JP2021108341A - Method of manufacturing light-emitting module - Google Patents

Abstract

To precisely form a square or rectangular plane view shape of a device.SOLUTION: A method of manufacturing a light-emitting module includes processes of: preparing a light guide body collective substrate 300 having a principal surface 300a, the light guide body collective substrate including a plurality of module regions 310, a pair of first margin regions 311T, 311B, and a plurality of first alignment marks 11t; arranging a plurality of light sources 220 corresponding to the plurality of module regions; and cutting, based upon positions of the first alignment marks, the light guide body collective substrates along a second direction between a plurality of columns of the plurality of module regions, respectively, while not cutting, but leaving at least one of the pair of first margin regions as it is. The plurality of module regions is arranged on the principal surface linearly or in two dimensions along the first direction and second direction, the first margin regions are positioned at both second-directional ends of the plurality of columns in the module regions, and the first alignment marks are arrayed in the first direction in at least one of the first margin regions.SELECTED DRAWING: Figure 4

Description

The present disclosure relates to a method for manufacturing a light emitting module.

Conventionally, in the manufacture of a plurality of electronic devices having a common shape, an aggregate in which a plurality of units each function as an electronic device is integrally formed is first prepared, and the aggregate is divided into a plurality of units by cutting. As a result, it is common practice to efficiently obtain a plurality of electronic devices (for example, Patent Documents 1 and 2 below).

Japanese Unexamined Patent Publication No. 2008-147470 Japanese Unexamined Patent Publication No. 2012-226013

In the light emitting module, it may be required to accurately form a square or rectangular plan view shape.

The method for manufacturing a light emitting module according to an embodiment of the present disclosure is a step of preparing a light guide assembly substrate having a main surface, and the light guide assembly substrate is the first direction and the first on the main surface. A plurality of module regions arranged one-dimensionally or two-dimensionally so as to form one or more rows and a plurality of columns in two directions, each having a light source structure, and the main surface. Above, a plurality of first margin regions arranged in the first direction in at least one of a pair of first margin regions located at both ends of the plurality of rows in the second direction and the pair of first margin regions. Each of the plurality of first alignment marks including the first alignment mark is a light guide assembly substrate which is arranged at a corresponding position between a pair of adjacent rows of the plurality of rows. A step of preparing, a step of arranging a plurality of light sources each including one or more light emitting elements in a corresponding one of the plurality of module regions so that light emitted from the one or more light emitting elements is incident. With reference to the respective positions of the plurality of first alignment marks, among the plurality of columns of the plurality of module regions, at least one of the pair of first margin regions is left uncut. The step of cutting the light guide assembly substrate along the second direction is included.

According to at least one embodiment of the present disclosure, it is possible to accurately form a square or rectangular plan view shape of an individual device obtained by individualization.

FIG. 5 is a schematic perspective view showing an exemplary configuration of a light emitting module obtained by an embodiment of the present disclosure. Light emission when one of the light emitting units shown in FIG. 1 is taken out and the light emitting unit is cut perpendicularly to the upper surface of the light guide body near the center and when viewed perpendicularly to the upper surface of the light guide body. It is a figure which shows typically together with the exemplary appearance of a unit. It is a flowchart which shows the exemplary manufacturing method of a light emitting module. It is a schematic top view of the light guide body assembly substrate which can be applied to the manufacturing method by embodiment of this disclosure. It is a schematic bottom view of the light guide body assembly substrate which can be applied to the manufacturing method by embodiment of this disclosure. It is a schematic VI-VI line sectional view of FIG. 4 and FIG. It is a schematic cross-sectional view which shows the exemplary configuration of the light source arranged in each module area of the light guide body assembly substrate. It is a schematic cross-sectional view for demonstrating an example of the manufacturing method of the light source arranged in each module area of the light guide body assembly substrate. It is a schematic cross-sectional view for demonstrating an example of the manufacturing method of the light source arranged in each module area of the light guide body assembly substrate. It is a schematic cross-sectional view for demonstrating an exemplary manufacturing method of a light emitting module according to an embodiment of this disclosure. It is a schematic cross-sectional view for demonstrating an exemplary manufacturing method of a light emitting module according to an embodiment of this disclosure. It is a schematic perspective view for demonstrating the process of cutting a composite substrate using a cutting apparatus. It is a schematic plan view for demonstrating the cutting position of a composite substrate in the process of cutting along a 2nd direction. It is a schematic plan view for demonstrating the cutting position of a composite substrate in the process of cutting along a 1st direction after cutting along a 2nd direction. It is a schematic plan view which shows the other method of cutting a composite substrate. It is a figure for demonstrating arrangement of a plurality of through holes which may be provided in a composite substrate prior to cutting in a 2nd direction. It is a figure which shows the other example of arrangement of the through hole arranged along the Y direction schematically. It is a schematic plan view which shows the example which formed the plurality of through holes 51 in the pair of the 2nd margin regions in addition to the pair of the 1st margin regions. It is a schematic plan view which shows the example which formed the plurality of grooves in the 1st margin region and the 2nd margin region of a composite substrate. A composite substrate in a state in which a plurality of openings extending in the X direction and an opening extending in the Y direction are formed after the formation of the plurality of grooves in the first margin region and the second margin region is schematically shown. It is a schematic plan view which shows the example which cuts one of a pair of 2nd margin regions in the process of cutting along a 1st direction. It is a schematic plan view which shows the example which cuts both of a pair of 2nd margin regions in the process of cutting along a 1st direction. It is a schematic plan view which shows an example which performs cutting of a composite substrate along a 2nd direction while leaving one of a pair of 1st margin areas uncut. It is a schematic plan view which shows another example of the arrangement of a plurality of module regions. It is a schematic plan view which shows still another example of the arrangement of a plurality of module regions. It is a schematic plan view which shows the example which arranged a plurality of light emitting modules in two dimensions. It is a schematic cross-sectional view which shows the light source in a light emitting module and its periphery in an enlarged manner. It is a schematic plan view which shows an example of the appearance when the light emitting module shown in FIG. 1 is seen from the lower surface side opposite to the upper surface of a light guide body. It is a schematic cross-sectional view which shows the example which connected the light emitting module to a wiring board.

Hereinafter, embodiments of the present disclosure will be described in detail with reference to the drawings. The following embodiments are examples, and the method for manufacturing a light emitting module according to the present disclosure is not limited to the following embodiments. For example, the numerical values, shapes, materials, steps, the order of the steps, and the like shown in the following embodiments are merely examples, and various modifications can be made as long as there is no technical contradiction. Each embodiment described below is merely an example, and various combinations are possible as long as there is no technical contradiction.

The dimensions, shapes, etc. of the components shown in the drawings may be exaggerated for the sake of clarity, and may not reflect the dimensions, shapes, and magnitude relationships between the components in the actual light emitting module. In addition, some elements may be omitted in order to avoid overly complicated drawings.

In the following description, components having substantially the same function are indicated by common reference numerals, and the description may be omitted. In the following description, terms indicating a specific direction or position (for example, "top", "bottom", "right", "left" and other terms including those terms) may be used. However, these terms use relative orientation or position in the referenced drawings for clarity only. If the relative directions or positional relationships in terms such as "upper" and "lower" in the referenced drawings are the same, they are the same as the referenced drawings in drawings other than the present disclosure, actual products, manufacturing equipment, etc. It does not have to be an arrangement. In the present disclosure, "parallel" includes the case where two straight lines, sides, surfaces, etc. are in the range of about 0 ° to ± 5 ° unless otherwise specified. Further, in the present disclosure, "vertical" or "orthogonal" includes a case where two straight lines, sides, surfaces, etc. are in the range of about 90 ° to ± 5 ° unless otherwise specified.

(Structure of light emitting module)
In order to facilitate understanding of the embodiments of the present disclosure, first, an example of a light emitting module manufactured by using the light guide assembly substrate of the present disclosure will be described.

FIG. 1 shows an exemplary configuration of a light emitting module obtained by an embodiment of the present disclosure. The light emitting module 200 shown in FIG. 1 includes a light guide body 210 having a lower surface located on the opposite side of the upper surface 210a and the upper surface 210a, a plurality of light sources arranged on the lower surface side of the light guide body 210, and the light guide body 210. Includes a light-reflecting member 240 that covers the lower surface of the. As will be described later, each of the plurality of light sources includes one or more light emitting elements. For convenience of explanation, arrows indicating the X, Y, and Z directions orthogonal to each other are also shown in FIG. 1. Arrows pointing in these directions may also be shown in other drawings of the present disclosure.

The light emitting module 200 has a plate shape as a whole. The light guide body 210 has a function of diffusing the light emitted from a plurality of light emitting elements located on the lower surface side inside the light guide body 210 and emitting the light from the upper surface 210a. The upper surface 210a of the light guide body 210 is a light emitting surface of the light emitting module 200, and typically has a rectangular shape. Here, the above-mentioned X and Y directions coincide with one and the other of the rectangular side of the light guide body 210 that are orthogonal to each other. The length of one side of the rectangular shape of the upper surface 210a is, for example, in the range of 1 cm or more and 50 cm or less. In a typical embodiment of the present disclosure, one rectangular side of the upper surface 210a of the light guide body 210 has a length of 10 mm or more and 30 mm or less. The lengths of the top surface 210a along the rectangular X and Y directions can be, for example, approximately 24.3 mm and 21.5 mm, respectively. Hereinafter, the X direction and the Y direction may be referred to as a first direction and a second direction, respectively.

In the configuration illustrated in FIG. 1, the light emitting module 200 is an aggregate of a plurality of light emitting units 100 each including at least one light emitting element. As schematically shown in FIG. 1, in this example, the light emitting module 200 includes a total of 16 light emitting units 100 arranged in two dimensions, and here, these 16 light emitting units 100 are arranged in four rows. They are arranged in 4 rows. The number of light emitting units 100 included in the light emitting module 200 and the arrangement of these light emitting units 100 are arbitrary and are not limited to the configuration shown in FIG. For example, the number of light emitting units included in the light emitting module 200 may be one. That is, the light emitting module 200 may be composed of one light emitting unit 100.

In the example shown in FIG. 1, each light emitting unit 100 has a first hole portion 10 including an opening located on the upper surface 210a of the light guide body 210 as a part thereof. As will be described later, the light source of each light emitting unit 100 is arranged at a position substantially directly below the first hole portion 10. In this example, a total of 16 light sources are arranged in 4 rows and 4 columns along the X and Y directions. The arrangement pitch of the light source can be, for example, 0.05 mm or more and 20 mm or less, and may be in the range of 1 mm or more and 10 mm or less. Here, the arrangement pitch of the light source means the minimum distance between the optical axis of the light emitting element in a certain light source and the optical axis of the light emitting element in the light source closest to the light source. The plurality of light sources may be arranged at equal intervals in the light emitting module 200, or may be arranged at unequal intervals. The arrangement pitch of the light sources may be the same or different between two different directions.

FIG. 2 shows the light emitting unit 100. In FIG. 2, a cross section when the light emitting unit 100 is cut perpendicularly to the upper surface 210a of the light guide body 210 near the center of the light emitting unit 100, and a cross section when viewed perpendicularly to the upper surface 210a from the upper surface 210a side of the light guide body 210. Together with the exemplary appearance of the light emitting unit 100, it is schematically shown in one figure.

In the configuration illustrated in FIG. 2, the light emitting unit 100 includes a light guide body 110 having an upper surface 110a provided with a first hole 10 and a lower surface 110b opposite to the upper surface 110a, and a light source 220 including a light emitting element 120. , Includes an optical adjustment unit 130 located inside the first hole portion 10. The light guide body 110 is a part of the light guide body 210 shown in FIG. 1, and the first hole portion 10 of the light guide body 110 is one of a plurality of first hole portions 10 shown in FIG. Is. The light guide 110 may be formed in the light emitting module 200 in the form of a single continuous light guide plate between two light emitting units 100 adjacent to each other.

In the configuration illustrated in FIG. 2, the light emitting unit 100 further includes a light reflecting member 140 located on the lower surface 110b side of the light guide body 110. The light-reflecting member 140 is a part of the light-reflecting member 240 shown in FIG. In this example, the light reflecting member 140 includes a layered base portion 140n and a wall portion 140w that rises from the lower surface 110b side of the light guide body 110 toward the upper surface 110a side. As shown in the upper part of FIG. 2, the wall portion 140w of the light reflecting member 140 may have an inclined surface 140s facing the lower surface 110b of the light guide body 110. In the lower part of FIG. 2, which corresponds to the plan view of the light emitting unit 100, the position of the inner edge of the wall portion 140w is indicated by the broken line rectangle B. Here, an example is shown in which the inner edge of the wall portion 140w is rectangular, but the inner edge of the wall portion 140w may have another shape such as a circular shape or an elliptical shape. Similar to the light guide 110, the light reflecting member 140 can be continuously formed in the light emitting module 200 across two light emitting units 100 adjacent to each other. Here, the wiring layer 190 is provided on the lower surface 140b of the light reflecting member 140.

