Light emitting device, light emitting module, and method of manufacturing light emitting module

A light emitting device includes: a plurality of element structural bodies, each including: a substrate, a light emitting element mounted on or above the substrate, and a light-transmissive member disposed on or above the light emitting element, wherein at least three of the plurality of element structural bodies are disposed along a first direction; a first covering member that covers lateral surfaces of the substrate, the light emitting element, and the light-transmissive member of each of the plurality of element structural bodies; and a support member that covers a lateral surface of the first covering member, wherein at least a portion of the support member is disposed lateral to the plurality of element structural bodies and extends along the first direction. A rigidity of the support member is greater than a rigidity of the first covering member.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to Japanese Patent Application No. 2020-069883 filed on Apr. 8, 2020, and Japanese Patent Application No. 2020-161124 filed on Sep. 25, 2020, the disclosures of which are hereby incorporated by reference in their entireties.

BACKGROUND

The present disclosure relates to a light emitting device and a light emitting module, and also relates to a method of manufacturing a light emitting module.

There is known a light emitting device including a plurality of light emitting surfaces. For example, Japanese Patent Publication No. 2018-81832 discloses a light source unit in which 24 light emitting diodes are disposed in each of four rows on a substrate.

SUMMARY

There is room for further improvements in a structure to precisely dispose a plurality of light emitting surfaces with high density.

An object of certain embodiments of the present disclosure is to provide a light emitting device and a light emitting module in which a plurality of light emitting surfaces are precisely dispose with high density, and to provide a method of manufacturing such light emitting module.

A light emitting device according to one embodiment of the present disclosure includes element structural bodies, a first covering member, and a support member. Each of the element structural bodies includes a substrate, a light emitting element mounted on or above the substrate, and a light-transmissive member disposed on or above the light emitting element. At least three of the element structural bodies are disposed along a first direction. The first covering member is configured to cover lateral surfaces of the substrate, the light emitting element, and the light-transmissive member of each of the element structural bodies. The support member is configured to cover a lateral surface of the first covering member, and disposed lateral to the element structural bodies along the one direction. The support member has a rigidity greater than a rigidity of the first covering member.

A light emitting module according to another embodiment of the present disclosure includes the above-described light emitting device, and a module substrate on which the light emitting device is mounted, with the module substrate facing the substrate of the light emitting device.

A method of manufacturing a light emitting module according to another embodiment of the present disclosure includes providing the above-described light emitting device, and mounting the light emitting device so that the substrate faces a module substrate. The module substrate has holes at positions respectively facing through holes of the support member. The mounting the light emitting device includes aligning positions of the through holes of the support member and of the holes of the module substrate to mount the light emitting device on the module substrate.

In a light emitting device according to certain embodiments of the present disclosure, a plurality of light emitting surfaces can be precisely positioned at a desired position with high density. In a light emitting module according to certain embodiments of the present disclosure, a plurality of light emitting surfaces can be precisely positioned at a desired position with high density. With a method of manufacturing a light emitting module according to certain embodiments of the present disclosure, it is possible to precisely position a plurality of light emitting surfaces at a desired position with high density.

DESCRIPTION OF EMBODIMENTS

Embodiments will be described below with reference to the drawings. Note that the following embodiments illustrate a light emitting device, a light emitting module, and a method of manufacturing a light emitting module for embodying the technical concepts of the present invention, but the present invention is not limited to the following embodiments. In addition, dimensions, materials, shapes, relative positions, or the like of components described in the embodiments are merely exemplary and are not intended to limit the scope of the present invention thereto, unless otherwise specified. Note that, size, positional relationship, and the like of members illustrated in the drawings can be exaggerated or simplified for clarity of description. In a cross-sectional view, an end view illustrating only a cutting surface can be used. Moreover, each of members including a light emitting element, an element structural body, and a support illustrated in the drawings is illustrated with the number of components set in an example to facilitate understanding of the described configuration. Furthermore, in the embodiments, “cover,” including its several tenses such as covering and covered, encompasses not only a case with direct contact, but also a case with indirect contact, that is, covering via other members, for example.

