JP6520996B2 - Light emitting device and method of manufacturing the same - Google Patents

Description

  The present invention relates to a light emitting device and a method of manufacturing the same.

  A light emitting device using a light emitting element is widely used as a headlight of a vehicle or illumination inside and outside the room. As one example, the light emitting device includes a circuit board, a light emitting element mounted on the upper surface of the circuit board, a phosphor resin layer disposed on the top surface of the light emitting element, and a light emitting element disposed on the top surface of the phosphor resin layer A diffusion resin layer for diffusing the irradiated light, a first reflection material provided on the upper surface of the circuit board to seal the side surface of the light emitting element, and a second reflection material surrounding the side surface of the diffusion resin layer (See Patent Document 1). In the light emitting device configured in this way, a part of the light emitted from the light emitting element is wavelength-converted by the phosphor in the phosphor resin layer, and the other light from the light emitting element is fluorescence in the phosphor resin layer It is emitted to the outside as direct radiation without being wavelength-converted to the body.

  The light emitting device described above has a configuration in which both the phosphor resin layer and the diffusion resin layer are formed of resin. The phosphor resin layer is larger in area than the diffusion resin layer, and is formed to exceed the area of the top surface of the light emitting element. Furthermore, a part of the second reflector is disposed above the top surface of the light emitting element. Therefore, it is equipped with the structure which can irradiate light to the upper narrower range.

International Publication No. 2014/081042

  However, in the light emitting device proposed in Patent Document 1, since the light emitting surface of the light emitting device is formed of resin, there is a possibility that the resin member to be the light emitting surface may be deteriorated by long-term use.

  An object of the embodiments of the present invention is to provide a light emitting device in which the light emitting surface is not easily deteriorated and a method of manufacturing the same.

  A light emitting device according to an embodiment of the present invention includes a light emitting element having an upper surface as a light extraction surface, and a first light transmitting property provided by bonding to the upper surface of the light emitting element and formed of a resin material containing a phosphor. Member, and a second light transmitting member provided by bonding to the upper surface of the first light transmitting member and made of a glass material, and the lower surface peripheral edge of the first light transmitting member is seen in plan view The outer peripheral edge of the second light transmitting member is positioned outside the upper peripheral edge of the light emitting element, and the lower surface peripheral edge of the second light transmitting member coincides with the upper edge of the first light transmitting member in plan view The upper surface peripheral edge of the second light transmitting member is located inside the peripheral edge, and the upper surface peripheral edge of the second light transmitting member is located inside the upper surface peripheral edge of the first light transmitting member in plan view.

  A light emitting device according to an embodiment of the present invention includes a light emitting element having an upper surface as a light extraction surface, and a first light transmitting member provided by bonding to the upper surface of the light emitting element and including a phosphor-containing resin material. A light transmitting member, and a second light transmitting member provided by bonding to the upper surface of the first light transmitting member and formed of a glass material, and the upper surface peripheral edge of the first light transmitting member is The area of the lower surface of the first light transmitting member is larger than the area of the upper surface of the light emitting element, and coincides with the lower surface peripheral edge of the second light transmitting member in plan view. The area is smaller than the area of the upper surface of the light emitting element.

  In the method of manufacturing a light emitting device according to an embodiment of the present invention, the upper surface of a flat plate-like first light transmitting member aggregate made of a resin material containing a phosphor and a harder surface than the first light transmitting member aggregate Preparing a plate-like light-transmissive member assembly joined to a lower surface of a flat-plate-like second light-transmissive member assembly made of a material; and in the light-transmissive member assembly, the second light transmission Forming a groove on the upper surface of the elastic member assembly, and dividing the light transmitting member assembly by the groove, and forming a plurality of light transmitting members having a first light transmitting member and a second light transmitting member And a lower surface of the first light transmissive member and an upper surface of the light emitting element such that the lower surface peripheral edge of the first light transmissive member in the light transmissive member is positioned outside the upper surface peripheral edge of the light emitting element. And bonding. The second light transmitting member can be formed of a glass material.

  According to the light emitting device according to the embodiment of the present invention, deterioration of the light emitting surface is less likely to occur. Moreover, according to the method of manufacturing a light emitting device according to the embodiment of the present invention, it is possible to provide a light emitting device in which deterioration of the light emitting surface is less likely to occur.

FIG. 1 is a plan view schematically showing a light emitting device according to an embodiment. It is sectional drawing in the II-II line of the light-emitting device of FIG. It is a disassembled perspective view which decomposes | disassembles and shows the light-emitting device which concerns on embodiment typically. It is sectional drawing which shows typically the light emission state of the light-emitting device which concerns on embodiment. It is explanatory drawing which shows typically the translucent member assembly to which the 1st translucent member assembly and the 2nd translucent member assembly were joined in the manufacturing method of the light-emitting device which concerns on embodiment. It is explanatory drawing which shows typically the state which forms a groove part in the upper surface of a 2nd translucent member aggregate | assembly in the manufacturing method of the light-emitting device which concerns on embodiment. It is explanatory drawing which shows typically the state which formed the groove part in the upper surface of a 2nd translucent member assembly in the manufacturing method of the light-emitting device which concerns on embodiment. It is explanatory drawing which shows typically the state which cut | disconnects a 1st translucent member aggregate | assembly in the groove part formed in the process of the manufacturing method of the light-emitting device which concerns on embodiment. It is an explanatory view showing typically the state where the translucent member was separated into pieces in the manufacturing method of the light emitting device concerning an embodiment. It is explanatory drawing which shows typically the state which joined the light emitting element and the translucent member in the manufacturing method of the light-emitting device which concerns on embodiment. In the manufacturing method of the light-emitting device which concerns on embodiment, it is explanatory drawing which shows typically the state which provided the light-reflective member around the light emitting element and the translucent member. In the manufacturing method of the light-emitting device which concerns on embodiment, it is explanatory drawing which shows typically the state cut | disconnected for every light-emitting device. It is a flowchart which shows the manufacturing method of the light-emitting device which concerns on embodiment. It is a top view which shows the light-emitting device showing the modification of embodiment typically. It is a top view which shows typically the light-emitting device showing the other modification of embodiment. It is explanatory drawing of the manufacturing process which shows the modification of the translucent member in the light-emitting device of embodiment. It is sectional drawing which shows the modification of the translucent member in the light-emitting device of embodiment. It is sectional drawing which shows typically the modification of the division position of the 1st translucent member in the light-emitting device of embodiment, and a 2nd translucent member. It is sectional drawing which shows typically the other modification of the division position of the 1st translucent member in the light-emitting device of embodiment, and a 2nd translucent member. It is a top view which shows typically the positional relationship of a translucent member and a light emitting element in the light-emitting device of embodiment. It is the expanded sectional view in the XB-XB line of FIG. 10A. It is the expanded sectional view in the XC-XC line of Drawing 10A.

  Hereinafter, the light emitting device according to the embodiment will be described with reference to the drawings. Note that the drawings referred to in the following description schematically show the embodiment, and therefore the scale, intervals, positional relationship, etc. of each member are exaggerated, or some of the members are not shown. There is a case. Further, in the following description, the same names and reference numerals indicate the same or the same members in principle, and the detailed description will be appropriately omitted. Furthermore, the directions shown in the figures indicate relative positions between components, and are not intended to indicate absolute positions.