The first hole portion 10 of the light guide body 110 is formed near the center of the upper surface 110a, and here, the first hole portion 10 has a first portion 11 having a substantially inverted conical shape and a substantially inverted conical base. Includes a second portion 12 having a shape. As shown, the second portion 12 is located closer to the upper surface 110a of the light guide body 110 than the first portion 11. In the present embodiment, the light adjusting unit 130 is located in the first portion 11 of the first hole portion 10. In the configuration illustrated in FIG. 2, the light adjusting unit 130 is a light-reflecting member that occupies almost the entire first portion 11 of the first hole portion 10.

The light guide body 110 has a second hole portion 20 on the lower surface 110b side at a position facing the first hole portion 10. The second hole portion 20 has, for example, a quadrangular pyramid shape. Typically, the center of the second hole portion 20 located on the lower surface 110b side of the light guide body 110 is substantially aligned with the center of the first hole portion 10 located on the upper surface 110a side.

In the light emitting unit 100, the light source 220 is arranged on the lower surface 110b side of the light guide body 110 so as to face the first hole portion 10 provided on the upper surface 110a of the light guide body 110. In the example shown in FIG. 2, the second hole portion 20 is provided on the lower surface 110b side of the light guide body 110, and the light source 220 is located inside the second hole portion 20 in a plan view. The optical axis of the light source 220 is approximately aligned with the center of the first hole 10. In this example, the first hole portion 10 and the second hole portion 20 are separated by the light guide body 110. In other words, a part of the light guide body 110 is interposed between the first hole portion 10 and the second hole portion 20, but for example, the second hole portion 20 is connected to the first hole portion 10. As a result, a through hole extending from the lower surface 110b of the light guide body 110 to the upper surface 110a may be formed in the light guide body 110.

(Manufacturing method of light emitting module)
Next, a method of manufacturing a light emitting module according to an embodiment of the present disclosure will be described.

FIG. 3 is a flowchart showing an exemplary manufacturing method of the light emitting module. The manufacturing method illustrated in FIG. 3 includes a step of preparing a light guide assembly substrate including a plurality of module regions, a pair of margin regions, and a plurality of alignment marks, each of which has a light guide structure (step S1). Based on the step of arranging a plurality of light sources corresponding to a plurality of module regions (step S2) and the positions of the alignment marks, the light guide assembly is set while leaving at least one of the pair of margin regions uncut. The step of cutting the substrate (step S3) is included. The details of each step will be described below.

[Step of preparing the light guide assembly substrate]
First, a light guide assembly substrate is prepared (step S1 in FIG. 3). The light guide assembly substrate may be prepared by fabrication or by purchase.

4 and 5 show an exemplary appearance of a light guide assembly substrate that can be applied to the manufacturing method according to the embodiments of the present disclosure. FIG. 4 is a top view of the light guide assembly substrate, and FIG. 5 is a bottom view of the light guide assembly substrate. FIG. 6 schematically shows the VI-VI line cross sections of FIGS. 4 and 5.

The light guide assembly substrate 300 shown in FIGS. 4 to 6 is a translucent substrate having a main surface 300a and a back surface 300b located on the opposite side of the main surface 300a. In the present embodiment, the outer shape of the light guide assembly substrate 300 is rectangular in a plan view. It should be noted that the terms "translucent" and "translucent" in the present specification are also interpreted to include exhibiting diffusivity with respect to incident light, and are not limited to "transparent".

As schematically shown in FIG. 4, the light guide assembly substrate 300 has a plurality of module regions 310 arranged one-dimensionally or two-dimensionally. In the configuration illustrated in FIG. 4, the plurality of module regions 310 form a plurality of rows and columns in the X direction and the Y direction (first direction and second direction) on the main surface 300a of the light guide assembly substrate 300. Is located in. In this example, a total of 20 module regions 310 are arranged two-dimensionally on the main surface 300a of the light guide assembly substrate 300 in 4 rows and 5 columns at intervals of each other. Needless to say, the number and arrangement of the plurality of module areas 310 are not limited to this example, and the plurality of module areas 310 are arranged one-dimensionally on the main surface 300a so as to form, for example, one row and a plurality of columns. May be good.

As shown in FIGS. 4 and 5, the plurality of module regions 310 may be spaced apart from each other on the main surface 300a and the back surface 300b of the light guide assembly substrate 300. Under such an arrangement of the module regions 310, a margin region 311 is located around each module region 310 on the main surface 300a and the back surface 300b of the light guide assembly substrate 300. That is, here, a margin area 311 is provided between two module areas 310 adjacent to each other. A part or all of the region sandwiched between the two module regions 310 adjacent to each other in the light guide assembly substrate 300 can be removed by cutting in the step of individualization described later.

The margin region 311 also has a portion located outside the group of a plurality of module regions 310 arranged in 4 rows and 5 columns on the main surface 300a. In the configurations illustrated in FIGS. 4 and 5, the margin region 311 includes four regions provided along each rectangular side of the light guide assembly substrate 300. Specifically, the margin region 311 includes a pair of first margin regions 311T and 311B extending along the X direction and a pair of second margin regions 311R and 311L extending along the Y direction. There is. The first margin regions 311T and 311B are outside of both ends of the plurality of rows of the module region 310 in the Y direction on the main surface 300a of the light guide assembly substrate 300, in other words, outside of the upper end and outside of the lower end. And are located in each. The second margin regions 311R and 311L are outside of both ends of the plurality of rows of the module region 310 in the X direction on the main surface 300a of the light guide assembly substrate 300, in other words, outside of the right end and outside of the left end. And are located in each.

The light guide assembly substrate 300 is provided with a plurality of alignment marks for specifying the positions of the plurality of module regions 310. In the embodiment of the present disclosure, the light guide assembly substrate 300 has at least a plurality of first alignment marks arranged in the first direction on the main surface 300a. The first alignment mark is arranged in one or both of the pair of first margin regions 311T and 311B. In the example shown in FIG. 4, the light guide assembly substrate 300 has a first alignment mark 11t arranged in the first margin region 311T and a first alignment mark 11u arranged in the first margin region 311B.

Here, the first alignment mark 11t includes four marks arranged along the X direction, and similarly, the first alignment mark 11u also includes four marks arranged along the X direction. Each of the four first alignment marks 11t and the four first alignment marks 11u corresponds to the arrangement of the columns 31C of the module region 310 in the X direction, and is a pair of adjacent rows 31C of the plurality of columns 31C of the module region 310. It is provided at a corresponding position between the rows 31C of.

In this example, each of the four first alignment marks 11t and the four first alignment marks 11u is in the form of a cross-shaped mark in the form of a margin region 300a of the main surface 300a of the light guide assembly substrate 300 (first margin region 311T, It is formed in 311B). The position of each first alignment mark with respect to the X direction is specified by the position of the center of the cross. Here, "the alignment mark is at a position corresponding to a pair of columns adjacent to each other among the plurality of columns of the module area" means that the rows of the plurality of module areas arranged in one dimension or two dimensions are used. In the extending direction (eg, the X direction), it means that the position specified by the alignment mark is between the two rows of the module area. For example, in the example shown in FIG. 4, each first alignment mark is located approximately in the center of two adjacent rows 31C in the X direction. However, the position of the first alignment mark is not limited to this example. For example, in the first margin area 311T and / or 311B, on the extension line along the Y direction of the side R1 located at the left end of the rectangle of the module area 310 and / or the Y of the side R2 located at the right end of the rectangle. The first alignment mark may be located on an extension line along the direction. Similarly, in the present specification, "the alignment mark is located at a position corresponding to a pair of adjacent rows of a plurality of rows of the module region" means that the plurality of module regions arranged in two dimensions. It refers to the position specified by the alignment mark between the two rows of the module area with respect to the direction in which the column extends (eg, the Y direction).

As described above, in this example, the first alignment mark of the light guide assembly substrate 300 is a set of four first alignment marks 11t arranged in the first margin region 311T of the margin region 311 and the margin region 311. Of these, it has a set of four first alignment marks 11u arranged in the first margin region 311B. In other words, in this example, the plurality of first alignment marks are one of the first alignment marks 11t arranged in the first margin area 311T and the first one arranged in the first margin area 311B, respectively. It contains four pairs consisting of one of the alignment marks 11u. These pairs of first alignment marks are arranged along the X direction, and the straight line connecting the positions of the two first alignment marks 11t and 11u included in each pair is here two rows 31C adjacent to each other. It is a vertical bisector of a line segment connecting the left end and the right end of the line segment in parallel in the X direction.

In the configuration illustrated in FIG. 4, the light guide assembly substrate 300 has a plurality of second alignment marks on the main surface 300a in addition to the plurality of first alignment marks. The second alignment mark is provided on one or both of the pair of second margin regions 311R and 311L. In the example shown in FIG. 4, three second alignment marks 12v arranged along the second direction are formed in the second margin region 311L, and the second margin region 311R is also arranged along the second direction 3 Two second alignment marks 12w are formed. The second alignment mark of the light guide assembly substrate 300 is arranged in a set of three second alignment marks 12v arranged in the second margin area 311L of the margin area 311 and in the second margin area 311R of the margin area 311. It may be said that it has a set of three second alignment marks 12w.

Each of the three second alignment marks 12v and the three second alignment marks 12w corresponds to the arrangement of rows 31R of the module region 310 in the Y direction, and is a pair of adjacent rows 31R of the module region 310 that are adjacent to each other. It is provided at the corresponding position between the rows 31R of. Here, each second alignment mark is located approximately in the center of two rows 31R adjacent to each other in the Y direction.

Further, in this example, the light guide assembly substrate 300 is further located at positions corresponding to the corners of the rectangle defined by the entire plurality of module regions 310, respectively, at the third alignment mark 13 and the fourth alignment mark 14. Has four sets with. As shown in FIG. 4, the third alignment mark 13 is located on an extension of the array of the plurality of first alignment marks 11t or the array of the plurality of first alignment marks 11u in the X direction. Further, the straight line connecting the two third alignment marks 13 arranged along the Y direction is, for example, an extension line of the side R1 of the module region 310 located at the left end on the main surface 300a or the side R2 of the module region 310 located at the right end. It roughly matches the extension line of. On the other hand, the fourth alignment mark 14 is located on an extension of the array of the plurality of second alignment marks 12v or the array of the plurality of second alignment marks 12w in the Y direction. Further, the straight line connecting the two fourth alignment marks 14 arranged along the X direction is, for example, an extension line of the upper side of the module area 310 located at the upper end of the main surface 300a or an extension of the bottom side of the module area 310 located at the lower end. It roughly matches the line.

In the present embodiment, the first alignment marks 11t and 11u, the second alignment marks 12v and 12w, the third alignment mark 13 and the fourth alignment mark 14 are located on the main surface 300a side of the light guide assembly substrate 300. It is formed. However, these alignment marks may be formed on the back surface 300b side of the light guide assembly substrate 300. If the alignment mark can be detected by, for example, image recognition in the step of cutting the composite substrate including the light guide assembly substrate 300 as a part thereof, the alignment mark will be on the main surface 300a and the back surface 300b of the light guide assembly substrate 300. It may be formed on any surface.

Each of the first alignment mark 11t, 11u, the second alignment mark 12v, 12w, the third alignment mark 13, and the fourth alignment mark 14 is mainly in the form of a convex portion or a concave portion formed by utilizing, for example, injection formation. It may be provided on the surface 300a, or a mark that can specify the position of the module area 310 on the main surface 300a may be drawn on the main surface 300a by printing or the like. Each shape of the alignment mark may also be an arbitrary shape such as a cross shape, a straight line shape, or a shape in which a plurality of figures are combined.

[Process of arranging multiple light sources]
Next, a plurality of light sources are arranged on the prepared light guide assembly substrate (step S2 in FIG. 3). At this time, corresponding to the light guide assembly substrate 300 having a plurality of module regions 310, a light source including a light emitting element such as an LED is arranged in each module region 310. The light source may be prepared by purchase.

Here, the above-mentioned light sources 220 including the light emitting element 120 are prepared, and these light sources 220 are arranged on the back surface 300b side of the light guide assembly substrate 300. FIG. 7 schematically shows an exemplary configuration of the light source 220. FIG. 7 corresponds to an enlarged view of the light source 220 taken out from the cross section shown in the upper part of FIG.

In the example shown in FIG. 7, the light source 220 includes a light emitting element 120, a plate-shaped translucent member 150, a translucent joining member 160, and a covering member 170. The translucent member 150 may contain particles of a phosphor or the like. In the configuration illustrated in FIG. 7, the light emitting element 120 has an element body 122 and an electrode 124. The light emitting element 120 has an upper surface 120a and is joined to the translucent member 150 by the joining member 160 so that the upper surface 120a faces the lower surface 150b of the translucent member 150. The covering member 170 covers the light emitting element 120 and the joining member 160 on the lower surface 150b of the translucent member 150, except for the lower surface 124b of the electrode 124 located on the opposite side of the upper surface 120a of the light emitting element 120. In other words, the lower surface 124b of the electrode 124 of the light emitting element 120 is exposed from the lower surface 170b of the covering member 170.

