 on the upper surface of the LED chip, it is preferable to use a surface activated bonding method or an atomic diffusion bonding method, and it is more preferable to use a surface activated bonding method. This is because according to the surface activated bonding method, since no other member is interposed between the LED chip and the fluorescent member 10, light absorption by the other member can be eliminated. Further, it is preferable that the adjacent LED chips are shielded from light by the light shielding member 80 or the like. Thereby, only the fluorescent member 10 located above the LED chip which is lit can be made to emit light.

<Third Embodiment>
11A to 11G show a method for manufacturing the phosphor-containing member 300 according to this embodiment. The manufacturing method of the phosphor-containing member 300 is substantially the same as that described in the second embodiment except for the items described below.

  In this embodiment, in the step of preparing the light reflecting member 20, the light reflecting member 20 provided with a plurality of through holes penetrating the first main surface and the second main surface on the opposite sides is prepared (FIG. 11A). To FIG. 11D). Then, the powdery fluorescent member 10 is arranged in the plurality of through holes (FIG. 11E), the powdery fluorescent member 10 is sintered, and the light reflecting member 20 and the fluorescent member 10 are integrally formed. A body is obtained (FIG. 11F). Further, one surface of the first main surface side or the second main surface side is composed of both the fluorescent member 10 and the light reflecting member 20, and the first main surface side surface or the second main surface side surface. The first main surface side of the fluorescent member 10 so that the other surface of the main surface side is made only of the fluorescent member 10 or a phosphor-containing member made of both the fluorescent member 10 and the light reflecting member 20 is obtained. Alternatively, a part of the sintered body is removed from at least one side of the second main surface (FIG. 11G). When preparing the light reflecting member 20 made of a sintered body in the step of preparing the light reflecting member 20, the powdery fluorescent member 10 is arranged in a container and the light reflecting member 20 made of the sintered body is pressed. The fluorescent member 10 may be disposed in the through hole.

  In this embodiment, the same effect as that of the second embodiment can be obtained.

  In the present embodiment, in the step of obtaining the sintered body, the upper surface is made of only the fluorescent member 10 and the lower surface is made of the fluorescent member 10 and the light reflecting member 20. In this case, when removing a part of the sintered body from the lower surface side, a part of the sintered body is removed so as not to reach at least the upper surface of the light reflecting member 20. Moreover, when removing a part of sintered compact from the upper surface side, as shown to FIG. 11G, you may remove a part of sintered compact until the light reflection member 20 is exposed, or the light reflection member 20 may be removed. A part of the sintered body may be removed so as not to be exposed.

  In the step of arranging the fluorescent member, when the fluorescent member is arranged so as to cover the upper surface and the lower surface of the light reflecting member, in the step of obtaining the sintered body, as shown in FIG. A sintered body whose lower surface is covered with the fluorescent member is obtained. In this case, a part of the sintered body is removed from one side of the upper surface side or the lower surface side so that one surface of the upper surface side or the lower surface side is made of a fluorescent member and a light reflecting member. To do. At this time, a part of the sintered body may be further removed from the other side of the upper surface side or the lower surface side. When removing a part of the sintered body from the other side of the upper surface side or the lower surface side, remove a part of the sintered body so that the surface after the removal consists of a fluorescent member and a light reflecting member. Alternatively, a part of the sintered body may be removed so that the surface after the removal is made of only the fluorescent member.

Hereinafter, the phosphor-containing member of each example will be described.
<Example 1>
First, as shown in FIG. 3C, a plate-like fluorescent member 10 made of a sintered body containing Y ₃ Al ₅ O ₁₂ : Ce and aluminum oxide was prepared as the fluorescent member 10. Then, as shown in FIG. 3D, a plurality of convex portions were formed on the upper surface of a plate-like fluorescent member 10 (hereinafter referred to as “YAG plate”) made of a sintered body using a dicing apparatus. In FIG. 3D, the shape of the convex portion is a circle when viewed from above, but in the present embodiment, it is a square having a side of 1 mm. The distance between one convex part and the adjacent convex part was 1 mm.

  Next, as shown in FIGS. 3A and 3B, a buffer member 30 made of powdered aluminum oxide was filled in a sintered mold, and a carbon sheet was disposed. And as shown to FIG. 3E, the YAG board 10 was arrange | positioned so that the side in which the convex part was provided may face upward.

  Next, as shown in FIG. 3F, the sintered light mold was filled with a powdery light reflecting member 20 made of aluminum oxide. At this time, the buffer member 30 and the light reflecting member 20 were made to have the same thickness. And as shown to FIG. 3G, the light reflection member 20 was sintered by SPS method at 1100 degreeC with the pressure of 30 Mpa, and the sintered compact with which the fluorescent member 10 and the light reflection member 20 were united was obtained.