Embodiments

FIG.1Ais a schematic perspective view illustrating an example of a light emitting module including a light emitting device according to an embodiment.FIG.1Bis a schematic top view illustrating an example of the light emitting module including the light emitting device according to the embodiment.FIG.1Cis a schematic cross-sectional view taken along line IC-IC ofFIG.1B.FIG.1Dis a schematic cross-sectional view taken along line ID-ID ofFIG.1B.FIG.1Eis a schematic cross-sectional view illustrating an example of the light emitting device according to the embodiment.FIG.1Fis a schematic bottom view illustrating an example of the light emitting device according to the embodiment.FIG.1Gis a schematic top view illustrating an example of a support member of the light emitting device according to the embodiment.

Alight emitting module200includes a light emitting device100and a module substrate80on which the light emitting device100is mounted.

Light Emitting Device

First, the light emitting device100will be described.

The light emitting device100includes a plurality of light emitting surfaces on a top surface thereof.

The light emitting device100includes a plurality of element structural bodies15each including a substrate10, a light emitting element20mounted on or above the substrate10, and a light-transmissive member30disposed on or above the light emitting element20. At least three of the element structural bodies15are disposed along one direction X (i.e., a first direction). The light emitting device100further includes a first covering member51that covers lateral surfaces of the substrate10, the light emitting element20, and the light-transmissive member30of each of the element structural bodies15; and a support member60that covers a lateral surface of the first covering member51, that is disposed lateral to the plurality of element structural bodies15along the one direction X, and that has higher rigidity than a rigidity of the first covering member51.

The light emitting device100mainly includes the element structural bodies15, the first covering member51, and the support member60.

Each of the element structural bodies15primarily includes the substrate10, the light emitting element20, a protecting element25, the light-transmissive member30, a light-guiding member40, a third covering member53, and a second covering member52. An external shape of the element structural body15is, for example, a substantially rectangular parallelepiped. A top surface of the element structural body15includes a top surface of the light-transmissive member30and a top surface of the second covering member52surrounding the top surface of the light-transmissive member30. One or more lateral surfaces of the element structural body15include one or more lateral surfaces of the second covering member52and one or more lateral surfaces of the substrate10. A bottom surface of the element structural body15includes a bottom surface of the substrate10. In the element structural body15, in a top view from a direction perpendicular to the top surface of the light-transmissive member30, the light emitting element20and the light-transmissive member30are positioned inside the substrate10. Further, either one of the light emitting element20or the light-transmissive member30is preferably positioned inside the other of the light emitting element20or the light-transmissive member30.

In the light emitting device100, each of the plurality of element structural bodies15includes the light emitting element20, and thus, the light emitting element20can be driven individually for each of the plurality of element structural bodies15.

Configurations of the light emitting device100will be described below.

The substrate10is a component on which the light emitting element20and the protecting element25are mounted. The substrate10has, for example, a substantially rectangular plate shape as seen in a top view. As a result, the plurality of element structural bodies15can be disposed close to one another in the light emitting device100.

The substrate10includes wirings for electrically connecting a base1with the light emitting element20and an external light source, on a top surface of the base1, a bottom surface thereof, and inside thereof. Examples of a material of such wiring include metals such as Fe, Cu, Ni, Al, Ag, Au, Pt, Ti, W, and Pd, and alloys including at least one type of these metals.

An example of the substrate10includes a substrate including a top surface wiring2connected to the light emitting element20on the top surface on which the light emitting element20is mounted, for example, and an external connection electrode3(for example, an anode electrode3aand a cathode electrode3b) electrically connected to an external power source on the bottom surface opposite to the top surface on which the light emitting element20is mounted. In this case, the top surface wiring2and the external connection electrode3can include a via4that extends to both the top surface and the bottom surface, that is, passes through the base1. As a result, the top surface wiring2and the external connection electrode3are electrically connected. The base1can have a single layer structure or can have a multilayer structure. If the base1has a multilayer structure, a via passing through each of the layers can electrically connect the top surface wiring2and the external connection electrode3on the bottom surface via an inner layer wiring provided between each of the plurality of layers.

An insulating material is preferably employed for the base1, and a material through which light emitted from the light emitting element20, external light, and the like are not easily transmitted is preferably employed for the base1. Examples of the material of the base1include: ceramics such as alumina, aluminum nitride, and mullite; a thermoplastic resin such as polyamide (PA), polyphthalamide (PPA), polyphenylene sulfide (PPS), or liquid crystal polymer; and a resin such as an epoxy resin, a silicone resin, a modified epoxy resin, an urethane resin, and a phenol resin.