The light source 220 can be manufactured, for example, as follows. First, a plate-shaped translucent member 150S is prepared. The translucent member 150S is not limited to the single-layer member, and may have a laminated structure. The translucent member 150S may include a layer formed of a light-reflecting material, or may include a layer containing particles of a phosphor. For example, the thickness of the translucent member 150S can be adjusted by stacking a plurality of layers containing the same type of phosphor. The translucent member 150S may include a plurality of layers containing different types of phosphors. In addition, the translucent member 150S may have a phosphor-free layer. The translucent member 150S can obtain the required characteristics by appropriately combining these layers.

After that, as schematically shown in FIG. 8, a translucent adhesive 160R is applied to a plurality of locations on one main surface 150b of the translucent member 150S, and light is emitted to each region to which the adhesive 160R is applied. The element 120 is arranged. At this time, the light emitting element 120 is arranged in each region to which the adhesive 160R is applied so that the electrode 124 of the light emitting element 120 faces the side opposite to the main surface 150b of the translucent member 150S. The plurality of light emitting elements 120 may be arranged two-dimensionally on the main surface 150b of the translucent member 150S. By curing the adhesive 160R, the bonding member 160 can be formed from the adhesive 160R and the light emitting element 120 can be fixed to the main surface 150b side of the translucent member 150S.

After that, a resin composition containing a light-reflecting filler is applied to the main surface 150b side of the translucent member 150S, and the resin composition is cured to cover the light-emitting element 120 and the joining member 160. A coating layer 170T is formed (see FIG. 9). After the coating layer 170T is formed, the lower surface 124b of the electrode 124 of the light emitting element 120 is exposed from the coating layer 170T by grinding or the like, as shown in FIG. Further, by cutting the translucent member 150S and the coating layer 170T at positions between the light emitting elements 120 adjacent to each other (schematically indicated by the thick arrow DC in FIG. 9), the light sources each include the light emitting element 120. 220 can be obtained efficiently. As can be understood from the steps described above, the translucent member 150 and the coating member 170 in the light source 220 are a part of the translucent member 150S and the coating layer 170T shown in FIG. 9, respectively. The covering member 170 is not limited to this example, and may be a translucent member containing particles of a phosphor.

In the present embodiment, as schematically shown in FIG. 10, a translucent adhesive 180R is applied to the second hole portion 20 located on the back surface 300b side of the light guide assembly substrate 300 by a dispenser or the like, and the second hole portion 20 is applied. A light source 220 is further arranged inside the hole 20. One of the plurality of light sources 220 is arranged in each of the plurality of second hole portions 20 of each module region 310. At this time, the upper surface 150a on the side opposite to the lower surface 150b of the translucent member 150 so that the light emitted from the corresponding light emitting element 120 is incident on the portion of the light guide assembly substrate 300 included in the module region 310. Light source 220 is arranged inside the second hole portion 20 so as to face the bottom portion of the second hole portion 20.

With the light source 220 arranged inside the second hole 20, the adhesive 180R covers at least a part of the side surface of the translucent member 150 and the side surface of the covering member 170 that form the side surface of the light source 220. By curing the adhesive 180R by irradiation with light, heating, or the like, a second joining member 180 whose part is located inside the second hole 20 can be formed from the adhesive 180R. The light source 220 is joined to the back surface 300b side of the light guide assembly substrate 300 by the joining member 180. As a result, the translucent member 150 is located at the bottom of the second hole portion 20 in each module region 310, and the light emitted from the light emitting element 120 is transmitted into the light guide body 110 which is a light guide body structure. It becomes possible to make the incident through the optical member 150. The light emitted from the light emitting element 120 arranged in the second hole portion 20 passes through the corresponding module region 310 and is emitted from the main surface 300a side including the first hole portion 10.

In a state where the light source 220 is joined to the light guide assembly substrate 300, the light emitting element 120 in the light source 220 is located substantially directly below the first hole 10 of the corresponding module region 310. The light source 220 arranged in each module region 310 may include two or more light emitting elements.

Next, the material of the light-reflecting member 140, which is in an uncured state, is applied to the back surface 300b side of the light guide assembly substrate 300 by a dispenser or the like, and the applied material is cured by irradiation with light, heating, or the like. Therefore, the light reflecting layer 340 is formed (see FIG. 11). Injection molding, transfer molding and the like can be applied to the formation of the light reflecting layer 340. As schematically shown in FIG. 11, here, the light reflection layer 340 is formed so as to cover the entire back surface 300b of the light guide assembly substrate 300. It can be said that the light reflecting layer 340 has a structure in which the above-mentioned light reflecting member 140 is formed over a plurality of module regions 310. The light reflecting layer 340 also covers the surface of the joining member 180 located in each of the second hole portions 20. When the alignment mark is provided on the back surface 300b side of the light guide assembly substrate 300, the light reflecting layer 340 covers a region of the back surface 300b of the light guide assembly substrate 300 excluding the region where the alignment mark is provided. It is formed in a covering shape.

If necessary, the light reflecting layer 340 may be subjected to a grinding process or the like. By thinning the light reflecting layer 340, the position of the lower surface 340b of the light reflecting layer 340 is aligned with the position of the lower surface 124b of the electrode 124 of the light emitting element 120, and the electrode 124 of the light emitting element 120 in the light source 220 is exposed from the light reflecting layer 340. Can be made to.

The formation of the light adjustment unit 130 may be executed at any stage after the step of preparing the light guide assembly substrate 300. For example, after preparing the light guide assembly substrate 300, the material of the optical adjustment unit 130, which is in an uncured state, is applied to, for example, the first portion 11 of the first hole portion 10, and the applied material is cured. May be good. As a result, the light adjusting portion 130 located in the first hole portion 10 can be formed. After that, the arrangement of the light source 220 and the formation of the light reflecting layer 340 inside the second hole 20 can be executed. The step of forming the light adjusting portion 130 may be before or after the formation of the light reflecting layer 340.

Here, the wiring layer 190 is further formed on the lower surface 340b of the light reflecting layer 340. Through the above steps, a composite substrate is completed, each of which has a plurality of module regions 310 including a light emitting element 120 and a light guide structure.

[Step of cutting the light guide assembly substrate]
Next, the obtained composite substrate is cut. At this time, the light guide assembly substrate is cut while leaving at least one of the pair of first margin regions uncut (step S3 in FIG. 3).

In the present embodiment, first, cutting along the second direction is performed, and then cutting along the first direction is performed. A cutting device used in a manufacturing process of a semiconductor device, such as a semiconductor resin package or a semiconductor substrate, can be applied to cut a composite substrate including the light guide assembly substrate 300 as a part thereof. The cutting device may include a rotary blade or a straight blade. Hereinafter, an example in which a cutting device provided with a straight blade is applied to cutting a composite substrate will be described.

In the process of cutting the composite substrate, first, the composite substrate is placed on the stage of the cutting device. At this time, for example, the composite substrate is temporarily fixed to the stage of the cutting device by vacuum suction. The composite substrate may be fixed at a predetermined position such as an adhesive tape supported by the ring frame, and the composite substrate supported by the adhesive tape may be arranged on the stage of the cutting device. Here, since the first alignment marks 11t and 11u, the second alignment marks 12v and 12w, the third alignment mark 13 and the fourth alignment mark 14 are located on the main surface 300a side of the light guide assembly substrate 300. The composite substrate is arranged on the stage of the cutting device so that the main surface 300a of the light guide assembly substrate 300 faces up.

FIG. 12 schematically shows a state in which the composite substrate is temporarily fixed on the stage of the cutting device. In the configuration illustrated in FIG. 12, the cutting device has a plurality of straight blades 500 including a first straight blade 510 and a second straight blade 520. The directions in which the cutting edges of the first straight blade 510 and the second straight blade 520 extend are parallel. These straight blades 500 are configured to be movable along the Z direction in the drawing in the cutting device by a drive mechanism including a ball screw or the like. Here, the second straight blade 520 is used for cutting along the second direction of the composite substrate 400, and the first straight blade 510 is used for cutting along the first direction. In the configuration illustrated in FIG. 12, the length of the second straight blade 520 is smaller than the length of the first straight blade 510.

In the present embodiment, with reference to the respective positions of the plurality of first alignment marks (here, the first alignment marks 11t and 11u), the positions between the two rows 31C adjacent to each other are in the second direction (here, the Y direction). ), The composite substrate 400 is cut. In this example, the main surface 300a of the light guide assembly substrate 300 has a set of a plurality of first alignment marks 11t located in the first margin region 311T and a plurality of first alignment marks 11u located in the first margin region 311B. Has a set of. Therefore, the respective positions of the plurality of first alignment marks 11t and 11t included in these two sets can be used as a reference for determining the cutting position.

Specifically, the light guide assembly substrate 300 is photographed from the main surface 300a side by an image pickup device mounted on the cutting device, and the position of the alignment mark in the acquired image is acquired by using image recognition. For example, one of the plurality of first alignment marks 11t and one of the plurality of first alignment marks 11u corresponding to the one are detected, and the line connecting them is the Y-axis on the cutting device. Rotate the stage appropriately so that they are parallel. Further, the stage is appropriately moved along the X axis on the cutting device so that the cutting edge of the second straight blade 520 is located directly above the line connecting the first alignment marks 11t and 11u. After that, the second straight blade 520 is lowered along the Z axis on the cutting device until it reaches the lower surface 340b of the light reflecting layer 340 located on the side opposite to the main surface 300a of the light guide assembly substrate 300, thereby forming a composite. The substrate 400 can be cut along the second direction.

At this time, as schematically shown by a broken line in FIG. 12, the cutting edge of the second straight blade 520 is lowered between two of the plurality of rows 31C each including one or more module regions 310. In this example, a part of the margin region 311 is located in each of the plurality of regions between the two rows 31C adjacent to each other, and the cutting edge of the second straight blade 520 is adjacent to each other in the margin region 311. It descends towards each region between the two rows 31C.

When the alignment mark is located on the back surface 300b side of the light guide assembly substrate 300, the composite substrate 400 is arranged on the stage of the cutting device so that the back surface 300b of the light guide assembly substrate 300 faces up. , Just perform the disconnection. However, according to the study of the present inventor, due to the difference in material between the light guide assembly substrate 300 and the light reflection layer 340, the straight blade is made to face the light guide assembly substrate 300 side of the composite substrate 400 for cutting. When executed, cracks due to cutting tend to be less likely to occur as compared with the case where the straight blade is opposed to the light reflecting layer 340. Therefore, from the viewpoint of suppressing cracking of the light guide assembly substrate 300 due to cutting, it is more advantageous to cut the composite substrate 400 so that the main surface 300a of the light guide assembly substrate 300 faces up. possible.

FIG. 13 shows the cutting position of the composite substrate in the cutting step along the second direction. In this example, by cutting, a linear opening connecting the first alignment mark 11t and the corresponding first alignment mark 11u in each of the regions 314 located between the two adjacent rows 31C of the margin region 311. Forming CT. As schematically shown in FIG. 13, the light guide assembly substrate 300 in the composite substrate 400 is cut along the second direction at the position of the opening CT. By repeating the detection of the pair of the first alignment marks 11t and 11t and the descent of the second straight blade 520 while moving the stage of the cutting device in the X-axis direction, the plurality of rows 31C are separated from each other in the first direction. Can be made to. If necessary, Z so that the direction connecting the first alignment marks 11t and 11u and the extending direction of the cutting edge of the second straight blade 520 are parallel to each detection of the pair of the first alignment marks 11t and 11u. Adjustment of the angle of the stage around the axis may be performed. Here, an opening CT extending in the second direction is formed in each of the second margin regions 311L and 311R so as to connect the two third alignment marks 13.

Then, by rotating the stage by 90 ° and performing cutting along the first direction, a plurality of light emitting modules 200, each of which has a rectangular shape in a top view, as shown in FIGS. 1 and 2 can be obtained. Here, in the present embodiment, as shown in FIG. 13, in the step of cutting along the second direction, a pair of first margin regions 311T and 311B located at both ends of the light guide assembly substrate 300 with respect to the second direction. The composite substrate is cut by leaving at least one of them uncut. In other words, in the embodiment of the present disclosure, it is possible that both the first margin regions 311T and 311B are cut by the second straight blade 520 and each of these regions is divided into a plurality of portions in one cutting. do not have.