  Next, the sintered body was taken out from the sintering mold, and the sintered body was released at the position where the carbon sheet was disposed. And the obtained sintered compact was heat-processed at 1100 degreeC in the atmospheric condition.

  Next, as shown in FIGS. 3H and 3I, by removing a part of the sintered body from above and below the obtained sintered body, the fluorescent member 10 and the light reflecting member 20 are removed on the surface after the removal. Was exposed.

<Example 2>
Example 2 is substantially the same as Example 1 except that it is sintered at 1200 ° C.

<Example 3>
Example 3 is substantially the same as Example 1 except that it is sintered at 1150 ° C. and heat treated at 1000 ° C.

<Example 4>
The fourth embodiment is substantially the same as the third embodiment except for the items described below. First, a plate-like fluorescent member 10 made of a sintered body is prepared as shown in FIG. 3C, and a plurality of projections are formed on the upper surface of the plate-like fluorescent member 10 made of a sintered body using a machining center as shown in FIG. 3D. Part was formed. The shape of the convex portion is a circle when viewed from above, and the side surface is inclined so that the inner diameter of the convex portion decreases from the lower side to the upper side. The inner diameter of the top of the protrusion was 0.3 mm, and the inner diameter of the bottom of the protrusion was 0.5 mm. The shortest distance between the bottom of the convex part and the bottom of the convex part adjacent to the convex part was 5 mm. And the temperature of heat processing was 1100 degreeC.

<Example 5>
Example 5 is substantially the same as Example 3 except that 80% by mass of aluminum oxide and 20% by mass of boron nitride are used as the light reflecting member 20, and the temperature of the heat treatment is 1100 ° C.

<Example 6>
First, as shown in FIG. 3A, a buffer member 30 made of powdered aluminum oxide was filled in a sintered mold, and a carbon sheet was placed as shown in FIG. 3B.

Next, as shown in FIG. 4A, a powdery fluorescent member 10 containing Y ₃ Al ₅ O ₁₂ : Ce and aluminum oxide was filled. Then, as shown in FIGS. 4B to 4D, the fluorescent member 10 was manufactured by pressing the fluorescent member 10 with the pressing member 51 provided with a plurality of concave portions. The convex portion was a square having a side length of 1 mm as viewed from above. Moreover, the distance between one convex part and the adjacent convex part was 1 mm.

  Next, as shown in FIG. 3F, the sintered light mold was filled with a powdery light reflecting member 20 made of aluminum oxide. In FIG. 3F, the fluorescent member 10 made of a sintered body is used in the description of the first embodiment, but in this example, the fluorescent material is in a powder form but has a certain shape (a shape provided with a plurality of convex portions). This is the member 10. At this time, the buffer member 30 and the light reflecting member 20 were made to have the same thickness. Then, as shown in FIG. 3G, both the fluorescent member 10 and the light reflecting member 20 are sintered by the SPS method at 1250 ° C. at a pressure of 50 MPa, and the sintered body in which the fluorescent member 10 and the light reflecting member 20 are integrated. Got.

  Next, the sintered body was taken out from the sintering mold, and the sintered body was released at the position where the carbon sheet was disposed. The obtained sintered body was heat-treated at 1400 ° C. in an air atmosphere, and further heat-treated at 1400 ° C. in a nitrogen atmosphere.

  Next, as shown in FIG. 3H and FIG. 3I, by removing a part of the sintered body from above and below the obtained sintered body, the fluorescent member 10 and the light reflecting member 20 are removed on the surface after the removal. Was exposed.

<Example 7>
In Example 7, first, as shown in FIG. 8A, a light reflecting member 20 made of aluminum oxide was filled in a sintered mold. Then, as shown in FIGS. 8B to 8D, the light reflecting member 20 provided with a plurality of concave portions was manufactured by pressing the light reflecting member 20 with the pressing member 52 provided with the plurality of convex portions. The concave portion was a square having a side length of 1 mm as viewed from above. The distance between one recess and the adjacent recess was 1 mm.

Next, as shown in FIG. 8E, a powdery fluorescent member 10 containing Y ₃ Al ₅ O ₁₂ : Ce and aluminum oxide was filled into a sintered mold.

  Next, a carbon sheet was disposed on the upper surface of the fluorescent member 10. And the buffer member 30 which consists of aluminum oxide was arrange | positioned on the upper surface of a carbon sheet so that it might become substantially the same thickness as the thickness of the light reflection member 20. As shown in FIG. Then, as shown in FIG. 8F, the fluorescent member 10 and the light reflecting member 20 were sintered by the SPS method at 1250 ° C. at a pressure of 50 MPa.