In particular, ceramics having good heat dissipation are preferably used.

In the light emitting device100, a distance L1between the adjacent element structural bodies15is preferably in a range from 0.01 mm to 0.15 mm. As a result, a thickness of the first covering member51disposed between the element structural bodies15can be in a range from 0.01 mm to 0.15 mm, and thus, the adjacent element structural bodies15can be brought close or joined together. Further, in the light emitting device100including the plurality of element structural bodies15, each of the plurality of element structural bodies15includes the substrate10, and the first covering member51is disposed between the substrates10, and thus, it is possible to suppress an influence of thermal stress due to expansion or contraction of the substrate10resulting from heat generated in each of the element structural bodies15and from thermal history at the time of mounting the light emitting device100.

The light emitting element20is mounted on the substrate10. Any shape, size, and the like can be selected for the light emitting element20. A shape of the light emitting element20in a top view is, for example, rectangular. For example, in order to realize a high-power light emitting device, lengthwise dimension and lateral dimension of the light emitting element20in a top view respectively are preferably equal to or greater than 600 μm, and more preferably equal to or greater than 800 μm. Furthermore, from a perspective of uniformity of light emission intensity, ease of mounting, and the like, the lengthwise and lateral dimensions are respectively preferably equal to or less than 1500 μm.

In terms of the color of the light emitted from the light emitting element20, light with any wavelength appropriate for application can be selected. For example, examples of a blue light (light having a wavelength of 430 to 500 nm) emitting element20or a green light (light having a wavelength of 500 to 570 nm) emitting element20include those using a nitride-based semiconductor (InXAlYGa1-X-YN, 0≤X, 0≤Y, X+Y≤1), GaP, and the like. Examples of a red light (light having a wavelength of 610 to 700 nm) emitting element20include those using not only a nitride-based semiconductor element but also GaAlAs, AlInGaP, and the like.

The light emitting element20preferably includes positive and negative element electrodes on one surface, and as a result, the light emitting element20can be flip-chip mounted to a wiring on the substrate10with an electrically conductive adhesive8. For example, eutectic solder, electrically conductive paste, or a bump can be employed for the electrically conductive adhesive8.

For example, a Zener diode can be employed for the protecting element25. The protecting element25includes positive and negative element electrodes on one surface, and is flip-chip mounted to a wiring on the substrate10with the electrically conductive adhesive8. Note that the light emitting device may not include the protecting element25. A shape of the protecting element25in a top view is, for example, rectangular.

The light-transmissive member30is a member that is disposed on or above the light emitting element20and that transmits light emitted from the light emitting element20and emits the light to the outside. Examples of the light-transmissive member30include a member that transmits 60% or greater of light from the light emitting element20and/or light obtained after a wavelength of light from the light emitting element20is converted (for example, light with a wavelength in a range from 320 nm to 850 nm), and preferably include a member that transmits 70% or greater of the light.

The light-transmissive member30is a plate-like member including a top surface serving as a main light emitting surface of the individual element structural bodies15and the light emitting device100, and a bottom surface opposite to the top surface. The light-transmissive member30can be formed from an inorganic material such as glass, ceramics, or sapphire, or an organic material such as a resin or a hybrid resin containing one or more of silicone resins, modified silicone resins, epoxy resins, modified epoxy resins, acrylic resins, phenol resins, and fluorine resins. The light-transmissive member30is disposed on or above the light emitting element20. The light-transmissive member30preferably has a top surface and/or a bottom surface wider than the top surface of the light emitting element20, and is preferably disposed so as to encompass the light emitting element20in a top view.

On the top surface of the light emitting device100, a distance L2between the adjacent light-transmissive members30is preferably equal to or less than 0.2 mm. As a result, for example, if the light emitting device100is employed for a light source of an Adaptive Driving Beam headlight (ADB headlight) of a vehicle, the light source can be reduced in size, and a size of the headlight lens can be reduced.