In the example shown in FIG. 13, both of the first margin regions 311T and 311B are not cut in the cutting along the second direction of the composite substrate 400, and each of them is left in the state of a single continuous region. .. Therefore, the relative positional relationship between the plurality of rows 31C does not change before and after cutting the composite substrate 400 along the second direction. Therefore, there is a positional deviation between the plurality of rows 31R including the five module regions 310, each of which is arranged in the X direction, and the second alignment marks 12v and 12w located in the second margin regions 311L and 311R, respectively. It can be avoided. In other words, in the step of cutting along the first direction (for example, the X direction), it is possible to avoid the misalignment of the cutting position with respect to the first direction using the second alignment marks 12v and 12w.

In the process of individualizing the composite substrate, for example, when the composite substrate is cut by pressing the cutting edge of a straight blade against the composite substrate, the composite substrate exerts a force in a direction perpendicular to the extending direction of the cutting edge in a plan view. receive. Therefore, the two substrate pieces separated by cutting are spread on the stage of the cutting device in a direction perpendicular to the extending direction of the cutting edge. In the process of cutting the composite substrate along the second direction, if the cutting along the Y direction is performed with a straight blade longer than the length of the composite substrate in the Y direction, a plurality of substrate pieces generated by the cutting may be formed. A shift parallel to the extending direction of the cutting edge may occur as well as the direction perpendicular to the extending direction of the cutting edge.

In the example shown in FIG. 12, it is assumed that instead of the second straight blade 520, the composite substrate 400 is cut along the Y direction with a straight blade longer than the length in the Y direction. In this case, cutting along the Y direction produces five strip-shaped substrate pieces from the composite substrate 400 and two scraps corresponding to the second margin regions 311L and 311R, respectively. Each of the five substrate pieces comprises four module regions 310 aligned along the Y direction, and each of the two offcuts is either a set of a plurality of second alignment marks 12v or a plurality of second alignment marks 12w. including. In such a cutting method in which a plurality of strip-shaped members, each of which is independent, are generated, the position of the center of each substrate piece and the position of the center of each end material may not match with respect to the Y direction.

Therefore, when the composite substrate 400 is cut along the Y direction so as to completely cut both the first margin regions 311T and 311B, between the two scraps located on both sides of the five substrate pieces in the X direction. The straight line connecting the two alignment marks is not parallel to the X direction because the positions of these centers may not match. That is, the angle of the corners of the outer shape of each module obtained by cutting the substrate piece along the first direction can deviate from 90 °. Further, the straight line connecting the second alignment mark 12v on one end material and the second alignment mark 12w on the other end material corresponding to the mark may overlap with a part of the module area 310. It can happen. That is, since the center of each substrate piece is located at various positions with respect to the Y direction, there is a possibility that a module region 310 that is damaged by cutting in the X direction may occur.

On the other hand, in the embodiment of the present disclosure, as illustrated in FIG. 13, at least one of the pair of first margin regions 311T and 311B is left uncut, and the composite substrate 400 is formed along the second direction. Perform a disconnect. In other words, when the cutting of the composite substrate 400 along the second direction is completed, a plurality of substrate pieces separated from each other are not generated. Therefore, even after cutting the composite substrate 400 along the second direction, the Y direction is related between the plurality of module regions 310 and the second alignment marks 12v and 12w located in the second margin regions 311L and 311R. There is no deviation in the positional relationship. Therefore, in cutting with reference to the plurality of second alignment marks 12v and 12w, the composite substrate 400 can be cut along the first direction at the desired position of the composite substrate 400. In other words, it is possible to efficiently obtain a plurality of light emitting modules having the desired dimensions and shapes. In particular, the embodiment of the present disclosure is advantageous for manufacturing a light emitting module having a square shape or a rectangular shape because the deviation of the angle of the corner portion of the shape in the top view of the light emitting module from a right angle can be suppressed.

FIG. 14 shows the cutting position of the composite substrate in the step of cutting along the first direction after cutting along the second direction. In the present embodiment, after rotating the stage by 90 °, the light guide is provided between the plurality of rows 31R of the plurality of module regions 310 with reference to the respective positions of the plurality of second alignment marks 12v and 12w. The assembly substrate 300 and the light reflecting layer 340 are cut along the X direction.

Here, the first straight blade 510 of the straight blades 500 is used for cutting along the first direction. By repeatedly detecting the pair of the second alignment marks 12v and 12w and lowering the first straight blade 510 while moving the stage of the cutting device in the Y-axis direction, a plurality of module regions 310 in the second direction are executed. Can be separated from each other. Here, cutting along a straight line connecting the fourth alignment mark 14 located in the second margin region 311R and the fourth alignment mark 14 located in the corresponding second margin region 311L is also executed.

In the example shown in FIG. 14, a second alignment mark 12v and a corresponding second alignment mark 12w are provided in each of the regions 313 located between two rows R31 adjacent to each other in the margin region 311 by cutting. A linear opening CU to connect is formed. Further, here, an opening CU is formed in each of the first margin regions 311T and 311B so as to connect the two fourth alignment marks 14. As a result, the light guide body 210 and the light reflective member 240 are formed from the light guide body assembly substrate 300 and the light reflection layer 340, respectively, and a plurality of light emitting modules 200, each of which has a rectangular shape in a top view, as shown in FIG. Is obtained.

As can be seen from the shapes of the opening CT and the opening CU shown in FIG. 14, in the present embodiment, the length of the cutting edge of the first straight blade 510 applied to cutting along the first direction is in the second direction. It differs from the length of the cutting edge of the second straight blade 520 applied to cutting along. In this example, the composite substrate 400 has a rectangular shape that is longer in the X direction than in the Y direction in a plan view. In such a case, the length of the straight blade used in the step of cutting the composite substrate 400 along the first direction is compared with the length of the straight blade used in the step of cutting the composite substrate 400 along the second direction. By increasing the size, the plurality of rows 31C can be collectively cut over the entire plurality of rows 31C formed on the light guide assembly substrate 300.

Further, in the step of cutting the composite substrate 400 along the second direction by not making the length of the straight blade used in the step of cutting the composite substrate 400 along the second direction longer than necessary, a pair of firsts. At least one of 1 margin areas 311T and 311B can be left uncut. Of the first direction and the second direction, the length of the opening formed in the composite substrate is relatively short with respect to the direction in which the cutting is executed first, so that the plurality of modules are formed even when the opening is formed in the composite substrate. Occurrence of misalignment between regions 310 can be suppressed. Therefore, it becomes possible to efficiently obtain a plurality of light emitting modules 200 having a desired shape.

In the process of cutting the composite substrate, the light-transmitting substrate may be cracked by pressing the straight blade. According to the study of the present inventor, cracks are likely to occur especially near the end of a linearly extending opening formed by pressing a straight blade. When the crack caused by the cutting reaches the outer edge at the position of the outer edge of the composite substrate, the light guide assembly substrate is cracked. From such a viewpoint, it is beneficial to cut the composite substrate 400 so that the distance from the outer edge of the composite substrate 400 to the end of the opening CT or the opening CU is not less than 3 mm. The distance from the outer edge of the composite substrate 400 to the end of the opening CT (indicated by the double-headed arrow Ds in FIG. 14) is preferably 5 mm or more, more preferably 10 mm or more. The same can be said for the distance from the outer edge of the composite substrate 400 to the end of the opening CU.

FIG. 15 schematically shows another method of cutting the composite substrate 400. As shown in FIG. 15, a plurality of through holes 52 may be formed in the composite substrate 400 prior to cutting along the second direction using the second straight blade 520. Each of the plurality of through holes 52 is located on a virtual straight line connecting the first alignment mark 11t located in the first margin region 311T and the corresponding first alignment mark 11u located in the first margin region 311B. do. As shown in FIG. 15, these pairs of through holes 52 are provided at positions substantially symmetrical with respect to the center of four module regions 310 arranged in the Y direction. As illustrated in FIG. 15, the plurality of through holes 52 are virtual connecting the third alignment mark 13 located in the first margin region 311T and the corresponding third alignment mark 13 located in the first margin region 311B. It can also be provided on a straight line.

The arrangement of the plurality of through holes 52 that can be provided in the composite substrate 400 will be described with reference to FIGS. 16 and 17. Each through hole 52 is formed in the composite substrate 400 at a position that does not overlap any of the plurality of module regions 310 and the plurality of alignment marks. With respect to the Y direction, the through holes 52 are located outside the outer edge of the four module regions 310 arranged in the Y direction. In the example shown in FIG. 16, the through hole 52 is located further outside the line segment connecting the first alignment mark 11u and the first alignment mark 11t.

Here, for convenience of explanation, a rectangular region defined by the outermost circumferences of a plurality of module regions 310 arranged along the X direction or the Y direction in the composite substrate 400 will be referred to as a “product region PA”. The double-headed arrow D1 in FIG. 16 represents the length of the product area PA in the Y direction. The double-headed arrow D2 in FIG. 16 represents the distance between the centers of the two through holes 52 arranged along the Y direction. The two through holes 52 arranged along the Y direction are formed in the composite substrate 400 at a position separated from the product region PA by at least a predetermined distance with respect to the Y direction. That is, the relationship of D2> D1 is established. In this example, the two through holes 52 are located further outside the line segment connecting the first alignment mark 11u and the first alignment mark 11t. However, the arrangement of the through hole 52 is not limited to this example, and as illustrated in FIG. 17, the first alignment mark 11u and the first alignment mark 11t are connected as long as the relationship of D2> D1 is satisfied. It may be on a line segment. That is, the through hole 52 may be formed at a position between the first alignment mark 11u and the first alignment mark 11t.

The arrangement of the two through holes 52 along the Y direction is determined according to the length of the cutting edge of the second straight blade 520. More specifically, the arrangement and the distance between the centers of the two through holes 52 are determined so that both ends of the cutting edge of the second straight blade 520 overlap with these through holes 52. That is, in cutting the composite substrate 400 along the second direction, the end of the cutting edge of the second straight blade 520 passes through the inside of the through hole 52.

In general, both ends of the cutting edge of a straight blade tend to be inferior in shape surface accuracy (eg, the shape of the cutting edge in a cross-sectional profile) as compared to the central portion of the straight blade. Therefore, cracks caused by cutting often occur starting from the position where the end of the cutting edge of the straight blade is pressed on the composite substrate 400. As in this example, by providing a plurality of through holes 52 in advance in the composite substrate 400 so that the end of the cutting edge passes through the position of the through holes 52, in the process of the composite substrate 400 along the second direction. The occurrence of cracks starting from the position of the end of the cutting edge can be effectively suppressed. As a result, it is possible to avoid cracking of the composite substrate 400 or cracking of the light guide assembly substrate 300 that reaches the outer edge of the composite substrate 400.

The length of the cutting edge of the second straight blade 520 is such that the end of the cutting edge is at least 1 mm away from the product area PA when the second straight blade 520 is pressed against the main surface 300a of the light guide assembly substrate 300. It is said to be the size to be used. The double-headed arrow D3 in FIGS. 16 and 17 represents the distance from the position of the cutting edge of the second straight blade 520 to the outer edge of the product region PA extending in the X direction, whichever is closer. Of FIGS. 16 and 17, FIG. 17 shows an example in which two through holes 52 are arranged inside the first alignment marks 11t and 11u. The length of the double-headed arrow D3 in FIG. 17 is smaller than the length of the double-headed arrow D3 in FIG. The length of the second straight blade 520 is equal to the length of the double-headed arrow D1 indicating the width of the product area PA plus twice the length of the double-headed arrow D3. It can be said that this length is substantially equal to the length of the double-headed arrow D2 indicating the distance between the centers of the two through holes 52.

The plurality of through holes 52 can be formed, for example, by punching using a die. Alternatively, a plurality of through holes 52 may be formed by drilling using a drill or a laser. Each through hole 52 has, for example, a circular shape in a plan view. From the viewpoint of allowing the end of the cutting edge to pass through the position of the through hole 52, the circular diameter of the through hole 52 is typically 5 times or more the thickness of the second straight blade 520. The shape of the through hole 52 is not limited to a circle, and may be another shape such as an ellipse or a polygon. Further, regardless of the shape, it is beneficial that the maximum width of the through hole 52 in a plan view is five times or more the thickness of the second straight blade 520.

Prior to cutting the composite substrate 400 along the first direction, instead of forming the plurality of through holes 52 in the composite substrate 400, or in addition to forming the plurality of through holes 52 as illustrated in FIG. , A plurality of through holes 51 may be formed in the pair of second margin regions 311R and 311L. As shown in the example shown in FIG. 18, a plurality of through holes 51 are provided at positions where the end of the blade edge touches when the first straight blade 510 is pressed against the main surface 300a of the light guide assembly substrate 300. , It is possible to avoid the occurrence of cracks starting from the positions of both ends of the cutting edge of the first straight blade 510 due to the cutting along the first direction. The formation of the plurality of through holes 51 in the composite substrate 400 may be performed before the step of cutting the composite substrate 400 along the second direction, or the composite substrate 400 may be cut along the second direction. It may be executed between the step of the above step and the step of cutting the composite substrate 400 along the first direction.