  Next, the sintered body was taken out from the sintering mold, and the sintered body was released at the position where the carbon sheet was disposed. The obtained sintered body was heat-treated at 1400 ° C. in an air atmosphere, and further heat-treated at 1400 ° C. in a nitrogen atmosphere.

  Next, as shown in FIGS. 8G and 8H, by removing a part of the sintered body from above and below the obtained sintered body, the fluorescent member 10 and the light reflecting member 20 are removed on the surface after the removal. Was exposed.

<Example 8>
Example 8 is substantially the same as Example 7 except that 80 wt% aluminum oxide and 20 wt% boron nitride are used as the light reflecting member 20.

<Evaluation>
In each example, sufficient bonding strength was obtained between the fluorescent member 10 and the light reflecting member 20. Table 1 shows the results of evaluating the light reflecting member 20 made of a sintered body formed under substantially the same conditions as in each example from the three viewpoints of “strength”, “reflectance”, and “transmittance”. Shown in In Table 1, sample numbers correspond to example numbers (for example, sample 1 corresponds to example 1). The evaluation of strength was made by comparing the resistance to cracking when each sample was divided by hand, and evaluated from five levels (from the ones that are difficult to crack to the ones that are easy to crack) to have a higher value. The reflectance was evaluated based on the measurement result obtained by the spectrocolorimeter. Specifically, first, a sample (light reflecting member 20) having a thickness of 5 mm was placed on the base. Next, the sample surface was irradiated with measurement light of 370 nm to 740 nm, and the reflectance of reflected light from the sample surface was measured. And the result of the reflectance of each sample in 440 nm was compared, and the thing from a thing with a high reflectance to a low thing was evaluated in five steps (a thing with a higher reflectance has a larger value). In addition, the transmittance was evaluated based on the measurement result by the illuminometer. Specifically, first, the sample used for the measurement of reflectance was polished until the thickness became 1 mm, and the sample was placed on the base. Next, light having a wavelength of 445 nm was irradiated, and light transmitted through the sample was measured with an illuminometer. And the result of each sample was compared, and the thing from the thing with a low transmittance | permeability to the high thing was evaluated in five steps (a value is so large that the thing with a low transmittance | permeability). In the measurement of reflectance, it is necessary to increase the thickness of the sample in order to make it less susceptible to the reflectance from the base, but in the measurement of transmittance, the difference is compared if the thickness of the sample is too large. Therefore, the thickness of the sample is changed between the reflectance measurement and the transmittance measurement.

  As shown in Table 1, Samples 1 to 5 had high reflectance, and Samples 1 and 3 to 5 had suppressed transmittance. This is considered due to the fact that the sintering temperature of the light reflecting member was low. In Sample 2, the transmittance was high even though good results were obtained in reflectance. This is considered to be because the light absorptance of the light reflecting member 20 in the sample 2 is low for some reason.

  On the other hand, the strength of Samples 2 to 4 and Samples 6 to 8 was high. This is presumably because the light-reflecting member 20 did not contain a hardly sinterable additive, or the grain growth of the light-reflecting member 20 was promoted by sintering at a certain temperature or higher.

  The phosphor-containing member described in each embodiment can be used for in-vehicle use, illumination, and the like.

DESCRIPTION OF SYMBOLS 10 ... Fluorescent member 20 ... Light reflecting member 30 ... Buffer member 40 ... Sintering die 50 ... Punch 51, 52 ... Pressing member 60 ... Release sheet 70 ... Light-emitting element 80 ... light-shielding member 90 ... base 100, 200, 300 ... phosphor-containing member 400, 500 ... light-emitting device

Claims (15)