An example of the configuration of the light emitting device according to the embodiment will be described with reference to FIGS. 1 to 4.
The light emitting device 100 includes a light emitting element 30 whose upper surface is a light extraction surface, a first light transmitting member 1 which is provided in contact with the upper surface of the light emitting element 30 and is formed of a resin material containing a phosphor. A second light transmitting member 2 which is provided in contact with the upper surface of the first light transmitting member 1 and is made of a glass material. The lower surface peripheral edge of the first light transmissive member 1 is positioned outside the upper surface peripheral edge of the light emitting element 30 in plan view, and the lower surface peripheral edge of the second light transmissive member 2 is of the first light transmissive member 1 in plan view It is located inside the upper surface periphery of the first light transmissive member 1 in agreement with the upper surface peripheral edge, the upper surface peripheral edge of the second light transmissive member 2 is located inside the upper surface periphery of the first light transmissive member in plan view Do.
In the present embodiment, the first light transmitting member 1 and the second light transmitting member 2 are formed as an integral light transmitting member 10. The translucent member 10 includes a first translucent member 1 and a second translucent member 2 each having an upper surface and a lower surface, and the upper surface 5 of the first translucent member and the lower surface of the second translucent member And 8 are joined to constitute the light transmitting member 10. Light from the light emitting element 30 is incident from the lower surface 7 of the first light transmissive member and emitted from the upper surface 3 of the second light transmissive member to the outside.

(Light emitting element)
In the present embodiment, the light emitting element 30 is flip-chip mounted on the conductor wiring of the substrate 40 via the bonding member. The light emitting element 30 has a pair of electrodes on the same surface side, the surface on which the pair of electrodes is formed is the lower surface, and the upper surface 31 facing the lower surface is the main light extraction surface. The light emitting element 30 can use a well-known thing, for example, it is preferable to use a light emitting diode and a laser diode. Moreover, the light emitting element 30 can select the thing of arbitrary wavelengths. For example, the blue, the green light emitting element, the nitride semiconductor _{(In X Al Y Ga 1-} X-Y N, 0 ≦ X, 0 ≦ Y, X + Y ≦ 1), be used those using GaP it can. Further, as the red light emitting element, GaAlAs, AlInGaP or the like can be used besides the nitride based semiconductor element. In addition, the light emitting element 30 can also use the semiconductor light emitting element which consists of materials other than the above-mentioned. The composition, emission color, size, number, etc. of the light emitting elements 30 can be appropriately selected according to the purpose. The light emitting element 30 preferably has a pair of positive and negative electrodes on the same side. Thereby, the light emitting element 30 can be flip chip mounted on the substrate 40. In this case, the surface facing the surface on which the pair of electrodes is formed is the main light extraction surface of the light emitting element. When the light emitting element 30 is mounted face up on the substrate 40, the surface on which the pair of electrodes are formed is the main light extraction surface of the light emitting element 30. The light emitting element 30 is electrically connected to the substrate 40, for example, via a bonding member such as a bump.

(Translucent member)
The translucent member 10 is provided in contact with the upper surface 31 of the light emitting element 30 included in the light emitting device 100. The translucent member 10 includes a first translucent member 1 and a second translucent member 2 each having an upper surface and a lower surface, and the upper surface 5 of the first translucent member and the lower surface of the second translucent member And 8 are joined to constitute the light transmitting member 10. The first light transmitting member 1 is a resin layer containing a phosphor, the second light transmitting member 2 is a glass plate, and the second light transmitting member 2 is a support of the first light transmitting member 1. Have a role. The translucent member 10 is formed in a convex shape in which the area of the upper surface 3 of the second translucent member is smaller than the lower surface 7 of the first translucent member, and the side surface 6 of the first translucent member is a plan view And the outer side of the side surface 4 of the second light-transmissive member.
The thickness of the translucent member 10 is, for example, about 60 to 300 μm. Among the thicknesses described above, the thickness of the second light transmitting member 2 is, for example, about 50 to 90% of the thickness of the light transmitting member 10.

(First translucent member)
The first translucent member 1 is provided in contact with the upper surface 31 of the light emitting element 30.
The first translucent member 1 is formed of a resin material containing a phosphor 11. The first light transmitting member 1 is, for example, flat and has an upper surface 5, a lower surface 7 opposed to the upper surface 5, and a side surface 6 in contact with the upper surface 5 and the lower surface 7.
The lower surface 7 of the first translucent member is a surface on which light from at least one light emitting element 30 provided in the light emitting device 100 is incident. The lower surface 7 is formed to have a larger area than the sum of the areas of the upper surfaces 31 of the one or more light emitting elements 30 joined to the lower surface 7. The lower surface 7 of the first light transmissive member is formed to be substantially flat.

  In the present embodiment, the upper surface 5 of the first light transmitting member is formed to be substantially parallel to the lower surface 7. The side surface 6 of the first translucent member is formed in a plane substantially perpendicular to the lower surface 7 of the first translucent member. Since the side surface 6 is formed substantially perpendicular to the lower surface 7, creeping up of the adhesive 15 for bonding the first light-transmissive member 1 and the light emitting element 30 to the side surface at the time of manufacturing the light emitting device 100 is suppressed. can do. By suppressing the creeping up of the adhesive 15 to the side surface 6, it is possible to prevent the light emitted from the light emitting element 30 from leaking out to the outside without passing through the first light transmitting member 1.

  The lower surface 7 of the first light transmissive member is formed to be larger than the upper surface 31 of the light emitting element 30 so as to entirely cover the upper surface 31 of the light emitting element 30. That is, the periphery of the lower surface 7 of the first light transmitting member is located outside the periphery of the upper surface 31 of the light emitting element 30 in plan view. By forming the lower surface 7 of the first light-transmissive member with an area larger than the upper surface 31 of the light-emitting element 30, light emitted from the light-emitting element 30 can be incident on the first light-transmissive member 1 without loss. it can. The lower surface 7 of the first light transmissive member has a large area in the range of 105 to 150% with respect to the sum of the areas on the upper surface 31 of at least one light emitting element 30 joined to the lower surface 7. It is formed. The first light-transmissive member 1 receives light emitted from the light emitting element 30 from the lower surface 7 and causes the light to enter the second light-transmissive member 2 from the lower surface 8 of the second light-transmissive member.

  In addition, the first light transmitting member 1 is formed of a resin material containing a phosphor 11 capable of wavelength converting at least a part of the light emitted from the light emitting element 30. Examples of the resin material include silicone resin, epoxy resin, phenol resin, polycarbonate resin, acrylic resin, TPX resin, polynorbornene resin, or modified resin or hybrid resin thereof. Among them, it is preferable to contain a flexible silicone resin which is excellent in heat resistance and electrical insulation.

As the fluorescent substance 11, the fluorescent substance 11 used in this field | area can be selected suitably. As a phosphor that can be excited by a blue light emitting element or an ultraviolet light emitting element, for example, a cerium-activated yttrium aluminum garnet-based phosphor (YAG: Ce), a cerium-activated lutetium aluminum garnet-based phosphor Nitrogen-containing calcium aluminosilicate phosphor activated with (LAG: Ce), europium and / or chromium (CaO-Al ₂ O ₃ -SiO ₂ : Eu), europium activated silicate-based phosphor ((Sr, Ba) ₂ SiO ₄ : Eu), β sialon phosphor, nitride phosphor such as CASN phosphor (CaAlSiN ₃ : Eu), SCASN phosphor ((Sr, Ca) AlSiN ₃ : Eu), KSF phosphor phosphor _{(K 2 SiF 6: Mn)} , sulfide phosphors, and the like quantum dot phosphor. By combining these phosphors 11 with a blue light emitting element or an ultraviolet light emitting element, light emitting devices of various colors (for example, white light emitting devices) can be manufactured. When a light emitting device 100 capable of emitting white light is used, the white light is adjusted to be white depending on the type and concentration of the phosphor 11 contained in the first light transmitting member 1. The concentration of the phosphor 11 contained in the first light transmitting member 1 is, for example, about 30 to 80 mass%.