The arrangement relationship between the product area PA and the plurality of through holes 51 may be the same as the arrangement relationship between the product area PA and the plurality of through holes 52 described above. That is, each of the plurality of through holes 51 is on a virtual straight line connecting the second alignment mark 12w located in the second margin region 311R and the corresponding second alignment mark 12v located in the second margin region 311L. It is provided at a position at least 1 mm away from the outer edge of the product area PA in the X direction. As shown in FIG. 18, the distance between the centers of the two through holes 51 arranged along the X direction may be larger than the distance between the second alignment mark 12w and the corresponding second alignment mark 12v. Alternatively, the through hole 51 may be located on a line segment connecting the second alignment mark 12w and the second alignment mark 12v. In this example, a through hole 51 is also formed on a virtual straight line connecting the fourth alignment mark 14 located in the second margin region 311R and the corresponding fourth alignment mark 14 located in the second margin region 311L. is doing.

The arrangement of the two through holes 51 along the X direction is determined according to the length of the cutting edge of the first straight blade 510, and in cutting the composite substrate 400 along the first direction, the cutting edge of the first straight blade 510 The end of the through hole 51 passes through the inside of the through hole 51. The length of the first straight blade 510 is approximately equal to the width of the product region PA along the X direction plus twice the distance from the outer edge of the product region PA to the center of the through hole 51.

Similar to the plurality of through holes 52, the shape of each of the plurality of through holes 51 may be a circular shape having a diameter of 5 times or more the thickness of the first straight blade 510. The shape of each of the through hole 51 and the through hole 52 is not limited to a perfect circle, and may be an ellipse, a distorted circle, or the like. Similar to the cutting of the composite substrate 400 along the second direction, from the viewpoint of more effectively avoiding the occurrence of cracks starting from the positions of both ends of the cutting edge of the first straight blade 510, it is along the first direction. In cutting, it is preferable that the end portion of the cutting edge of the first straight blade 510 passes through the substantially central position of the through hole 51.

From the viewpoint of suppressing the occurrence of cracks in the composite substrate 400 that reach the outer edge of the composite substrate 400, a plurality of grooves may be formed in advance on the outside of the set of the plurality of module regions 310. In the example shown in FIG. 19, a plurality of groove portions 61 to 66 are formed on the main surface 300a side of the light guide assembly substrate 300 prior to the separation of the plurality of module regions 310 using the straight blade. Of these, the groove portion 61 and the groove portion 62 are located in the second margin region 311L and extend linearly along the Y direction. The groove portion 63 and the groove portion 64 are located in the second margin region 311R, and extend linearly along the Y direction like the groove portions 61 and 62. On the other hand, the groove portion 65 and the groove portion 66 are located in the first margin region 311T and the first margin region 311B, respectively, and extend linearly along the X direction.

Each of the groove portions 61 to 66 has a structure formed by pressing, for example, a straight blade against the main surface 300a of the light guide assembly substrate 300. In the formation of the groove portions 61 to 66, the straight blade for forming these grooves is provided on the main surface of the composite substrate 400 on the side opposite to the main surface 300a of the light guide assembly substrate 300 (hereinafter, simply the composite substrate 400). (Sometimes called the back side of.) Is not reached. Each of the grooves 61 to 66 may be formed on the composite substrate 400 by dicing using a rotary blade, machining using a bit, laser machining, or the like.

In this example, the groove 61 and the groove 62 are provided at positions farther than the second alignment mark 12v with respect to the plurality of module regions 310, and the groove 63 and the groove 64 are also provided with respect to the plurality of module regions 310. It is provided at a position farther than the second alignment mark 12w. Further, the groove portion 65 is provided at a position farther than the first alignment mark 11t with respect to the plurality of module regions 310, and the groove portion 66 is farther than the first alignment mark 11u with respect to the plurality of module regions 310. It is provided at the position of.

FIG. 20 schematically shows a composite substrate 400 in a state in which a plurality of openings CU and CT are formed after the formation of the plurality of groove portions 61 to 66. As can be seen from FIG. 20, the plurality of openings CU extending in the X direction and the plurality of openings CT extending in the Y direction are basically formed inside the rectangular region defined by these grooves. By removing a part of the composite substrate 400 on the light guide assembly substrate 300 side prior to the separation of the plurality of module regions 310 using the linear blade, the composite substrate 400 along the second direction or the first direction. Even if cracks occur starting from the position of the end of the cutting edge in the cutting, it is possible to stop the progress of the cracks at the positions of these grooves. By providing a plurality of grooves in advance in the margin region of the composite substrate 400, the effect of suppressing the occurrence of cracks in the composite substrate 400 that reaches the outer edge of the composite substrate 400 can be expected.

The plurality of groove portions 61 to 66 described above may be formed on the composite substrate 400 in the order of, for example, the groove portions 61, 62, 63, 64, 65 and 66. In this example, two groove portions 61 and 62 are formed in the second margin region 311L, and two groove portions 63 and 64 are formed in the second margin region 311R. However, the configuration of the plurality of grooves is not limited to this example. The groove on the main surface 300a side of the light guide assembly substrate 300 is basically provided so as to surround a region in which a plurality of openings CU and CT are formed. Therefore, for example, the formation of the groove portion 62 inside the groove portion 61 and the groove portion 63 inside the groove portion 64 may be omitted.

The width of each of the grooves 61 to 66 can be arbitrarily set as long as it does not come into contact with the plurality of openings CU and CT. The depth of each of the grooves 61 to 66 is about 30% or more and 70% or less of the thickness of the composite substrate 400, in other words, the distance from the main surface 300a of the light guide assembly substrate 300 to the back surface of the composite substrate 400. It can be a range.

See FIG. 14 again. In the example described with reference to FIG. 14, in the cutting step along the first direction, both the pair of second margin regions 311R and 311L located at both ends of the light guide assembly substrate 300 with respect to the first direction are completely completed. The composite substrate 400 is cut by leaving the composite substrate 400 without cutting. However, the present invention is not limited to this example, and as illustrated in FIG. 21, the composite substrate 400 may be cut by selectively leaving one of the pair of second margin regions 311R and 311L. In the example shown in FIG. 21, one end of each of the plurality of opening CUs extending in the X direction reaches one side of the light guide assembly substrate 300 on the rectangular second margin region 311L side. That is, in this example, of the pair of second margin regions 311R and 311L, the second margin region 311L is cut, but the second margin region 311R is left uncut.

In the embodiment of the present disclosure, at least one of the pair of first margin regions 311T and 311B located at both ends of the light guide assembly substrate 300 with respect to the second direction is not cut in the cutting step along the second direction. Left in. Therefore, even if one of the pair of second margin regions 311R and 311L is cut in the cutting step along the first direction following the cutting step along the second direction, the plurality of module regions 310 are paired. Cutting along the first direction can be performed without being separated from at least one of the first margin regions 311T and 311B. Therefore, it is possible to avoid a large deviation of the outer shape of the light emitting module 200 in the top view from a square or a rectangle. In this way, by cutting the composite substrate 400 along the first direction while leaving at least one of the pair of second margin regions 311R and 311L uncut, the outer shape of the light emitting module 200 in the top view. Has the effect of avoiding a large deviation from a square or rectangle.

Alternatively, as illustrated in FIG. 22, in the step of cutting the composite substrate 400 along the first direction, both the pair of second margin regions 311R and 311L may be cut. Even with such a configuration, cutting of the plurality of columns 31C is executed in a state where each of the plurality of columns 31C of the module region 310 is connected to at least one of the first margin regions 311T and 311B (see FIG. 13). That is, with respect to the second direction, there is basically no extreme deviation in the arrangement relationship between the plurality of module regions 310 and the second alignment marks 12v and 12w and the fourth alignment mark 14. Therefore, by executing the cutting along the first direction with reference to the respective positions of the plurality of second alignment marks 12v and 12w, it is possible to prevent the outer shape of the light emitting module 200 from being significantly deviated from the square or rectangle in the top view. It is possible.

In the step of cutting the composite substrate 400 along the second direction, which is executed prior to the cutting of the composite substrate 400 along the first direction, as shown in FIG. 23, the pair of first margin regions 311T and 311B One of them may be cut. FIG. 23 shows an example of cutting the first margin region 311B along the second direction while leaving the first margin region 311T of the pair of first margin regions 311T and 311B without cutting.

Similar to the example described with reference to FIG. 13, in this example as well, the module while maintaining the arrangement relationship between the plurality of module regions 310 and the second alignment marks 12v and 12w and the fourth alignment mark 14. The plurality of rows 31C of the region 310 can be separated from each other. Therefore, as in each of the examples described so far, it is possible to avoid a large deviation of the outer shape of the light emitting module 200 in the top view from a square or a rectangle.

In the above-described embodiment, in the cutting step along the first direction, an opening CU is formed in each of the margin regions 311 located between two rows R31 adjacent to each other (third margin region). (See FIG. 14) In the step of cutting along the second direction, an opening CT is formed in each of the region 314 (fourth margin region) located between two rows 31C adjacent to each other in the margin region 311. (See FIG. 13). In other words, in the above-described embodiment, the light guide assembly substrate 300 has a plurality of third margin regions located between the plurality of rows R31 of the module region 310 and a plurality of columns 31C of the module region 310. It includes a plurality of fourth margin areas located between each. However, the light guide assembly substrate 300 is located between two module regions 310 adjacent to each other in the direction in which the columns of the plurality of module regions 310 extend (column direction) and in the direction in which the rows of the plurality of module regions 310 extend (row direction). It is not essential in the embodiments of the present disclosure to have a third margin region and a fourth margin region between two module regions 310 adjacent to each other.

24 and 25, respectively, show other examples of arrangements of a plurality of module regions 310. In the configuration illustrated in FIG. 24, each of the plurality of rows R31 of the plurality of module regions 310 is arranged in contact with the rows of the adjacent module regions 310 on the main surface 300a of the light guide assembly substrate 300A. In other words, the light guide assembly substrate 300A shown in FIG. 24 has a region 314 as a fourth margin region, but does not have a region 313 as a third margin region. In the configuration illustrated in FIG. 25, each of the plurality of rows 31C of the plurality of module regions 310 is arranged in contact with the rows of the adjacent module regions 310 on the main surface 300a of the light guide assembly substrate 300B. In other words, the light guide assembly substrate 300B shown in FIG. 25 has a region 313 as a third margin region, but does not have a region 314 as a fourth margin region. It is possible that the light guide assembly substrate does not have either the third margin region or the fourth margin region.

(Application example of light emitting module 200)
Here, an application example of the light emitting module 200 will be described. The light emitting module 200 can be used alone, but as described below, a set of a plurality of light emitting modules 200 can be applied to, for example, a backlight module.

FIG. 26 shows an example in which a plurality of light emitting modules 200 are arranged in two dimensions. By arranging the plurality of light emitting modules 200 in two dimensions, a light emitting surface having a larger area can be obtained.

The planar light source 600 shown in FIG. 26 has a plurality of light emitting modules 200 shown in FIG. FIG. 26 is an example in which the light emitting modules 200 are arranged in 8 rows and 16 columns, and schematically shows the appearance of the two-dimensional arrangement of the light emitting modules 200 as viewed from the upper surface 210a side of the light guide body 210. Here, the shape of the upper surface 210a of each light guide 210 when viewed from the normal direction of the upper surface 210a of the light guide 210 is rectangular, and the light guide 210 as a light emitting surface of the planar light source 600. The set of the upper surfaces 210a is also rectangular as a whole. The planar light source 600 may further have an optical sheet such as a diffusion sheet or a prism sheet above the light guide body 210.

When the vertical length L and the horizontal length W of each light emitting module 200 are, for example, approximately 24.3 mm and 21.5 mm, respectively, the arrangement of the light emitting modules 200 shown in FIG. 26 has an aspect ratio of 16 :. It fits 10 and 15.6 inch screen sizes. For example, the planar light source 600 shown in FIG. 26 can be suitably used for a backlight unit of a laptop personal computer having a screen size of 15.6 inches.

In the planar light source 600, the light guides 210 of two light emitting modules 200 that are adjacent in the row or column direction typically come into direct contact with each other. In such a configuration, if the corners of the rectangular outer shape of the light emitting module are deviated from the right angle, a gap is generated between two adjacent light emitting modules 200, and as a result, a dark line is formed at the boundary position of the light emitting module 200 on the light emitting surface. Can occur.

However, in the manufacturing method according to the embodiment of the present disclosure, at least one of the pair of first margin regions 311T and 311B located at both ends of the light guide assembly substrate in the second direction is left uncut. A plurality of light emitting modules 200 are obtained by performing cutting along the direction. As a result, even when the cutting step along the second direction is completed, the arrangement relationship between the plurality of module regions 310 and the second alignment marks 12v and 12w and the fourth alignment mark 14 is maintained. As a result, it is possible to prevent the outer shape of the light emitting module 200 from being significantly deviated from the square or rectangle when viewed from above. This facilitates the arrangement of the plurality of light emitting modules 200 in two dimensions without gaps.