A step of preparing a fluorescent member including a phosphor, wherein a plurality of convex portions are provided on the first main surface side;
Preparing a powdery light reflecting member;
Arranging the powdery light reflecting member between a plurality of convex portions in the fluorescent member;
Sintering the powdery light reflecting member to obtain a sintered body in which the fluorescent member and the light reflecting member are integrally formed; and
The surface on the first main surface side is composed of both the fluorescent member and the light reflecting member, and the surface on the second main surface side is composed only of the fluorescent member, or of the fluorescent member and the light reflecting member. Removing a part of the sintered body from at least one side of the first main surface side or the second main surface side of the fluorescent member so that a phosphor-containing member composed of both is obtained; The manufacturing method of the fluorescent substance containing member characterized by the above-mentioned. Preparing a light reflecting member provided with a plurality of recesses on the first main surface side;
A step of preparing a powdery fluorescent member containing a phosphor;
Arranging the powdery fluorescent member in a plurality of recesses in the light reflecting member;
Sintering the powdery fluorescent member to obtain a sintered body in which the light reflecting member and the fluorescent member are integrally formed;
A surface on the second main surface side opposite to the first main surface is composed of both the fluorescent member and the light reflecting member, and a surface on the first main surface side is composed of only the fluorescent member. Or removing a part of the sintered body from at least the second main surface side of the light reflecting member so that a phosphor-containing member composed of both the fluorescent member and the light reflecting member is obtained; The manufacturing method of the fluorescent substance containing member characterized by the above-mentioned. Preparing a light reflecting member provided with a plurality of through holes penetrating the first main surface and the second main surface on opposite sides;
A step of preparing a powdery fluorescent member containing a phosphor;
Arranging the powdery fluorescent member in the plurality of through holes;
Sintering the powdery fluorescent member to obtain a sintered body in which the light reflecting member and the fluorescent member are integrally formed;
One surface of the first main surface side or the second main surface side surface is composed of both the fluorescent member and the light reflecting member, and the first main surface side surface or the The first main surface of the fluorescent member is obtained such that the other surface of the second main surface side is made of only the fluorescent member or a phosphor-containing member made of both the fluorescent member and the light reflecting member. And a step of removing a part of the sintered body from at least one of the surface side and the second main surface side.   In the step of removing a part of the sintered body, each of the surface on the first main surface side and the surface on the second main surface side is composed of both the fluorescent member and the light reflecting member. The phosphor-containing member according to any one of claims 1 to 3, wherein a part of the sintered body is removed from at least one of the first main surface and the second main surface. Manufacturing method.   The method for producing a phosphor-containing member according to any one of claims 1 to 4, wherein in the step of obtaining the sintered body, sintering is performed by a discharge plasma sintering method or a hot press sintering method. The fluorescent member includes an oxide phosphor containing Al,
The said light reflection member contains aluminum oxide, The manufacturing method of the fluorescent substance containing member of any one of Claims 1-5 characterized by the above-mentioned.   The said fluorescent member contains aluminum oxide as a sintering auxiliary agent, The manufacturing method of the fluorescent substance containing member of Claim 6 characterized by the above-mentioned.   The method for producing a phosphor-containing member according to claim 6 or 7, further comprising a step of heat-treating the sintered body in an oxidizing atmosphere after the step of obtaining the sintered body. The step of preparing the fluorescent member includes
Filling a container with a powdery fluorescent member containing a phosphor;
Producing a fluorescent member provided with the plurality of convex portions by pressing the powdery fluorescent member with a pressing member provided with a plurality of concave portions,
The fluorescence according to any one of claims 4 to 8, wherein the fluorescent member and the light reflecting member are sintered in the step of obtaining the sintered body. A method for producing a body-containing member.   The method for manufacturing a phosphor-containing member according to claim 9, wherein the pressing member is formed so that the opening of the concave portion becomes wider as the distance from the bottom surface increases. In the step of preparing the fluorescent member, the powdery phosphor and a powdery sintering aid containing the same material as the light reflecting member are mixed and then sintered. Having a step of obtaining a fluorescent member made of a sintered body provided on the first main surface side,
The sintering temperature when sintering the powdery light reflecting member is lower than the sintering temperature when sintering after mixing the powdered phosphor and the powdery sintering aid. The method for producing a phosphor-containing member according to any one of claims 4 to 8, which refers to claim 1 or claim 1.   In the step of preparing the fluorescent member, by forming a plurality of convex portions on the fluorescent member made of a sintered body, a fluorescent member in which the plurality of convex portions are provided on the first main surface side is obtained. The manufacturing method of the fluorescent substance containing member of any one of Claims 4-8 which cites Claim 1 and Claim 1 which are to be referred to, or Claim 11.   The method for producing a phosphor-containing member according to claim 12, wherein in the step of forming the convex portion, the convex portion is formed using a machining center. After the step of removing a part of the sintered body, comprising a step of dividing the sintered body into pieces,
In the step of dividing into pieces, the light reflecting member is formed around the fluorescent member on at least one surface of the first main surface side or the second main surface side after being divided into pieces. The method for producing a phosphor-containing member according to claim 1, wherein the phosphor-containing member arranged is obtained. The step of preparing the light reflecting member includes:
Filling the container with a powdery light reflecting member;
Producing a light reflecting member provided with the plurality of recesses by pressing the powdery light reflecting member with a pressing member provided with a plurality of protrusions,
9. The method according to claim 4, wherein in the step of obtaining the sintered body, the fluorescent member and the light reflecting member are sintered. 9. A method for producing a phosphor-containing member.

Images