Furthermore, the first translucent member 1 may contain a light diffusing material. For example, titanium oxide, barium titanate, aluminum oxide, silicon oxide or the like can be used as the light diffusion material. In the first light-transmissive member 1, the phosphors 11 may be dispersed in the entire first light-transmissive member 1, or may be unevenly distributed on the upper surface or the lower surface side of the first light-transmissive member 1. .
In addition, by using a blue light emitting element for the light emitting element 30 and using a nitride-based semiconductor containing a large amount of red component for the phosphor, a light emitting device that emits red light can be obtained. Furthermore, by using a blue light-emitting element as the light-emitting element 30 and using a YAG-based fluorescent substance and a nitride-based fluorescent substance containing a large amount of red component as the fluorescent substance, it is possible to emit amber color. Amber color refers to the area consisting of the long wavelength area of yellow and the short wavelength area of yellow red in JIS standard Z8110, and the area sandwiched by the yellow area and the short wavelength area of yellow red according to JIS standard Z9101 of the safety color. The chromaticity range of is applicable. For example, it is a region located in the range of 580 nm to 600 nm as a dominant wavelength. Many phosphors that emit red and amber colors have low light exchange efficiency, and in order to obtain a desired color tone, it is preferable to increase the phosphor concentration. When it is set as the light-emitting device which light-emits red or an amber color, the density | concentration of the fluorescent substance contained in the 1st translucent member 1 is about 60-80 mass%, for example.

(Second translucent member 2)
The second light transmitting member 2 is provided in contact with the upper surface of the first light transmitting member 1. The second light transmitting member 2 is formed of a glass material. The second light transmitting member 2 has, for example, a flat plate shape, and includes the upper surface 3, the lower surface 8 facing the upper surface 3, and the side surface 4 in contact with the upper surface 3 and the lower surface 8. The lower surface 8 of the second light transmitting member is formed to have a smaller area (for example, a smaller area in FIGS. 1 to 4) than the upper surface 5 of the first light transmitting member or smaller than that of the first light transmitting member 1. That is, in the second light transmitting member 2, the periphery of the lower surface 8 of the second light transmitting member coincides with the edge of the upper surface 5 of the first light transmitting member in plan view or from the periphery of the upper surface 5 of the first light transmitting member Also, the peripheral edge of the top surface 3 of the second light transmitting member is positioned inside the peripheral edge of the top surface 5 of the first light transmitting member in plan view. The area of the upper surface 3 of the second light transmitting member is preferably smaller than the sum of the areas of the upper surfaces 31 of one or more light emitting elements 30 provided in the light emitting device 100. Furthermore, the area of the upper surface 3 of the second light-transmissive member is preferably 70% or less, and more preferably 50% or less, with respect to the area of the lower surface 7 of the first light-transmissive member. Thus, by making the area of the upper surface 3 of the second light transmitting member smaller than the area of the lower surface 7 of the first light transmitting member, light emitted from the lower surface 7 of the first light transmitting member The emission light from the element 30 can be emitted from the upper surface 3 of the second light-transmissive member (that is, the light emitting surface of the light emitting device 100) in an area smaller than the upper surface 31 of the light emitting element 30. That is, the area of the light emitting surface of the light emitting device 100 is narrowed by the second light transmitting member 2, and it becomes possible to illuminate a further distance as a light emitting device with higher luminance.

  The side surface 4 of the second light transmitting member is formed substantially perpendicular to the upper surface 3 of the second light transmitting member. The side surface 4 is formed substantially perpendicular to the upper surface 3 of the second light transmissive member, whereby the light reflective member 20 covering the side surface 4 of the second light transmissive member at the time of manufacture of the light emitting device 100. The creeping of the upper surface 3 can be suppressed. The side surface 4 of the second light-transmissive member is, for example, a range of 90 degrees plus or minus 5 degrees with respect to the upper surface 3 as an angle at which the creeping up of the light reflective member 20 can be suppressed. It is almost vertical. When the side surface 4 of the second light transmitting member is formed substantially perpendicular to the upper surface 3, the upper surface 3 of the second light transmitting member is the light emitting surface of the light emitting device 100. The light emitting device 100 can have a clear boundary between the light emitting portion and the non-light emitting portion.

  The thickness of the second light transmitting member 2 is preferably, for example, equal to or greater than the thickness of the first light transmitting member 1. For example, the second light transmitting member 2 is about 30 to 270 μm. The second light transmitting member 2 is formed of a glass material, and as the glass material, for example, borosilicate glass, quartz glass, sapphire glass, calcium fluoride glass, aluminoborosilicate glass, oxynitride glass, chalcogenide glass, etc. It can be mentioned. In addition, the glass material to be used may be provided with AR (Anti Reflection) coating for anti-reflection on the upper surface and / or the lower surface. Further, it is preferable that the second light transmitting member 2 has a refractive index close to that of the first light transmitting member 1.

As described above, the first light transmitting member 1 is a resin layer containing the phosphor 11, the second light transmitting member 2 is a glass plate, and the second light transmitting member 2 is a first light transmitting member. It functions as a support of the sexing member 1. For this reason, it is possible to increase the concentration of the phosphors 11 contained in the first translucent member 1 and to form the phosphor layer (that is, the thickness of the second translucent member 2) thin.
Further, since the first light-transmissive member 1 is formed of a resin material, it has more flexibility than the second light-transmissive member 2 formed of a glass material, and is less likely to be damaged even if the thickness thereof is reduced. Therefore, even if the area of the upper surface 5 of the first light transmitting member is larger than the area of the lower surface 8 of the second light transmitting member, cracking, chipping, etc. of the second light transmitting member 2 during manufacture or use Damage to the As a result, the top surface area of the second light transmitting member 2 can be made smaller than the bottom surface area of the first light transmitting member 1, and the light emitting device 100 with higher brightness can be obtained.
Furthermore, in the light-emitting device 100 with high luminance in which the light-emitting surface is narrowed as described above, since the second light-transmissive member 2 is formed of a glass material, the light-emitting device is unlikely to cause deterioration of the light-emitting surface due to long-term use. It can be 100.

(Adhesive material)
The light emitting element 30 and the light transmitting member 10 can be bonded by an adhesive 15. The adhesive 15 is provided continuously from at least a part of the top surface to the side surface of the light emitting element 30 and interposed between the light reflective member 20 and the side surface of the light emitting element 30. The upper surface of the adhesive 15 interposed between the light reflective member 20 and the side surface of the light emitting element 30 is provided in contact with the lower surface 7 of the first light transmissive member. The adhesive 15 is preferably made of a translucent material capable of guiding the light emitted from the light emitting element 30 to the first translucent member 1. The adhesive 15 may be a known adhesive such as an epoxy resin or a silicone resin, an organic adhesive of high refractive index, an inorganic adhesive, an adhesive of low melting point glass, or the like. The adhesive 15 preferably extends from the top surface 31 to the side surface of the light emitting element 30 and is provided as the fillet 16. The fillet 16 is preferably in contact with both the lower surface 7 of the first light transmissive member and the side surface of the light emitting element 30 and has a concave curved surface on the light reflective member 20 side. With such a shape, light emitted from the light emitting element 30 is reflected by the fillet surface of the adhesive 15 and easily guided to the first light transmissive member 1.
The translucent member 10 and the light emitting element 30 may be joined by pressure bonding or the like without using the adhesive 15.