In this example, the set of the upper surfaces 210a of the light guide body 210, which is the upper surface of each light emitting module 200, constitutes the light emitting surface. Therefore, by changing the number of light emitting modules 200 included in the planar light source 600 or changing the arrangement of the light emitting modules 200, the planar light source 600 can be easily applied to a plurality of types of liquid crystal panels having different screen sizes. can do. That is, it is not necessary to redo the optical calculation for the light guide body 210 or the like in the light emitting module 200 or to remanufacture the mold for forming the light guide body 210, and it flexibly responds to the change of the screen size. It is possible. Therefore, the change in screen size does not cause an increase in manufacturing cost and lead time. For example, by arranging a set of a plurality of light emitting modules 200 shown in FIG. 26 in 2 rows and 2 columns, a planar light source having an aspect ratio of 16:10 and suitable for a screen size of 31.2 inches can be constructed. Can be done. Such an arrangement of the light emitting module 200 can be used for a backlight unit of a liquid crystal television or the like. As described above, according to the present embodiment, it is relatively easy to obtain a light emitting surface having a larger area.

According to the method of constructing a light emitting surface having a larger area by combining a plurality of light emitting modules 200, the design of the optical system is redesigned according to the screen size, and the mold for forming the light guide body is remanufactured. It is possible to flexibly support liquid crystal panels of various screen sizes without any trouble. That is, it is possible to provide a backlight unit suitable for the screen size at low cost and in a short delivery time. Further, even if there is a light emitting element that does not light due to disconnection or the like, there is an advantage that the light emitting module including the defective light emitting element can be replaced.

Hereinafter, each component of the light emitting module 200 will be described in more detail. FIG. 27 shows an enlarged view of the light source in the light emitting module and its periphery.

[Light guide body 110 (light guide body 210)]
The light guide body 110 (and the light guide body 210 which is an aggregate thereof) has a function of diffusing the light from the light emitting element 120 in the light source 220 inside and emitting the light from the upper surface 110a. The light guide body 110 is a substantially plate-shaped member formed of a thermoplastic resin such as acrylic, polycarbonate, cyclic polyolefin, polyethylene terephthalate, polyester, a thermosetting resin such as epoxy or silicone, or glass, and is transparent. Has sex. Among these materials, polycarbonate in particular can obtain high transparency while being inexpensive. The light guide body 110 may have a light diffusing function, for example, by dispersing a material having a refractive index different from that of the base material. Further, they may be laminated.

The first hole portion 10A provided on the upper surface 110a of the light guide body 110 reflects the light emitted from the light emitting element 120 and introduced from the lower surface 110b side of the light guide body 110 and diffuses in the plane of the light guide body 110. It has a function to make it. By providing the light guide body 110 with the first hole portion 10 as such a light diffusion structure, it is possible to improve the brightness in a region of the upper surface 110a other than directly above the light emitting element 120. That is, it is possible to suppress uneven brightness on the upper surface of the light emitting unit 100, and the first hole portion 10 contributes to thinning the light guide body 110. The thickness of the light guide body 110, that is, the distance from the lower surface 110b to the upper surface 110a is typically about 0.1 mm or more and 5 mm or less. The thickness of the light guide body 110 according to the embodiment of the present disclosure can be, for example, about 0.25 mm. According to the embodiment of the present disclosure, for example, the thickness of the structure including the light reflecting member 140, in other words, the distance from the lower surface 124b of the electrode 124 of the light emitting element 120 to the upper surface 110a of the light guide body 110. Can be reduced to, for example, 5 mm or less, 3 mm or less, or 1 mm or less. The distance from the lower surface 124b of the electrode 124 of the light emitting element 120 to the upper surface 110a of the light guide body 110 may be about 0.7 mm or more and 1.1 mm or less.

As described above, in the embodiments of the present disclosure, the first hole portion 10 includes two portions, a first portion 11 and a second portion 12. The first portion 11 has a first side surface 11c inclined with respect to the upper surface 110a, and the second portion 12 has a second side surface 12c inclined with respect to the upper surface 110a. The second side surface 12c of the second portion 12 has an opening 12a located on the upper surface 110a of the light guide body 110 and the first side surface of the first portion 11 among one or more side surfaces that define the shape of the first hole portion 10. It is a part located between 11c and 11c. The first hole portion 10 can function as a lens that controls the light emission direction by utilizing the refraction of light at the boundary between the light guide body 110 and the environment of the outside.

The specific shape of the first hole portion 10 is not limited to the shape illustrated in FIG. 27, and is appropriately determined according to the shape and characteristics of the light emitting element 120 arranged on the lower surface 110b side of the light guide body 110. obtain. For example, the first portion 11 of the first hole portion 10 may further have a bottom surface substantially parallel to the upper surface 110a of the light guide body 110 in addition to the first side surface 11c. That is, the first portion 11 may have a shape such as an inverted conical table. The circular diameter of the bottom surface of the first hole can be, for example, about 0.3 mm. The shape of the bottom surface of the first hole in a plan view is not limited to a circle, and may be another shape such as an ellipse or a polygon. That is, the first hole portion 10 may have a shape such as an inverted pyramid including a plurality of side surfaces.

The depth of the first hole portion 10, that is, the distance from the deepest portion of the first portion 11 to the upper surface 110a of the light guide body 110 along the Z direction in the drawing is, for example, in the range of 200 μm or more and 400 μm or less. .. Among them, the depth of the first portion 11 can be, for example, in the range of 80 μm or more and 200 μm or less.

In the configuration illustrated in FIG. 27, the inclination of the first side surface 11c with respect to the upper surface 110a is gentler than the inclination of the second side surface 12c with respect to the upper surface 110a. According to the shape of the first hole portion 10 as described above, the area of the first side surface 11c can be increased while suppressing the increase in the depth of the first hole portion 10. Therefore, the light incident on the first side surface 11c inside the light guide body 110 can be more effectively diffused in the plane of the light guide body 110 while avoiding an increase in the thickness of the light guide body 110.

The magnitude of the inclination of the first side surface 11c is determined as an angle formed by a line segment connecting the lower end and the upper end of the first side surface 11c and a straight line parallel to the upper surface 110a of the light guide body 110 in a cross-sectional view. Similarly, the inclination of the second side surface 12c can be obtained as an angle formed by a line segment connecting the lower end and the upper end of the second side surface 12c and a straight line parallel to the upper surface 110a of the light guide body 110 in a cross-sectional view. ..

However, in the example shown in FIG. 27, both the first side surface 11c and the second side surface 12c have a curved shape in a cross-sectional view. In such a case, the magnitude of the inclination of these side surfaces may be determined as follows. For example, regarding the magnitude of the inclination of the first side surface 11c, a line segment C1 connecting the deepest portion of the first hole portion 10 and the opening 11a of the first portion 11 and a straight line parallel to the upper surface 110a of the light guide body 110. The formed angle θ1 may be adopted as the magnitude of the inclination of the first side surface 11c. When the first portion 11 has a bottom surface substantially parallel to the upper surface 110a of the light guide body 110, a line segment connecting the boundary between the bottom surface of the first portion 11 and the first side surface 11c and the opening 11a is formed. As C1, the angle θ1 formed by the line segment C1 and the straight line parallel to the upper surface 110a of the light guide body 110 may be adopted as the magnitude of the inclination of the first side surface 11c. Similarly, as the magnitude of the inclination of the second side surface 12c, the angle θ2 formed by the line segment C2 connecting the opening 11a and the opening 12a located on the upper surface 110a of the light guide body 110 and the straight line parallel to the upper surface 110a is set. You can use it.

Here, the angle formed by the upper surface 110a of the light guide body 110 and the line segment C1 shown by the broken line in FIG. 27 is formed by the upper surface 110a of the light guide body 110 and the line segment C2 shown by the broken line in FIG. 27. Smaller than a corner. That is, the relationship of θ1 <θ2 is established. On the contrary, the inclination of the second side surface 12c with respect to the upper surface 110a of the light guide body 110 may be gentler than the inclination of the first side surface 11c. In other words, the angle formed by the upper surface 110a of the light guide body 110 and the line segment C1 may be larger than the angle formed by the upper surface 110a of the light guide body 110 and the line segment C2. That is, the relationship of θ1> θ2 may be established. According to such a configuration, the volume of the second portion 12 can be expanded while avoiding an increase in the thickness of the light guide body 110, and for example, the air layer in the first hole portion 10 can be expanded to a wider region. .. Therefore, more light is incident on the second side surface 12c, and the light can be more effectively diffused in the plane of the light guide body 110.

Here, the shapes of the first side surface 11c and the second side surface 12c in a cross-sectional view are curved. However, the shape of the first side surface 11c and the second side surface 12c in cross-sectional view is not limited to a curved shape, and may be a shape including bending and / or a step, a straight line, or the like. It is not necessary that the shapes of the first side surface 11c and the second side surface 12c in the cross-sectional view match. When the shape of the first side surface 11c and / or the second side surface 12c in a cross-sectional view is a curved shape as illustrated in FIG. 27, particularly a convex curved shape bulging toward the inside of the first hole portion 10, it is derived. It is easy to diffuse the light to a position away from the center of the optical body 110, which is advantageous from the viewpoint of obtaining uniform light on the upper surface 110a side.

A second hole 20 is provided on the lower surface 110b side of the light guide body 110. A joining member 180 and a light source 220 are located inside the second hole portion 20. As can be seen from FIG. 2, the second hole portion 20 has, for example, a quadrangular pyramid shape. The light guide body 210 of the light emitting module 200 can be formed by injection molding, transfer molding, thermal transfer, or the like. By providing a convex portion protruding from the inner wall of the cavity at a predetermined position inside the cavity of the mold, the cross-sectional shape as shown in FIGS. 2 and 27 can be accurately formed. That is, according to the molding method using a mold, the center of the second hole portion 20 and the center of the first hole portion 10 corresponding to the second hole portion 20 can be aligned relatively easily. The second hole portion 20 may be provided in the light guide body 210 so as to be connected to the facing first hole portion 10. In other words, the second hole portion 20 may be provided in the light guide body 210 in the form of a through hole.

When the shape of the second hole portion 20 in a plan view is rectangular, the rectangular side of the second hole portion 20 is parallel to the rectangular side of the light guide body 110 as shown in the lower part of FIG. It may be formed on the lower surface 110b of the light guide body 110 so as to be. Alternatively, the second hole portion 20 may be formed on the lower surface 110b of the light guide body 110 so that one side of the rectangular outer shape thereof is inclined with respect to the rectangular side of the light guide body 110. For example, the second hole portion 20 may be formed in the light guide body 110 so that the rectangular side of the opening 20a of the second hole portion 20 is substantially parallel to the rectangular diagonal line of the light guide body 110.

As the shape of the second hole portion 20 in a plan view, a circular shape as well as a rectangular shape can be adopted. The shape and size of the second hole portion 20 can be appropriately determined according to the desired optical characteristics. For example, the second hole portion 20 may have a conical trapezoidal shape or the like. The size of the opening 20a of the second hole 20 formed in the lower surface 110b of the light guide body 110 can be, for example, 0.05 mm or more and 10 mm or less, preferably 0.1 mm or more and 1 mm or less. Here, the size of the opening 20a of the second hole portion 20 is the length along the diagonal direction of the rectangular shape when the second hole portion 20 has, for example, a rectangular opening in a plan view, and is the second. When the hole 20 has a circular opening in a plan view, it is the diameter of the circular shape.

[Light adjustment unit 130]
The light adjustment unit 130 is located inside the first hole portion 10, and in particular, in the present embodiment, the light adjustment unit 130 is located in the first portion 11 of the first hole portion 10. The light adjusting unit 130 is formed of, for example, a resin in which a light-reflecting filler is dispersed, or a light-reflecting material such as metal. Here, in the present specification, "reflectivity" and "light reflectivity" mean that the reflectance of the light emitting element 120 at the emission peak wavelength is 60% or more. It is more beneficial when the reflectance of the light adjusting unit 130 at the emission peak wavelength of the light emitting element 120 is 70% or more, and further useful when it is 80% or more.

Here, the light adjusting unit 130 occupies the entire first portion 11 inside the first hole portion 10. By arranging the light adjusting unit 130 above the light emitting element 120, the light adjusting unit 130 emits light emitted from the light emitting element 120 and travels toward the upper surface 110a of the light guide body 110 near the center of the light guide body 110. Can be reflected. Therefore, the light emitted from the light emitting element 120 can be diffused more efficiently in the plane of the light guide body 110. Further, it is possible to prevent the brightness of the region directly above the light emitting element 120 of the upper surface 110a of the light guide body 110 from becoming extremely high locally. However, it is not essential that the light adjusting unit 130 completely shields the light from the light emitting element 120. In this sense, the light adjusting unit 130 may have a semi-transmissive property of transmitting a part of the light from the light emitting element 120.