That is, on the top surface of the light emitting device100, a space between the adjacent light-transmissive members30(that is, between the adjacent light emitting surfaces) is a non-light emitting region, and thus, when the adjacent light-transmissive members30are lighted simultaneously, a dark portion may be generated in an irradiated region. Therefore, it is necessary to suitably adjust a configuration of an optical system, for example, by adjusting a focal position of the plurality of light emitting surfaces using a primary lens, so that a dark portion is not generated in an irradiated region. On the other hand, in the light emitting device100according to the present embodiment, the distance L2between the adjacent light emitting surfaces (that is, the top surfaces of the adjacent light-transmissive members30) can be made smaller than 0.2 mm. As a result, a configuration of an entire light appliance including an optical system such as a lens or the like can be simplified or downsized, that is, the primary lens in the optical system can be omitted, for example. Further, omission of the lens can reduce loss of light when the light passes through the optical system can be reduced.

The distance L2between the adjacent light-transmissive members30is more preferably 0.1 mm or less. An example of the distance L2between the light-transmissive members30includes 0.02 mm or greater, from a perspective of ease of manufacturing the element structural body15and the light emitting device100.

A planar shape of the light-transmissive member30is rectangular, for example. As a result, the plurality of light emitting surfaces can be highly densely positioned in close proximity. In particular, the planar shape of the light-transmissive member30is preferably similar to the planar shape of the light emitting element20. An area of the bottom surface of the light-transmissive member30is preferably approximately 0.8 to 1.5 times an area of the top surface of the light emitting element20. An entire thickness of the light-transmissive member30can be constant or can be partially thin or thick. The thickness of the light-transmissive member30can be, for example, in a range from 50 μm to 300 μm.

The light-transmissive member30can contain phosphor that can convert a wavelength of at least a part of incident light. Examples of the light-transmissive member30containing the phosphor include sintered bodies of one or more phosphors and members in which one or more phosphors are contained in the one or more materials described above. Further, the light-transmissive member30can include a phosphor layer such as a resin layer containing a phosphor, a glass layer containing a phosphor, or the like, on a surface of a body formed of resin, glass, ceramics, or the like. Furthermore, the light-transmissive member30can contain a filler such as a diffusing material depending on a purpose. Furthermore, if a filler such as a diffusing material is contained, the light-transmissive member30can include a filler contained in the above-described material, and can include a diffusing material layer such as a resin layer containing a filler, a glass layer containing a filler, or the like, on the surface of a body formed of resin, glass, ceramics, or the like.

Phosphors known in the art can be employed for the phosphor. Examples of a phosphor that emits green light include a yttrium aluminum garnet-based phosphor (for example, Y3(Al,Ga)5O12:Ce), a lutetium aluminum garnet-based phosphor (for example, Lu3(Al,Ga)5O12:Ce), a terbium-aluminum-garnet-based phosphor (for example, Tb3(Al,Ga)5O12:Ce), a silicate-based phosphor (for example, (Ba,Sr)2SiO4:Eu), a chloro-silicate-based phosphor (for example, CasMg(SiO4)4Cl2:Eu), a β-sialon-based phosphor (for example, Si6-zAlzOzN8-z:Eu(0<z<4.2)), and an SGS-based phosphor (for example, SrGa2S4:Eu). Examples of a phosphor that emits yellow light include an α-sialon-based phosphor (for example, Mz(Si,Al)12(O,N)16(wherein 0<z≤2, and M is Li, Mg, Ca, Y, and a lanthanide element excluding La and Ce)). In addition, the above phosphors that emit green light include a phosphor that emits yellow light.

For example, if Y is partially substituted with Gd in the yttrium aluminum garnet-based phosphor, a light emission peak wavelength can be shifted to a long wavelength side, and thus, the yttrium aluminum garnet-based phosphor can emit yellow light. Further, some of the above phosphors are a phosphor that can emit orange light. Examples of a phosphor that emits red light include a nitrogen-containing calcium aluminosilicate (CASN or SCASN)-based phosphor (for example, (Sr,Ca)AlSiN3:Eu) and a BSESN-based phosphor (for example, (Ba,Sr,Ca)2Si5N8:Eu). In addition, another example includes a manganese-activated fluoride-based phosphor (a phosphor represented by a general formula (I) A2[M1-aMnaF6] (wherein in the above general formula (I), A is at least one selected from the group consisting of K, Li, Na, Rb, Cs, and NH4, M is at least one element selected from the group consisting of Group 4 elements and Group 14 elements, and a satisfies 0<a<0.2)). A typical example of the manganese-activated fluoride-based phosphor includes a manganese-activated potassium fluorosilicate phosphor (for example, K2SiF6:Mn).