  The light reflective member 20 reflects light directed to other than the upper surface 3 of the second light transmissive member so as to emit light from the upper surface 3 of the second light transmissive member, as shown in FIG. 1, FIG. 2 and FIG. And covers the side surfaces of the light emitting element 30 to protect the light emitting element 30 from external force, dust, gas and the like. The light reflecting member 20 exposes the upper surface 3 of the light transmitting member 10 (that is, the upper surface 3 of the second light transmitting member) as a light emitting surface of the light emitting device 100, and the light transmitting member 10, the light emitting element 30, and It is provided to cover a part of the upper surface of the substrate 40. Specifically, the light reflecting member 20 includes the side surface 4 of the second light transmitting member, the upper surface 5 and the side surface 6 of the first light transmitting member, the side surface of the adhesive 15, and the side surface and the lower surface of the light emitting element 30. It is provided to cover. The light extraction surface of the light emitting element 30 is exposed from the light reflective member 20 and joined to the lower surface 7 of the first light transmissive member, so that light can be incident on the light transmissive member 10 . The light reflective member 20 is made of a member capable of reflecting the light from the light emitting element 30, and the light from the light emitting element 30 is reflected at the interface between the light transmissive member 10 and the light reflective member 20 to transmit light. It injects into the sex member 10. Thus, the light emitted from the light emitting element 30 is reflected by the light reflecting member 20 and passes through the light transmitting member 10, and the upper surface 3 of the second light transmitting member which is the light emitting surface of the light emitting device 100. It is emitted from the outside.

  Here, it is preferable that the upper surface of the light reflecting member 20 be equal to the height of the upper surface 3 of the second light transmitting member or lower than the upper surface 3 of the second light transmitting member. The light emitted from the upper surface 3 of the second light transmissive member, which is the light emission surface of the light emitting device 100, also spreads in the lateral direction. Therefore, when the upper surface of the light reflecting member 20 is higher than the height of the upper surface 3 of the second light transmitting member, the light emitted from the upper surface 3 of the second light transmitting member is of the light reflecting member 20. The light is reflected on the upper surface, resulting in a distribution of light distribution. Therefore, the light reflecting member 20 covers the outer periphery of the side surface 4 of the second light transmitting member, and makes the height of the upper surface of the light reflecting member 20 equal to or lower than the upper surface 3 of the second light transmitting member. Set up. By doing so, the light emitted from the light emitting element 30 can be efficiently extracted to the outside, which is preferable.

  The light reflective member 20 is made by incorporating a light reflective substance in a base material made of silicone resin, modified silicone resin, epoxy resin, modified epoxy resin, acrylic resin, or hybrid resin containing at least one of these resins. It can be formed. As the light reflective substance, titanium oxide, silicon oxide, zirconium oxide, yttrium oxide, yttria stabilized zirconia, potassium titanate, alumina, aluminum nitride, boron nitride, mullite or the like can be used. Since the light reflecting member 20 has different amounts of light reflection and transmission depending on the concentration and density of the light reflecting substance, the concentration and density may be appropriately adjusted according to the shape and size of the light emitting device 100. In addition, when the light reflective member 20 is made of a material having heat dissipation as well as light reflectivity, it is possible to improve the heat dissipation while giving the light reflectivity. Such materials include aluminum nitride and boron nitride having high thermal conductivity.

(substrate)
The substrate 40 mounts at least one light emitting element 30 and electrically connects the light emitting device 100 to the outside. The substrate 40 is configured to include a flat support member and a conductor wiring disposed on the surface and / or inside of the support member. In addition, according to the structure of the electrode of the light emitting element 30, and the board | substrate 40, structures, such as a shape of an electrode and a magnitude | size, are set according to a size. In addition, the substrate 40 may be provided with a heat dissipation terminal which is electrically independent of the light emitting element 30 on the lower surface. It is preferable that the heat dissipation terminal be formed to have an area larger than the sum of the top surface areas of all the light emitting elements 30 included in the light emitting device 100, and be disposed so as to overlap with the region directly below the light emitting element 30. . With such a configuration of the heat dissipation terminal, the light emitting device 100 can be made more excellent in heat dissipation.

In addition, it is preferable to use an insulating material for the support member of the substrate 40, and it is preferable to use a material that does not easily transmit light emitted from the light emitting element 30, external light, and the like. The substrate 40 is preferably made of a material having a certain degree of strength. Specific examples thereof include ceramics such as alumina, aluminum nitride and mullite, resins such as phenol resin, epoxy resin, polyimide resin, BT resin (bismaleimide triazine resin), and polyphthalamide (PPA). The support member may have a structure having a cavity. Thereby, the above-mentioned light reflective member 20 can be dropped and hardened, etc., and can be formed easily.
The conductor wiring and the heat dissipation terminal can be formed using, for example, a metal such as Cu, Ag, Au, Al, Pt, Ti, W, Pd, Fe, Ni, or an alloy containing these. Such conductor wiring can be formed by electrolytic plating, electroless plating, vapor deposition, sputtering or the like.

  Since the light emitting device 100 has the configuration described above, as an example, the light emitted from the light emitting element 30 can be further used when used as a headlight of a motorcycle, an automobile or the like, or a vessel, an aircraft or the like. It can be irradiated far. That is, as shown in FIG. 4, in the light emitting device 100, when light is emitted from one or more light emitting elements 30, the light propagates in the light transmitting member 10 without being reflected by the light reflecting member 20. There are light directed directly to the upper surface 3 of the second light-transmissive member and light emitted from the upper surface 3 of the second light-transmissive member by being reflected by the light reflective member 20. Then, in the light emitting device 100, by making the area of the lower surface 7 of the first light transmitting member larger than the sum of the upper surface area of the light emitting element 30, light emitted from the light emitting element 30 can be received without loss. it can. Furthermore, the area of the upper surface 3 of the second light transmitting member is smaller than the sum of the areas of the upper surface 31 of the light emitting element 30 and smaller than the area of the lower surface 7 of the first light transmitting member. Therefore, the light emitted from the light emitting element 30 is collected by the light transmitting member 10 on the upper surface 3 of the second light transmitting member. As a result, it is possible to provide the light emitting device 100 which can emit light with high brightness and more distantly, which is suitable for a high beam application of a headlight and the like. In addition, in FIG. 4, the irradiation direction of typical light is typically shown by the arrow.

[Method of manufacturing light emitting device]
Next, a method S10 of manufacturing the light emitting device 100 shown in the flowchart of FIG. 6 will be described with reference to FIGS. 5A to 5H.
(Step S11 of preparing an assembly of translucent members)
As shown in FIG. 5A, the upper surface of a flat first light transmitting member aggregate A1 made of a resin material containing a phosphor and a second light transmitting material made of a material harder than the first light transmitting member aggregate A1. A flat light transmitting member assembly A10 is prepared, which is joined to the lower surface of the light emitting member assembly A2. The first light-transmissive member aggregate A1 is a phosphor-containing resin layer containing a phosphor 11 for wavelength-converting a part of light from the light emitting element 30, and the second light-transmissive member aggregate A2 Is formed or processed into a flat plate shape. For example, the translucent member assembly A10 can be formed by printing a phosphor-containing resin layer on the lower surface of the glass plate. The first light-transmissive member aggregate A1 may not only be in direct contact with the lower surface of the second light-transmissive member aggregate A2, but may be joined via another member such as an adhesive. For example, pressure bonding, fusion bonding, sintering, adhesion with an organic adhesive, and adhesion with an inorganic adhesive such as low melting point glass can be mentioned. A printing method, a compression molding method, a phosphor electrodeposition method, a phosphor sheet method or the like can be used as a method of forming the first light transmitting member assembly A1. In the printing method, a paste containing a phosphor, a binder and a solvent is prepared, and the paste is applied to the lower surface of the second light transmitting member assembly A2 and dried to form a phosphor layer.
The first light transmitting member assembly A1 and the second light transmitting member assembly A2 are provided to the light transmitting member 10 including the first light transmitting member 1 and the second light transmitting member 2 through each process described later. It is formed. The lower surface of the first light transmitting member assembly A1 forms the lower surface of the light transmitting member 10, and the upper surface of the second light transmitting member assembly A2 forms the upper surface of the light transmitting member 10.