When the light adjusting portion 130 is formed of a light-reflecting resin composition, as described with reference to FIG. 11, for example, the first portion 11 is filled with the light-reflecting resin composition by a dispenser and imparted. The light adjusting unit 130 can be formed by curing the material with heat, light, or the like. As a base material of the resin composition for forming the light adjusting unit 130, a silicone resin, a phenol resin, an epoxy resin, a BT resin, a polyphthalamide (PPA) or the like can be used. As the light-reflecting filler, metal particles or particles of an inorganic material or an organic material having a higher refractive index than the base material can be used. Examples of light-reflecting fillers include titanium dioxide, silicon oxide, zirconium dioxide, potassium titanate, aluminum oxide, aluminum nitride, boron nitride, murite, niobium oxide, barium sulfate particles, or yttrium oxide and gadolinium oxide. Particles of various rare earth oxides and the like. It is beneficial if the light adjuster 130 has a white color.

The distribution of the light-reflecting filler in the light adjusting unit 130 may be substantially constant in the light adjusting unit 130, or may have a bias or a gradient. For example, in the process of forming the light adjusting unit 130, the filler may settle or separate from the base material before the base material is cured, so that the distribution of the light-reflecting filler in the light adjusting unit 130 may be biased. When the number density of fillers defined by the number of fillers per unit area in a plan view is relatively high near the center as compared with the vicinity of the outer edge of the optical adjustment unit 130, the brightness of the region directly above the light emitting element 120 becomes high. It is beneficial because it is easy to suppress the local extreme increase.

It is not essential in the embodiments of the present disclosure that the entire first portion 11 of the first hole portion 10 is filled with the light adjusting portion 130. The light adjusting unit 130 may occupy at least a part of the first portion 11. For example, the light adjusting portion 130 may be formed in the first hole portion 10 in a layered manner so as to cover the first side surface 11c of the first portion 11. The light adjusting unit 130 may be a dielectric multilayer film.

In the example shown in FIG. 27, the upper surface 130a of the light adjusting unit 130 is a substantially flat surface. However, the shape of the upper surface 130a of the light adjusting unit 130 is not limited to this example, and may be a convex shape protruding to the opposite side of the light emitting element 120, a concave shape recessed to the light emitting element 120 side, or the like. In particular, when the upper surface 130a of the light adjustment unit 130 has a convex shape protruding to the opposite side of the light emitting element 120, the vicinity of the center of the light adjustment unit 130 when the position of the opening 11a of the first portion 11 is used as a reference. As a result of the relatively large thickness, it is possible to more effectively suppress that the brightness of the region directly above the light emitting element 120 becomes extremely high locally.

[Light emitting element 120]
A typical example of the light emitting element 120 is an LED. The light emitting element 120 has an element body 122 and an electrode 124. The element body 122 includes, for example, a support substrate such as sapphire or gallium nitride, and a semiconductor laminated structure on the support substrate. The semiconductor laminated structure includes an n-type semiconductor layer and a p-type semiconductor layer, and an active layer sandwiched between them. The semiconductor laminated structure may include a light emitting capable nitride semiconductor of ultraviolet to visible range _{(In x Al y Ga 1-} xy N, 0 ≦ x, 0 ≦ y, x + y ≦ 1). The electrode 124 includes a set of a positive electrode and a negative electrode, and has a function of supplying a predetermined current to the semiconductor laminated structure.

Each of the plurality of light emitting elements 120 provided in the light emitting module 200 may be an element that emits blue light or an element that emits white light. The plurality of light emitting elements 120 may include elements that emit light of different colors from each other. For example, the plurality of light emitting elements 120 may include an element that emits red light, an element that emits blue light, and an element that emits green light.

The shape of the light emitting element 120 in a plan view is typically rectangular. The length of one side of the rectangular shape of the light emitting element 120 is, for example, 1000 μm or less. The rectangular vertical and horizontal dimensions of the light emitting element 120 may be 500 μm or less. Light emitting elements having vertical and horizontal dimensions of 500 μm or less are easy to procure at low cost. Alternatively, the rectangular vertical and horizontal dimensions of the light emitting element 120 may be 200 μm or less. When the length of one side of the rectangular shape of the light emitting element 120 is small, it is advantageous for high-definition image expression, local dimming operation, etc. in application to the backlight unit of the liquid crystal display device. In particular, in a light emitting element having both vertical and horizontal dimensions of 250 μm or less, the area of the upper surface is small, so that the amount of light emitted from the side surface of the light emitting element is relatively large. Therefore, it is easy to obtain a butt wing type light distribution characteristic. Here, the butt-wing type light distribution characteristic is, in a broad sense, light emission with high light emission intensity at an angle in which the absolute value of the light distribution angle is larger than 0 °, where the light axis perpendicular to the upper surface of the light emitting element is 0 °. Refers to the light distribution characteristics as defined by the intensity distribution. A light emitting element can be used as the light source 220.

[Translucent member 150]
The translucent member 150 in the light emitting module 200 is located inside the second hole portion 20 between the light guide body 110 and the light emitting element 120. In other words, the translucent member 150 is located above the light emitting element 120 and at the bottom of the second hole portion 20. Here, the "bottom of the second hole 20" means a portion corresponding to the bottom of the second hole 20 when the lower surface 110b of the light guide body 110 is turned upward. As such, the terms "bottom" and "bottom" may be used herein without being bound by the orientation shown in the drawings for the light emitting module or light emitting unit. It can be said that the bottom portion of the second hole portion 20 is a ceiling portion having a dome-shaped structure formed on the lower surface 110b side of the light guide body 110 when the light emitting unit 100 is in the posture shown in FIG. 27.

The translucent member 150 can be formed from a material containing particles of a phosphor. In this case, the translucent member 150 absorbs at least a part of the light emitted from the light emitting element 120 and emits light having a wavelength different from the wavelength of the light emitted from the light emitting element 120. For example, the translucent member 150 wavelength-converts a part of the blue light from the light emitting element 120 to emit yellow light. According to such a configuration, white light is obtained by mixing the blue light that has passed through the translucent member 150 and the yellow light emitted from the translucent member 150. In the configuration illustrated in FIG. 27, the light emitted from the light emitting element 120 is basically introduced into the light guide body 110 via the translucent member 150. Therefore, as a result of the light after the color mixing being diffused inside the light guide body 110, it is possible to take out, for example, white light in which the brightness unevenness is suppressed from the upper surface 110a of the light guide body 110. This embodiment is advantageous in uniforming the light as compared with the case where the light is diffused inside the light guide and then the wavelength is converted.

As the base material of the translucent member 150, silicone resin, modified silicone resin, epoxy resin, modified epoxy resin, urea resin, phenol resin, acrylic resin, urethane resin or fluororesin, or two or more of these resins are used. The containing resin can be used. From the viewpoint of efficiently introducing light into the light guide body 110, it is beneficial that the base material of the translucent member 150 has a lower refractive index than the material of the light guide body 110. A light diffusing function may be imparted to the translucent member 150 by dispersing a material having a refractive index different from that of the base material in the material of the translucent member 150. For example, particles such as titanium dioxide and silicon oxide may be dispersed in the base material of the translucent member 150.

A known material can be applied to the phosphor dispersed in the translucent member 150. Examples of phosphors are fluoride-based phosphors such as KSF-based phosphors, nitride-based phosphors such as CASN, YAG-based phosphors, β-sialon phosphors, and the like. The KSF-based phosphor and CASN are examples of wavelength-converting substances that convert blue light into red light, and the YAG-based phosphors are examples of wavelength-converting substances that convert blue light into yellow light. The β-sialone phosphor is an example of a wavelength converting substance that converts blue light into green light. The phosphor may be a quantum dot phosphor.

It is not essential that the phosphor contained in the translucent member 150 is common in a plurality of light emitting units 100 included in the same light emitting module 200. It is also possible to disperse the phosphors dispersed in the base material of the translucent member 150 among the plurality of light emitting units 100. A translucent member that converts incident blue light into yellow light is arranged in a part of the second hole 20 of the plurality of second holes 20 provided in the light guide body 210 of the light emitting module 200. A translucent member that converts incident blue light into green light may be arranged in some other second hole portion 20. Further, a translucent member that converts the incident blue light into red light may be arranged in the remaining second hole portion 20.

[Joining member 160]
The joining member 160 is a translucent member that covers at least a part of the side surface of the light emitting element 120. As schematically shown in FIG. 27, the joining member 160 may have a layered portion located between the upper surface 120a of the light emitting element 120 and the translucent member 150.

As the material of the joining member 160, a resin composition containing a transparent resin as a base material can be used. The joining member 160 has, for example, a transmittance of 60% or more with respect to the light having the emission peak wavelength of the light emitting element 120. From the viewpoint of effective use of light, it is beneficial that the transmittance of the bonding member 160 at the emission peak wavelength of the light emitting element 120 is 70% or more, and it is more beneficial if it is 80% or more.

A typical example of the base material of the joining member 160 is a thermosetting resin such as an epoxy resin or a silicone resin. As the base material of the joining member 160, a silicone resin, a silicone-modified resin, an epoxy resin, a phenol resin, a polycarbonate resin, an acrylic resin, a polymethylpentene resin or a polynorbornene resin, or a material containing two or more of these may be used. good. The joining member 160 typically has a refractive index lower than that of the light guide 110. The joining member 160 may have a light diffusing function, for example, by dispersing a material having a refractive index different from that of the base material.

As described above, the joining member 160 covers at least a part of the side surface of the light emitting element 120. Further, the joining member 160 has an outer surface which is an interface with the covering member 170. The light emitted from the side surface of the light emitting element 120 and incident on the joining member 160 is reflected toward the upper side of the light emitting element 120 at the position of the outer surface of the joining member 160. The shape of the outer surface of the joining member 160 in cross-sectional view is not limited to the linear shape as shown in FIG. 27. The shape of the outer surface of the joining member 160 in a cross-sectional view may be a polygonal line shape, a curved shape that is convex in the direction approaching the light emitting element 120, a curved shape that is convex in the direction away from the light emitting element 120, or the like.

[Coating member 170]
The covering member 170 is a light-reflecting member located on the lower surface 150b side (in other words, the side opposite to the light guide body 110) of the translucent member 150 in the light source 220. As shown in FIG. 27, the covering member 170 is located on the outer surface of the joining member 160, the portion of the side surface of the light emitting element 120 that is not covered by the joining member 160, and the side surface of the light emitting element 120 opposite to the upper surface 120a. Covers the area of the lower surface excluding the electrode 124.

As the material of the covering member 170, the same material as the material of the light adjusting unit 130 can be used. For example, the material of the covering member 170 and the material of the light adjusting unit 130 may be common. By covering the region of the lower surface of the light emitting element 120 excluding the electrode 124 with the covering member 170, it is possible to suppress the leakage of light to the side opposite to the upper surface 110a of the light guide body 110. Further, by covering the side surface of the light emitting element 120 with the covering member 170, the light from the light emitting element 120 can be concentrated upward, and the light can be efficiently introduced into the translucent member 150. Not limited to this example, the covering member 170 may be formed integrally with the translucent member 150. In this case, the joining member 160 can be omitted.

[(Second) joining member 180]
The light source 220 is arranged at the bottom of the second hole 20 by the joining member 180. As shown in FIG. 27, at least a part of the joining member 180 is located inside the second hole portion 20. The joining member 180 may have a portion located between the bottom portion of the second hole portion 20 and the translucent member 150. The joining member 180 covers at least a part of the side surface of the translucent member 150 and the side surface of the covering member 170. As schematically shown in FIG. 27, the joining member 180 may have a portion that is raised on the side opposite to the upper surface 110a of the light guide body 110 with respect to the lower surface 110b of the light guide body 110.

Like the joining member 160, the joining member 180 can be formed from a resin composition containing a transparent resin as a base material. The material of the joining member 180 may be different from the material of the joining member 160 or may be common. The joining member 180 typically has a refractive index lower than that of the light guide 110.

[Light reflective member 140]
The light-reflecting member 140 has a light-reflecting structure that covers at least a part of the lower surface 210b of the light guide body 210. By arranging the light reflecting member 140 on the lower surface 110b side of the light guide body 110, the light directed to the lower surface 110b side of the light guide body 110 is directed to the upper surface 110a side at the interface between the light guide body 110 and the light reflecting member 140. It can be directed and reflected. Therefore, light can be extracted more efficiently from the upper surface 110a of the light guide body 110. In particular, here, the light reflecting member 140 covers the joining member 180 in addition to the lower surface 110b of the light guide body 110. By covering the joining member 180 with the light reflecting member 140, it is possible to suppress the leakage of light from the joining member 180 to the lower surface 110b side of the light guide body 110 and improve the light extraction efficiency.

As described with reference to FIG. 2, the light-reflecting member 140 may include a base 140n and a wall 140w rising from the base 140n. The thickness of the base 140n can be, for example, about 0.6 mm. By arranging the wall portion 140w on the peripheral portion of the light guide body 110 so as to surround the light source 220 in a plan view, the brightness at the peripheral portion of the light guide body 110 is relatively low as compared with the central portion. Can be avoided.