Diffusing materials known in the art can be employed for the diffusing material. For example, silica, alumina, barium titanate, and titanium oxide can be employed.

Further, if a resin is employed for a binder of a phosphor layer and a diffusing material layer, examples of the resin include a thermosetting resin such as an epoxy resin, a modified epoxy resin, a silicone resin, or a modified silicone resin.

The light-guiding member40is disposed between the light-transmissive member30and the light emitting element20and/or on lateral surface(s) of the light emitting element20. The light-guiding member40is a member that facilitates extraction of light from the light emitting element20and guides light from the light emitting element20to the light-transmissive member30. The light-guiding member40is, for example, an adhesive member that joins the light emitting element20and the light-transmissive member30. The light-guiding member40that joins the light emitting element20and the light-transmissive member30preferably extends from a space between the light-transmissive member30and the light emitting element20, and is preferably disposed on the lateral surface(s) of the light emitting element20. As a result, the light emitted from the lateral surface(s) of the light emitting element20can be guided to the light-transmissive member30to improve an extraction efficiency of the light from the light emitting element20.

The light-guiding member40has a shape inclined in a cross-sectional view so that a width of the light-guiding member40expands from the bottom surface side of the light emitting element20(that is, a side of a joint surface with the substrate10) toward the light-transmissive member30. With such a configuration, light traveling in a lateral direction from the light emitting element20is easily reflected upward, and thus, the light extraction efficiency is further improved. A cross-sectional shape of an outer surface of the light-guiding member40can be a straight line shape or a curved shape. For example, if the outer surface of the light-guiding member40in a cross-sectional view is in a curved shape, the curved shape can be a curved shape protruding toward a side of the third covering member53, or can be a curved shape recessed toward a side of the light emitting element20.

The light-guiding member40can suffice to cover a light emitting region of the lateral surface(s) of the light emitting element20, but from a viewpoint of improving the light extraction efficiency, it is more preferable that the light-guiding member40covers a substantially entire lateral surface(s) of the light emitting element20.

For example, a light-transmissive resin can be employed for the light-guiding member40. Additionally, examples of a material of the light-guiding member40can include a resin employed in the above-described light-transmissive member30. Further, the above-described diffusing material can also be contained. As a result, light can more evenly enter the light-transmissive member30to suppress color unevenness of the light emitting device100.

The third covering member53is provided on the substrate10around the light emitting element20. The third covering member53covers the lateral surface(s) of the light emitting element20and is provided to extend from the lateral surface of the light emitting element20to the top surface of the substrate10. The third covering member53can increase an adhesive strength between the substrate10and the light emitting element20. Here, the third covering member53covers the lateral surface(s) of the light emitting element20with the light-guiding member40disposed therebetween.

The third covering member53is formed in a fillet shape along the lateral surface of the light emitting element20from a side of the light-transmissive member30toward a side of the substrate10. In other words, a cross-sectional shape of an outer surface of the third covering member53has a shape inclined so that a width of the third covering member53expands from the side of light-transmissive member30toward the substrate10, for example. The cross-sectional shape of the outer surface of the third covering member53can be a straight line shape or a curved shape. For example, if the outer surface of the third covering member53in a cross-sectional view is in a curved shape, the curved shape of the third covering member53can be a curved shape protruding toward a side of the second covering member52, or can be a curved shape recessed toward a side of the light emitting element20.

The third covering member53preferably employs a resin. The third covering member53can be formed, for example, from a white resin having light reflectivity.

Examples of the third covering member53include a member obtained by containing a reflective material into a light-transmissive resin. Examples of the resin employed for the third covering member53include an epoxy resin, a modified epoxy resin, a silicone resin, and a modified silicone resin. In particular, it is preferable to employ a silicone resin having good light resistance and heat resistance. Examples of the reflective material include titanium oxide, silica, alumina, zirconium oxide, magnesium oxide, potassium titanate, zinc oxide, silicon nitride, boron nitride. Among these, from the perspective of light reflection, titanium oxide having a relatively high refractive index is preferably employed.