(Groove formation process S12)
Next, as shown in FIGS. 5B and 5C, in the translucent member assembly A10, a groove Dt is formed by the blade Br1 of a processing machine or the like on the upper surface of the second translucent member assembly A2. The groove Dt may penetrate the second light transmitting member assembly A2 and may or may not reach the first light transmitting member assembly A1. In the present embodiment, the groove portion Dt reaches the first light-transmissive member aggregate A1, and the first light-transmissive member aggregate A1 is exposed at the bottom surface of the groove portion Dt. Moreover, the groove part Dt formed at this process will comprise the side surface 4 of the 2nd translucent member in the translucent member 10. FIG. In the step of forming the groove portion Dt, processing is performed by the groove portion Dt so that the upper surface of the second light transmitting member assembly A2 has a rectangular area smaller than the upper surface 31 of the light emitting element 30. Further, since the second light transmitting member 2 is formed of a material harder than the first light transmitting member 1, it is easy to process when forming the groove portion by the blade Br1, and it is made of, for example, a high viscosity material such as resin. Thus, rectangular corners can be sharpened without being crushed. The groove Dt may be formed by another known method such as laser processing.
It is preferable that, for example, the second light transmitting member assembly A2 has a hardness in the range of 3 to 10 by Morse code. By setting this range, crushing or the like of the corner during processing can be suppressed.

(Translucent member forming step S13)
Subsequently, as shown in FIGS. 5D and 5E, the light-transmissive member assembly A10 is divided by the groove Dt, and the light-transmissive member 10 having the first light-transmissive member 1 and the second light-transmissive member 2 is provided. Get When this division is performed, a plurality of light transmitting members 10 in which the lower surface 7 on the first light transmitting member 1 side has a larger area than the upper surface of the light emitting element 30 will be obtained. In this step, the first light transmitting member set is divided into the light transmitting members 10 by the blade Br2 having a width narrower than that in which the groove Dt is formed at the position of the groove Dt. Body A1 is cut. The periphery of the lower surface 7 of the first light transmitting member in the divided light transmitting member 10 is formed to have an area larger than the sum of the areas of the upper surfaces 31 of the one or more light emitting elements 30 used in the light emitting device 100 Be done. The translucent member 10 thus obtained is formed in a convex shape in which the area of the upper surface 3 of the second translucent member is smaller than that of the lower surface 7 of the first translucent member. The cut surface of the first light-transmissive member assembly A1 is the side surface 6 of the first light-transmissive member in the light-transmissive member 10, and the groove Dt is the side surface 4 of the second light-transmissive member in the light-transmissive member 10. The side surface 6 of the first light-transmissive member is located outside the side surface 4 of the second light-transmissive member in plan view.

In addition, since 1st translucent member aggregate | assembly A1 is formed with the resin material, it is softer and is hard to be damaged rather than what was formed with the glass material. That is, since it is hard to produce a crack, a chipping, etc. at the time of division, thickness of the 1st translucent member can be formed thinner.
It is preferable that, for example, the first light transmitting member assembly A1 be used that has a hardness after curing in the range of A30 to D50 in Shore hardness. By setting this range, it is possible to suppress breakage such as cracking or chipping during manufacturing or in use while maintaining the strength when used as the light emitting device 100.
Furthermore, in the first light-transmissive member aggregate A1, the phosphors 11 are unevenly distributed on the lower surface side of the first light-transmissive member 1 (that is, the surface opposite to the bonding surface with the second light-transmissive member aggregate A2). In this case, in the above-described groove forming step S12, when the groove Dt reaches the first light-transmissive member aggregate A1, the first light-transmissive member aggregate A1 is exposed on the bottom surface of the groove Dt. The substantially phosphor-free region on the top side can be exposed. That is, even if the groove Dt reaches the first light-transmissive member aggregate A1 at the time of forming the groove, the amount of phosphors in the first light-transmissive member aggregate A1 does not change, resulting in a decrease in the amount of phosphors. Color shift and color unevenness can be suppressed.

(Step of preparing substrate and light emitting element)
The light emitting element 30 and the substrate 40 are prepared respectively. The light emitting element 30 and the substrate 40 may be prepared prior to the bonding step of the light transmitting member 10.
The substrate 40 is formed in a flat plate having a rectangular shape in a plan view, and for example, a conductor wiring and a heat dissipation terminal are provided on a support member. Further, in the present embodiment, the substrate 40 may be configured such that the cathode mark is provided along the one corner of the upper surface of the substrate with the same material as the electrode material which is a conductor wiring.
Then, the light emitting element 30 is mounted on the substrate 40. Here, one light emitting element 30 is mounted on the conductor wiring of the substrate 40 for each light emitting device 100 via a bonding member such as a bump.

(Bonding step S14 of translucent member)
As shown in FIG. 5F, the lower surface of the light transmissive member 10 and the light emission such that the lower surface peripheral edge of the first light transmissive member 1 in the light transmissive member 10 is positioned outside the peripheral edge of the upper surface 31 of the light emitting element 30 The upper surface 31 of the element 30 is joined.
In the present embodiment, the light emitting element 30 and the light transmitting member 10 are bonded by the adhesive 15. In bonding by the adhesive 15, first, the adhesive 15 is dropped on the upper surface 31 of the light emitting element 30, and the light transmitting member 10 is disposed on the adhesive 15. The dropped adhesive material 15 is pressed by the light-transmissive member 10, wets and spreads to the side surface of the light-emitting element 30, and forms a fillet 16 between the lower surface of the light-transmissive member 10 and the side surface of the light-emitting element 30. Provided. The amount and viscosity of the adhesive 15 to be dropped are appropriately adjusted to the extent that the fillet 16 is provided on the side surface of the light emitting element 30 and the adhesive 15 does not wet to the substrate 40.

  In the light-transmissive member 10, the lower surface 7 of the first light-transmissive member is bonded onto the light-emitting element 30 via the adhesive 15 disposed on the top surface of the light-emitting element 30. The light transmitting member 10 is formed such that the area of the lower surface 7 of the first light transmitting member is larger than the sum of the areas of the upper surfaces 31 of the one or more light emitting elements 30. It is preferable that the distance to the outer edge of the lower surface 7 of the light emitting member be equal. In addition, the translucent member 10 is the center of the entire one or more light emitting elements 30 arranged such that the center of the upper surface 3 of the second translucent member is rectangular as a whole in a plan view. It is preferable to arrange | position so that it may overlap substantially. In the translucent member 10 joined to the light emitting element 30, the area of the lower surface 7 of the first translucent member is larger than the sum of the areas of the upper surface 31 of the light emitting element 30. Therefore, the light transmitting member 10 takes in light emitted from the upper surface of the light emitting element 30 from the lower surface 7 of the first light transmitting member having a larger area than the upper surface 31 of the light emitting element 30, and the lower surface 7 of the first light transmitting member. It becomes a structure which can be light-guided to the upper surface 3 of the 2nd translucent member which becomes smaller than the upper surface 31 of the light emitting element 30, and is smaller.

(Light reflective member supply process S15)
Subsequently, as shown in FIG. 5G, a light reflective member 20 covering the light emitting element 30, the light transmissive member 10, and the substrate 40 is provided. The light emitting device 100 may have one or more types of light reflective members 20. The following is an example in which the light reflective member 20 is formed in two layers.
(First light reflective member supply step)
First, the light reflective member 20 is supplied to a height covering the light emitting element 30 and the substrate 40 and the light emitting element 30 and the adhesive 15 on the side surface. When the light reflective member 20 is disposed between the light emitting element 30 and the substrate 40, it is preferable to use a low linear expansion material. As a result, it is possible to relieve the thermal stress at the junction between the light emitting element 30 and the substrate 40.

(Second light reflective member supply step)
Next, the light reflective member 20 which covers the side surface of the translucent member 10 is supplied. The light reflective member 20 covers the side surface 4 of the second light transmissive member and the top surface 5 and the side surface 6 of the first light transmissive member. At this time, it is preferable that the light reflecting member 20 be dropped on the upper surface of the substrate 40 separated from the light transmitting member 10 so that the upper surface 3 of the second light transmitting member is exposed from the light reflecting member 20. Further, the light reflective member 20 is supplied so as to cover the surface of the light reflective member 20 previously supplied.
For the light reflective member 20, for example, a resin in which titanium oxide is contained in silicone resin is used here.