The height of the wall portion 140w surrounding the light source 220 may be different between the plurality of light emitting units 100 included in one light emitting module 200 or in one light emitting unit 100. For example, among the plurality of inclined surfaces 140s included in one light emitting module 200, the height of the inclined surface 140s located on the outermost periphery of the light guide body 210 of the light emitting module 200 is positioned at another portion of the light guide body 210. It may be larger than the height of the inclined surface 140s. The shape of the inclined surface 140s in a cross-sectional view may be curved or linear as shown in the upper part of FIG. The shape of the inclined surface 140s in a cross-sectional view is not limited to these, and may include steps, bends, and the like.

As the material of the light reflecting member 140, the same material as that of the covering member 170 can be applied. For example, a resin composition based on a silicone resin, an epoxy resin, or a hybrid resin containing at least one of these can be applied to the material of the light reflective member 140. By sharing the material of the light-reflecting member 140 and the material of the covering member 170, it is possible to integrally form the light-reflective member that covers substantially the entire lower surface 210b of the light guide body 210 with the light-reflective material. .. By forming the light reflecting member 140 on the lower surface 210b side of the light guide body 210, effects such as reinforcement of the light guide body 210 can be expected. The covering member 170 may be a laminated film of a plurality of insulating films. As this insulating film, for example, polyethylene terephthalate or polyester resin can be used. The covering member 170 does not have to contain a light diffusing material.

[Wiring layer 190]
In the configurations illustrated in FIGS. 2 and 27, the light emitting module 200 further includes a wiring layer 190 located on the lower surface 140b of the light reflective member 140. The wiring layer 190 is electrically connected to the electrode 124 of the light emitting element 120. As shown in FIG. 27, the wiring layer 190 may also include a portion located on the covering member 170.

The wiring layer 190 is typically a single-layer film or a laminated film formed of a metal such as Cu. The wiring layer 190 functions as a terminal for supplying a predetermined current to each light emitting element 120 by being connected to a power source (not shown) or the like.

FIG. 28 shows an example of the appearance of the light emitting module 200 shown in FIG. 1 when viewed from the lower surface side opposite to the upper surface 210a of the light guide body 210. In FIG. 28, the boundary between the plurality of light emitting units 100 is shown by a dotted line for the sake of clarity, but it is the implementation of the present disclosure that a clear boundary is formed between the plurality of light emitting units 100. Not required in form.

In the configuration illustrated in FIG. 28, the wiring layer 190 electrically connects the light emitting element 120 included in the light source 220 of each light emitting unit 100. The wiring pattern of the wiring layer 190 is appropriately determined according to the driving method of the light emitting module 200. In this example, eight series circuits including two series connections of the light emitting elements 120 arranged in 4 rows and 4 columns are connected in parallel, respectively. Of course, the electrical connection of the plurality of light emitting elements 120 is not limited to this example, and for example, a circuit for dividing the plurality of light emitting elements 120 in the light emitting module 200 into two or more groups and driving them in units of these groups. May be configured.

By providing the wiring layer 190 on the lower surface side of the light emitting unit 100 in this way, for example, it becomes easy to electrically connect the plurality of light emitting elements 120 in the light emitting module 200 to each other. In particular, in the example shown in FIG. 28, the wiring layer 190 includes a positive electrode 191 and a negative electrode 192 formed as a portion of the wiring having a relatively large area. According to such a configuration, the positive electrode 191 and the negative electrode 192 provided on the light emitting module 200 side can be connected to the driver or the like on the substrate by soldering or the like without forming a complicated wiring pattern on the substrate side supporting the light emitting module 200. By electrically connecting, it is possible to obtain an electrical connection between the plurality of light emitting elements 120 in the light emitting module 200 and the driver.

FIG. 29 shows an example in which the light emitting module 200 is connected to the wiring board. The light emitting module according to the embodiment of the present disclosure may further include a wiring board 260 as illustrated in FIG. The wiring board 260 is located on the lower surface side of the light emitting module 200, that is, on the side opposite to the upper surface 210 a of the light guide body 210, and is connected to the wiring layer 190 of the light emitting unit 100.

In the configuration illustrated in FIG. 29, the wiring board 260 has an insulating base material 265, a wiring layer 261 on the insulating base material 265, a coating layer 263, a plurality of vias 264, and a protective member 266. In this example, the wiring layer 261 is located on the main surface of the insulating base material 265 on the side opposite to the light emitting unit 100. The coating layer 263 covers at least a part of the wiring layer 261 with a predetermined thickness, and has a function of protecting the wiring layer 261.

As shown in FIG. 29, here, a third joining member 268 formed of resin or the like is interposed between the light emitting module 200 and the wiring board 260, and the light emitting module 200 is wired by the joining member 268. It is fixed to the substrate 260. As schematically shown in FIG. 29, each of the plurality of vias 264 penetrates the insulating base material 265 and electrically connects the above-mentioned wiring layer 261 to the wiring layer 190 of the light emitting module 200. The protective member 266 is provided so as to correspond to a plurality of vias 264 on the main surface side of the insulating base material 265 opposite to the light emitting unit 100, and is located around the vias 264 and the vias 264 of the wiring layer 261. Protect the parts.

For example, a driver for driving the light emitting module 200 on the wiring board 260 is connected to the wiring layer 261 of the wiring board 260. As a result, an electrical connection is formed between the plurality of light emitting elements 120 and the driver via the wiring layer 261 and the via 264 of the wiring board 260. According to this embodiment, since the wiring layer 190 having a connection with each light emitting element 120 can be provided on the light emitting module 200 side, local dimming or the like can be performed without forming a complicated wiring pattern on the wiring board 260 side. The required connection can be easily formed. Since the wiring layer 190 can have a larger area than the lower surface 124b of the electrode 124 of each light emitting element 120, it is relatively easy to form an electrical connection to the wiring board 260. When the light emitting unit 100 in the light emitting module 200 does not have the wiring layer 190, the via 264 of the wiring board 260 may be connected to the electrode 124 of the light emitting element 120.

In this way, by providing the wiring layer 190 on the side opposite to the upper surface 210a of the light guide body 210, that is, on the lower surface 100b side of the light emitting unit 100, wiring is formed on the light emitting module 200 side including the plurality of light emitting elements 120. Therefore, it is not necessary to form an electrical connection between the light emitting element 120 and the wiring board 260. In other words, the connection between the light emitting module 200 or the light emitting unit 100 and the power supply or the like becomes easy. That is, surface emission can be easily obtained by connecting the wiring board 260 connected to the power supply or the like to the light emitting module 200. In particular, by combining a plurality of light emitting modules 200 to construct a larger planar light source and driving the plurality of light emitting elements 120 in units of, for example, the light emitting module 200, the large planar light source is operated by local dimming. Can be done. Of course, a wiring pattern that drives the light emitting element 120 in units of one or more light emitting units 100 may be applied to the wiring layer 190.

The embodiments of the present disclosure are useful for various lighting light sources, vehicle-mounted light sources, display light sources, and the like. In particular, it can be advantageously applied to a backlight module directed to a liquid crystal display device. The light emitting module or the planar light source according to the embodiment of the present disclosure can be suitably used for a backlight for a display device of a mobile device, which is strictly required to reduce the thickness, a surface light emitting device capable of local dimming control, and the like.

10 1st hole part of the light guide body 11t, 11u 1st alignment mark 12v, 12w 2nd alignment mark 20 2nd hole part of the light guide body 31C Column of multiple module areas 31R Rows 51, 52 of multiple module areas Holes 61-66 Grooves 100 Light emitting unit 110 Light guide 120 Light emitting element 130 Light adjustment part 140 Light reflective member 150, 150S Translucent member 160, 180 Joining member 170 Coating member 190 Wiring layer 200 Light emitting module 210 Light guide 220 Light source 240 Light reflective member 300, 300A, 300B Light guide assembly substrate 310 Module area 311B, 311T 1st margin area 311L, 311R 2nd margin area 313 area (3rd margin area)
314 area (4th margin area)
340 Light Reflective Layer 400 Composite Substrate 510 1st Straight Blade 520 2nd Straight Blade 600 Planar Light Source CT, CU Aperture

Claims (16)

This is a process of preparing a light guide assembly substrate having a main surface.
The light guide assembly substrate is
A plurality of module regions arranged one-dimensionally or two-dimensionally on the main surface so as to form one or more rows and a plurality of columns in the first direction and the second direction, each of which has a light guide structure. With multiple module areas with
A pair of first margin regions located on the main surface at both ends of the plurality of rows in the second direction, respectively.
At least one of the pair of first margin regions includes a plurality of first alignment marks arranged in the first direction.
Each of the plurality of first alignment marks is arranged at a corresponding position between a pair of adjacent rows in the plurality of rows, and a step of preparing a light guide assembly substrate.
A step of arranging a plurality of light sources each including one or more light emitting elements in a corresponding one of the plurality of module regions so that light emitted from the one or more light emitting elements is incident.
With reference to the respective positions of the plurality of first alignment marks, among the plurality of columns of the plurality of module regions, at least one of the pair of first margin regions is left uncut. A method for manufacturing a light emitting module, which comprises a step of cutting the light guide assembly substrate along the second direction. In the step of cutting the light guide assembly substrate along the second direction, one of the first margin regions of the pair of first margin regions is left uncut, and the other first margin region is left uncut. The method for manufacturing a light emitting module according to claim 1, wherein the light emitting module is cut along the second direction. In the step of cutting the light guide assembly substrate along the second direction, the light guide assembly substrate is cut along the second direction while leaving both of the pair of first margin regions uncut. The method for manufacturing a light emitting module according to claim 1, wherein the light emitting module is cut. The plurality of module regions are arranged two-dimensionally on the main surface of the light guide assembly substrate so as to form a plurality of rows and a plurality of columns in the first direction and the second direction.
The light guide assembly substrate is
A pair of second margin regions located on the main surface at both ends of the plurality of rows in the first direction,
A plurality of second alignment marks arranged in the second direction in at least one of the pair of second margin regions on the light guide assembly substrate, each of which is adjacent to the plurality of rows. Further with a plurality of second alignment marks arranged at corresponding positions between a pair of rows,
After the step of cutting the light guide assembly substrate along the second direction, in each of the plurality of rows of the plurality of module regions with reference to the respective positions of the plurality of second alignment marks. The method for manufacturing a light emitting module according to any one of claims 1 to 3, further comprising a step of cutting the light guide assembly substrate along the first direction. The method for manufacturing a light emitting module according to claim 4, wherein in the step of cutting the light guide assembly substrate along the first direction, both of the pair of second margin regions are cut. In the step of cutting the light guide assembly substrate along the first direction, at least one of the pair of second margin regions is left uncut, and the light guide assembly is assembled. The method for manufacturing a light emitting module according to claim 4, wherein the substrate is cut along the first direction. The method for manufacturing a light emitting module according to any one of claims 4 to 6, wherein the step of cutting the light guide assembly substrate along the first direction is performed by a first straight blade. The method for manufacturing a light emitting module according to claim 7, wherein the step of cutting the light guide assembly substrate along the second direction is performed by a second straight blade. The method for manufacturing a light emitting module according to claim 8, wherein the length of the second straight blade is different from the length of the first straight blade. The method for manufacturing a light emitting module according to claim 9, wherein the second straight blade is shorter than the first straight blade. Two sets of the plurality of second alignment marks are provided.
One set of the two sets of the plurality of second alignment marks is arranged in one of the pair of second margin regions.
The other set of the two sets of the plurality of second alignment marks is arranged in the other of the pair of second margin regions.
The step of cutting the light guide assembly substrate along the first direction is according to any one of claims 4 to 10, wherein the positions of the plurality of second alignment marks of the two sets are used as a reference. How to manufacture a light emitting module. The method for manufacturing a light emitting module according to any one of claims 4 to 11, wherein the light guide assembly substrate further includes a plurality of third margin regions located between the plurality of rows. The method for manufacturing a light emitting module according to any one of claims 4 to 11, wherein each of the plurality of rows of the light guide assembly substrate is arranged in contact with adjacent rows. Two sets of the plurality of first alignment marks are provided.
One set of the two sets of the plurality of first alignment marks is arranged in one of the pair of first margin regions.
The other set of the two sets of the plurality of first alignment marks is arranged in the other of the pair of first margin regions.
The step of cutting the light guide assembly substrate along the second direction is according to any one of claims 1 to 13, wherein the positions of the plurality of first alignment marks of the two sets are used as a reference. How to manufacture a light emitting module. The method for manufacturing a light emitting module according to any one of claims 1 to 14, wherein the light guide assembly substrate further includes a plurality of fourth margin regions located between the plurality of rows. The method for manufacturing a light emitting module according to any one of claims 1 to 14, wherein in the light guide assembly substrate, each of the plurality of rows is arranged in contact with adjacent rows.

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