(Separation step S16)
As shown in FIG. 5H, after the formation of the light reflective member 20, the substrate 40 is cut for each unit of each light emitting device by a laser irradiation or a tool such as a blade to form the light emitting device 100. The light emitting device 100 manufactured by the above-described steps processes the light emitted from the one or more light emitting elements 30 from the lower surface 7 of the first light transmissive member which is larger than the sum of the areas in the upper surface 31 of the light emitting elements 30. The incident light can be emitted from the upper surface 3 of the second light transmitting member smaller than the lower surface 7 of the first light transmitting member to the outside as high-intensity light. Further, since the first light-transmissive member 1 is formed of a resin material, even if the difference in area between the first light-transmissive member 1 and the second light-transmissive member 2 is made large, The light transmissive member 1 is less likely to be broken and damaged, and the yield can be improved. Further, since the second light transmitting member is formed of a glass material, the light irradiation surface is hardly deteriorated even as the light emitting device 100, and the product quality is excellent.

(Modification)
The light emitting device 100 may be configured to include a plurality of light emitting elements 30, and the light transmitting member 10 may have various shapes. For example, as shown in FIG. 7, FIG. 8, and FIG. 9A to FIG. 9D, in the light emitting devices 100A and 100B, the light emitting element groups 30A and 30B including the plurality of light emitting elements 30 are provided. The light transmitting members 10A, 10B, and 10C may be configured. Each component will be described below. The configuration and the manufacturing method of the light emitting device 100 described above are denoted by the same reference numerals, and the description thereof will be appropriately omitted.
In the light emitting device 100A, a plurality of light emitting elements 30 may be arranged as the light emitting element group 30A. For example, as shown in FIG. 7, in the light emitting element group 30A, two light emitting elements 30 of the same size are arranged adjacent to each other and aligned. When the light emitting elements 30 are arranged adjacent to each other, the light transmitting member 10 has a lower surface 7 of the first light transmitting member than a region of the light emitting element group 30A having a total area in which the light emitting elements 30 are arranged in parallel. Will also be formed to be large. As the area of the light emitting element group 30A, the area between the light emitting elements 30 is a part of the upper surface area of the light emitting element group 30A as a region surrounding the outer circumferences of the two light emitting elements 30 in a straight line and a rectangle. In addition, the translucent member 10 is formed such that the top surface 3 of the second translucent member is smaller than the area of the light emitting element group 30A. In the light emitting device 100A having such a configuration, light from the plurality of light emitting elements 30 is incident from the lower surface 7 of the first light transmitting member, and the second light transmitting member smaller than the lower surface 7 of the first light transmitting member Since the light can be emitted to the outside from the upper surface 3 of the light emitting device, light can be emitted far with high brightness.

  Further, as shown in FIG. 8, as an example, six light emitting elements 30 may be arranged in alignment to form the light emitting element group 30B. The light transmitting member 10 is formed so that the lower surface 7 of the first light transmitting member is larger than the area of the light emitting element group 30B which is the total area of the six light emitting elements 30 arranged in parallel. As the area of the light emitting element group 30B, the area between the light emitting elements 30 is a part of the upper surface area of the light emitting element group 30B as a region surrounding the outer circumferences of the six light emitting elements 30 in a straight line and a rectangle. In addition, the translucent member 10 is formed such that the upper surface 3 of the second translucent member is smaller than the area of the light emitting element group 30B. Also in the light emitting device 100B having such a configuration, light from the plurality of light emitting elements 30 is incident from the lower surface 7 of the first light transmitting member, and the second light transmitting property smaller than the lower surface 7 of the first light transmitting member Since the light can be emitted to the outside from the upper surface 3 of the member, it is possible to irradiate light with higher brightness and far.

Furthermore, as shown to FIG. 9B, side 4A of a 2nd translucent member is good also as a structure provided with the perpendicular | vertical side 4a and the inclined surface 4b. The side surface 4A of the second light transmitting member is continuous over the vertical side surface 4a which is substantially vertically continuous from the top surface 3 of the second light transmitting member, and the vertical side surface 4a and the top surface 5 of the first light transmitting member. It is comprised from the inclined surface 4b. The inclined surface 4 b is formed to spread from the upper surface direction toward the lower surface direction. And the inclined surface 4b is comprised so that it may become a curved surface which becomes convex toward the down side over the perpendicular | vertical side 4a and the upper surface 5 of a 1st translucent member. By providing the inclined surface 4b with the second light transmitting member, the light from the light emitting element 30 can be efficiently directed toward the upper surface 3 of the second light transmitting member with reduced number of reflections, and the luminance is high. A light emitting device can be used. In addition, the presence of the inclined surface 4b enables the lower surface 8 of the second light transmitting member and the upper surface 5 of the first light transmitting member to have the same shape, and the first light transmitting property formed of resin Since the member 1 can be supported in a wider range, the structural strength of the translucent member 10A can be improved.
Note that the light emitting device 100 includes at least one or more light emitting elements 30, and as described above, two, six, three, four, five, or seven or more. It does not matter.

Further, as shown in FIG. 9A, the inclined surface 4b can be provided by using the blade Br3 when forming the groove Dt shown in FIG. 5C. The blade Br3 is thinner than the blade Br2 shown in FIG. 5D, and is operated by partially changing the penetration depth of the blade Br3 so that the groove Dt has the vertical side surface 4a and the inclined surface 4b. Thus, the side surface 4A having the inclined surface 4b is formed. Alternatively, the groove Dt having an inclined surface may be formed using a bevel cut blade. In addition, although the inclined surface 4b was shown as a curve in cross sectional view, it can also be formed as a straight line.
Furthermore, by changing the size, shape, penetration depth, etc. of the blade Br3 when forming the groove portion Dt, the light transmitting member 10B in which the side shapes of the first light transmitting member and the second light transmitting member are different. , 10C can be formed.

  As shown in FIG. 9C, the side surface 9B of the translucent member 10B has an inclined surface 4bb. The translucent member 10B is formed by integrating the first translucent member 1B and the second translucent member 2B in the same manner as the translucent member 10A. A first light transmitting member 1B and a second light transmitting member 2B, each having an upper surface and a lower surface, are provided, and the upper surface 5b of the first light transmitting member and the lower surface 8b of the second light transmitting member are joined The light transmissive member 10B is configured. Also in the translucent member 10B, light from the light emitting element 30 is incident from the lower surface 7 of the first translucent member and the upper surface 3 of the second translucent member as in the above-described translucent member 10 and the like. Can be released to the outside.

The translucent member 10B includes the lower surface 7, the upper surface 3 having an area smaller than the lower surface 7, and the side surface 9B, as the translucent member 10 described above.
The translucent member 10B includes, as the side surface 9B, the first vertical side surface 6B, the inclined surface 4bb, and the second vertical side surface 4ba in order from the lower surface side. The first vertical side surface 6B is a surface substantially perpendicular to the lower surface 7 continuous with the lower surface 7, and is a vertical side surface 4bc that is a part of the side surface 6b of the first light transmissive member 1B and the side surface of the second light transmissive member 2B. It is a face that Further, the second vertical side surface 4 ba is a surface that is substantially perpendicular to the upper surface 3 and is continuous with the upper surface 3. The inclined surface 4bb is located between the first vertical side surface 6B and the second vertical side surface 4ba, and is a surface inclined so as to extend from the upper surface direction toward the lower surface direction. The inclined surface 4bb is configured as a curved surface that is convex inward.

A boundary surface between the first light transmitting member 1B and the second light transmitting member 2B in the light transmitting member 10B (that is, a bonding surface of the first light transmitting member 1B and the second light transmitting member 2B) Substantially parallel to and in contact with the first vertical side surface 6B.
In the light transmitting member 10B, the side surface of the second light transmitting member 2B is a vertical side surface continuous with the upper surface 3 of the second light transmitting member 2B (that is, the second vertical side surface of the light transmitting member 10B) 4ba An inclined surface (that is, an inclined surface of the light transmitting member 10B) 4bb which is continuous with the side surface 4ba and extends from the upper surface direction to the lower surface direction, continuously with the lower surface of the second light transmitting member. A vertical side surface (that is, a vertical side surface of a portion of the first vertical side surface 6B of the translucent member 10B) 4bc.

Further, the side surface 6b of the first light transmitting member 1B is continuous with the second light transmitting member 2B, and forms the first vertical side surface 6B of the light transmitting member 10B together with the vertical side surface 4bc of the second light transmitting member 2B. doing. That is, the top surface peripheral edge of the first light transmitting member 1B in the light transmitting member 10B is substantially the same as the bottom surface peripheral edge of the second light transmitting member 2B in a plan view.
With such a shape, the thickness of the first light-transmissive member 1B formed of a resin material containing the phosphor 11 can be made thinner. The thickness of the thinnest part of the second light transmitting member 2B is the thickness of the first light transmitting member 1B in order to reliably support the thinner phosphor-containing resin layer and in consideration of ease of processing. The thickness is preferably equal to or greater than the thickness of the thinnest portion.

  As shown in FIG. 9D, the side surface 9C of the translucent member 10C has an inclined inclined surface 4C. The translucent member 10C is formed by integrating the first translucent member 1C and the second translucent member 2C in the same manner as the translucent member 10A. A first light transmitting member 1C and a second light transmitting member 2C each having an upper surface and a lower surface are provided, and the upper surface 5c of the first light transmitting member and the lower surface 8c of the second light transmitting member are joined The light transmissive member 10C is configured. Also in the translucent member 10C, similarly to the translucent member 10 and the like, light from the light emitting element 30 is incident from the lower surface 7 of the first translucent member, and the light from the upper surface 3 of the second translucent member is externally Can be released.

10 C of translucent members are equipped with the lower surface 7 and the upper surface 3 which has an area smaller than the lower surface 7, and the side surface 9C similarly to the translucent member 10 mentioned above.
In addition, the translucent member 10C includes, as the side surface 9C, the first vertical side surface 6c, the inclined surface 4C, and the second vertical side surface 4ca in order from the lower surface side. The first vertical side surface 6 c is a surface substantially perpendicular to the lower surface 7 continuous with the lower surface 7, and the second vertical side surface 4 ca is a surface substantially perpendicular to the upper surface 3 continuous with the upper surface 3. The inclined surface 4C is located between the first vertical side surface 6c and the second vertical side surface 4ca, and is a surface inclined so as to extend from the upper surface direction to the lower surface direction. The inclined surface 4C is configured to be a curved surface that is convex inward. The inclined surface 4C is formed across the first light transmitting member 1C and the second light transmitting member 2C, and is a surface including the inclined side surface 6cb and the inclined side surface 4cb.

A boundary surface between the first light transmitting member 1C and the second light transmitting member 2C in the light transmitting member 10C is a surface substantially parallel to the lower surface 7 and in contact with the inclined surface 4C.
In the light transmitting member 10C, the side surface of the second light transmitting member 2C is a vertical side surface continuous with the upper surface 3 of the second light transmitting member 2C (that is, the second vertical side surface of the light transmitting member 10C) 4ca It has an inclined side surface (that is, an inclined side surface of the light transmitting member 10C) 4cb which is continuous with the side surface 4ca and extends from the upper surface direction to the lower surface direction. The inclined side surface 4cb is continuous with the lower surface 8c of the second light transmitting member, and is continuous with the inclined side surface 6cb of the first light transmitting member 1C. Further, the side surface of the first light transmitting member 1C is continuous with the second light transmitting member 2C, and is an inclined side surface extending from the upper surface direction toward the lower surface direction (that is, part of the inclined surface 4C of the light transmitting member 10C). Inclined side surface) 6cb, and a first vertical side surface 6c which is continuous with the inclined side surface 6cb and extends substantially perpendicularly to the lower surface 7 of the first light transmitting member 1C.

That is, also in the light-transmissive member 10C, the upper surface peripheral edge of the first light-transmissive member 1C substantially matches the lower surface peripheral edge of the second light-transmissive member 2C in plan view.
In such a shape, since the ratio of the thickness of the first light transmitting member 1C in the light transmitting member 10C can be increased, for example, more phosphors 11 are required to obtain a desired emission color. It is effective in the case of
The first light-transmissive member 1B and the second light-transmissive member 2B of the light-transmissive member 10B and the first light-transmissive member 1C and the second light-transmissive member 2C of the light-transmissive member 10C As compared with the case of the light-emitting member 10, the thickness is appropriately adjusted to form the side surface 9B or the side surface 9C.

Furthermore, in the light transmitting member 10B, the inclined surface 4bb and the first vertical side surface 6B may be continuous or may have a surface substantially parallel to the upper surface 3 therebetween. When inclined surface 4bb has a tangent substantially perpendicular to upper surface 3 in the vicinity of the upper surface of light transmitting member 10B, this region is taken as second vertical side surface 4ba, and second vertical side surface 4ba is formed as inclined surface 4bb. The configuration may be included.
Similarly, in the translucent member 10C, the inclined surface 4C and the first vertical side surface 6c may be continuous, or may have a surface substantially parallel to the upper surface 3 therebetween. When the inclined surface 4C has a tangent line substantially perpendicular to the upper surface 3 in the vicinity of the upper surface of the light-transmissive member 10C, the second vertical side surface 4ca is the inclined surface 4C with this region as the second vertical side surface 4ca. The configuration may be included.

In addition, each of the translucent members 10, 10A, 10B, and 10C may be formed as a translucent member 10D shown in FIGS. 10A to 10C. In the translucent member 10D, two of the four side surfaces are vertical side surfaces 9D1 continuous with the upper surface and the lower surface. That is, in plan view, a part of the upper surface peripheral edge of the second light transmissive member 2D substantially matches the lower surface peripheral edge of the first light transmissive member 1D, and the other part is the first transparent It is located inside the lower surface periphery of light property member 1D.
Also in such a light emitting device 100D, the area of the lower surface of the first light transmitting member 1D is larger than the area of the upper surface of the light emitting element 30, and the area of the upper surface of the second light transmitting member 2D is By making the total area smaller than the total area of the top surface, a light emitting device with higher luminance can be obtained. Incidentally, in the light emitting device 100D, the side surface 9D having the inclined surface of the light transmitting member 10D is provided on the side along the longitudinal direction in which the light emitting elements 30 are aligned, and the vertical side surface 9D1 is formed on the side along the lateral direction. ing. That is, the vertical side surface 9D1 is a portion that matches the lower surface peripheral edge of the first light transmissive member 1D in a plan view as a part of the upper surface peripheral edge of the second light transmissive member 2D. The vertical side surface 9D1 may be provided on one side along the longitudinal direction together with the side along the lateral direction, either side of the rectangular shape in plan view, two sides adjacent to each other. , It may be any of three continuous sides.

  In the light emitting devices 100, 100A, and 100B described above, the lower surface 8 of the second light transmitting member and the upper surface 5 of the first light transmitting member are described as being different in size. Similarly, the lower surface 8 of the second light transmitting member and the upper surface 5 of the first light transmitting member have the same size, and the upper surface 3 of the second light transmitting member is higher than the upper surface 5 of the first light transmitting member You may comprise so that it may be located inside. With such a configuration, light is easily guided from the upper surface 5 of the first translucent member to the lower surface 8 of the second translucent member, and the light extraction efficiency of the light emitting devices 100, 100A, 100B is improved. improves. Furthermore, when a plurality of light emitting elements 30 are joined to one light transmitting member 10, the influence of the arrangement of each light emitting element 30 and the influence of light distribution, luminance unevenness and color unevenness due to it are preferable. Furthermore, the adhesive 15 for bonding the light-transmissive member 10 and the light emitting element 30 may contain a phosphor, a light diffusing material, and the like. Furthermore, when a plurality of light emitting elements 30 are mounted, the light transmitting member 10 may be bonded to each of the light emitting elements 30.

In the light emitting devices 100 and 100A to 100D according to the present invention, a protective element such as a Zener diode may be mounted on the substrate 40. By burying these protective elements in the light reflective member 20, it is possible to prevent a decrease in light extraction due to the light from the light emitting element 30 being absorbed by the protective elements or being shielded by the protective elements. .
Furthermore, when two light emitting elements 30 are used, the distance between the two light emitting elements 30 is such that the fillet 16 of the adhesive 15 is continuously formed between the two light emitting elements 30. Is preferred. Specifically, when the light emitting devices 100 and 100A to 100D include two or more light emitting elements 30, the distance between adjacent light emitting elements 30 is preferably equal to or less than twice the thickness of the light emitting element 30.

  The light emitting device according to the present invention can be used as a light source for headlights of vehicles such as motorcycles and automobiles or vehicles such as ships and aircraft. In addition, it can be used for various light sources such as various illumination light sources such as spotlights, display light sources, and in-vehicle components.

DESCRIPTION OF SYMBOLS 1, 1C, 1D 1st translucent member 2, 2B, 2C, 2D 2nd translucent member 3 upper surface of 2nd translucent member 4, 4A side 4a of 2nd translucent member 4a vertical side 4b, 4bb , 4C inclined surface 5 upper surface of first light transmitting member 6 side surface of first light transmitting member 7 lower surface of first light transmitting member 8 lower surface of second light transmitting member 10, 10A, 10B, 10C, 10D Light emitting member 11 phosphor 15 adhesive 16 fillet 20 light reflecting member 30 light emitting element 30A, 30B light emitting element group 31 upper surface (light extraction surface)
40 Substrates 100, 100A, 100B, 100C, 100D Light-Emitting Device A1 First Transparent Member Assembly (First Transparent Member)
A2 Second translucent member assembly (second translucent member)
A10 Aggregate Br1, Br2, Br3 Blade Dt Groove S10 Manufacturing Method of Light Emitting Device S11 Preparation Step S12 Groove Forming Step S13 Translucent Member Forming Step S14 Bonding Step S15 Light Reflecting Member Supply Step S16 Segmentation Step

Claims (17)

A light emitting element whose upper surface is a light extraction surface;
A first light transmissive member provided in contact with the upper surface of the light emitting element and formed of a resin material containing a phosphor;
And a second light transmitting member provided by bonding to the upper surface of the first light transmitting member and formed of a glass material,
The lower surface peripheral edge of the first light transmitting member is located outside the upper surface peripheral edge of the light emitting element in plan view,
The lower surface peripheral edge of the second light transmissive member coincides with the upper surface peripheral edge of the first light transmissive member in plan view, or is positioned inside the upper surface peripheral edge of the first light transmissive member, and the second The upper surface peripheral edge of the light transmissive member is located inside the upper surface peripheral edge of the first light transmissive member in plan view ,
The side surface of the second light transmitting member includes a substantially vertical second vertical side surface continuous with the upper surface of the second light transmitting member, and an inclined surface continuous with the second vertical side surface.
The side surface of the first light transmissive member includes a substantially vertical first vertical side surface continuous with the lower surface of the first light transmissive member,
The light emitting device , wherein the inclined surface extends from the second vertical side toward the first vertical side .   The light emission according to claim 1, wherein the first light transmitting member comprises a first inclined side surface continuous with a first vertical side surface, and the first inclined surface is continuous with an inclined surface of the second light transmitting member. apparatus. The light emitting device according to claim 1 , wherein the inclined surface is a curved surface that is convex downward .   The light emitting device according to claim 1, wherein the area of the upper surface of the second light transmitting member is smaller than the area of the upper surface of the light emitting element. The light emitting device according to any one of claims 1 to 4 , wherein the second light transmitting member is borosilicate glass or quartz glass. The light emitting device according to any one of claims 1 to 5 , wherein the first light transmitting member contains a silicone resin. The light emitting device according to any one of claims 1 to 6 , wherein the first light transmitting member and the light emitting element are bonded via an adhesive. The light emitting device according to any one of claims 1 to 7 , wherein side surfaces of the light emitting element, the first light transmitting member, and the second light transmitting member are covered with a light reflecting member. A light emitting element whose upper surface is a light extraction surface;
A first light transmissive member provided in contact with the upper surface of the light emitting element and formed of a resin material containing a phosphor;
And a second light transmitting member provided by bonding to the upper surface of the first light transmitting member and formed of a glass material,
The upper surface peripheral edge of the first light transmissive member coincides with the lower surface peripheral edge of the second light transmissive member in plan view,
The area of the lower surface of the first light transmitting member is larger than the area of the upper surface of the light emitting element,
Area of the upper surface of the second translucent member is minor than the area of the upper surface of the light emitting element,
The first light transmitting member side surface has a first vertical side surface,
The side surface of the second light transmitting member is a vertical side surface continuous with the first vertical side surface, an inclined surface continuously extending from the upper surface direction to the lower surface direction continuously with the vertical side surface, and the inclined surface. A light emitting device having a second vertical side surface continuous with the upper surface . The light emitting device according to claim 9 , wherein the lower surface peripheral edge of the first light transmitting member is located outside the upper surface peripheral edge of the light emitting element in plan view. The portion of the top rim of the second translucent member, the light emitting device according to claim 9 or claim 10 coincides with the lower surface peripheral edge of said first light-transmissive member in a plan view. The light emitting device according to claim 9, wherein the inclined surface is a curved surface that is convex toward the inside of the second light transmitting member . A method of manufacturing a light emitting device according to any one of claims 9 to 12, wherein
An upper surface of a flat plate-like first light transmitting member aggregate made of a resin material containing a phosphor and a flat plate-like second light transmitting member aggregate made of a material harder than the first light transmitting member aggregate Preparing a plate-like translucent member assembly joined to the lower surface of
Forming a groove in the upper surface of the second light transmitting member assembly in the light transmitting member assembly;
Dividing the light transmitting member assembly by the groove to obtain a plurality of light transmitting members having a first light transmitting member and a second light transmitting member;
The lower surface of the first light transmissive member and the upper surface of the light emitting element are joined such that the lower surface peripheral edge of the first light transmissive member in the light transmissive member is positioned outside the upper surface peripheral edge of the light emitting element and the process, only including,
In the groove portion, a vertical second vertical side surface in which the side surface of the second light transmitting member is continuous with the upper surface of the second light transmitting member, and a second vertical side surface of the second light transmitting member (1) A method of manufacturing a light emitting device formed to have an inclined surface extending toward a vertical side and a vertical side continuous with the inclined surface and continuous with a first vertical side of the first light-transmissive member . The method according to claim 13 , wherein the second light transmitting member is formed of a glass material. The method for manufacturing a light emitting device according to claim 13 , comprising the step of mounting the light emitting element on a substrate. The method according to any one of claims 13 to 15 , further comprising the step of providing a light reflecting member covering the side surface of the second light transmitting member, the side surface of the first light transmitting member, and the side surface of the light emitting element. The manufacturing method of the described light-emitting device. The method of manufacturing a light emitting device according to any one of claims 13 to 16 , wherein the first light transmitting member contains a silicone resin.

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