The third covering member53can suffice to cover at least a portion of the lateral surface(s) of the light emitting element20. It is preferable that the third covering member53covers the entire lateral surface(s) of the light emitting element20. It is more preferable that the third covering member53extends from the lateral surface(s) of the light emitting element20to cover at least a portion of the lateral surface(s) of the light-transmissive member30. As a result, in the individual element structural bodies15, a leakage of light emitted from the lateral surface(s) of the light emitting element20in a lateral direction can be suppressed. Furthermore, in the light emitting device100including the plurality of element structural bodies15, a leakage of light to the adjacent element structural bodies15is suppressed, and the light emitting device100having only a minor light emission unevenness can be realized. In addition, if the lateral surface(s) of the light-transmissive member30is covered by the third covering member53, when an optical characteristic of the element structural body15is measured, the optical characteristic can be more easily measured because chromaticity coordinates of the element structural body15can be easily recognized, for example. Furthermore, as described below, when a sorting step is performed after a block of element structural bodies are separated into individual element structural bodies15, the chromaticity coordinates of the element structural body15are more easily understood.

The third covering member53is preferably disposed also between the light emitting element20and the substrate10. As a result, light traveling downward from the light emitting element20is reflected by the third covering member53, and the light extraction efficiency of the light emitting device100can be further improved.

The light emitting device100includes the plurality of element structural bodies15, and each of the plurality of element structural bodies15includes the third covering member53that covers the lateral surface(s) of the light emitting element20, and thus, a leakage of light emitted from the light emitting element20in a lateral direction can be suppressed. This can allow the plurality of element structural bodies15to be disposed close to one another without reducing the light extraction efficiency of the individual element structural bodies15.

The second covering member52is a member that covers the lateral surface(s) of the light emitting element20and the lateral surface(s) of the light-transmissive member30on the substrate10. The second covering member52covers the lateral surface(s) of the light emitting element20via the light-guiding member40and the third covering member53, and covers the lateral surface(s) of the light-transmissive member30.

When the second covering member52is provided, the element structural body15can have a substantially rectangular parallelepiped shape. As a result, in the light emitting device100, the first covering member51can be disposed between the element structural bodies15at approximately the same width from the bottom surface to the top surface of the element structural bodies15.

A resin is preferably employed for the second covering member52. The second covering member52can be formed, for example, from a white resin having light reflectivity. The second covering member52covers the lateral surface(s) of the light emitting element20and the lateral surface(s) of the light-transmissive member30. Examples of the resin employed for the second covering member52include the examples described with respect to the resin employed in the third covering member53. Examples of the reflective material contained in the resin used in the second covering member52include the examples described with respect to the reflective material employed in the third covering member53.

The first covering member51is a member provided around the plurality of element structural bodies15. A resin is preferably employed for the first covering member51. The first covering member51can be formed, for example, from a white resin obtained by containing a reflective material into a light-transmissive resin. The first covering member51covers the lateral surface(s) of the element structural body15. That is, the first covering member51covers the lateral surface(s) of the substrate10, covers the lateral surface(s) of the light emitting element20via the light-guiding member40, the third covering member53, and the second covering member52, and covers the lateral surface(s) of the light-transmissive member30via the second covering member52. The first covering member51is provided between the adjacent element structural bodies15, and covers the lateral surface(s) of each of the plurality of element structural bodies15in a state in which the top surfaces of the element structural bodies15are exposed.

Examples of the resin employed for the first covering member51include the examples described with respect to the resin employed in the third covering member53. Examples of the reflective material contained in the resin used in the first covering member51include the examples described with respect to the reflective material employed in the third covering member53.

The first covering member51can be a colored resin. Examples of the colored resin include a black resin, and a gray resin. A black resin and a gray resin have higher light absorption than a white resin. Thus, if the first covering member51, which is a black resin or a gray resin, is provided between the element structural bodies15, a leakage of light in the lateral direction between the element structural bodies15can be effectively suppressed. If the black resin or the gray resin is employed for the first covering member51, the element structural body15is preferably configured to include the second covering member52so that the black resin or the gray resin and the light-transmissive member30are separated. This makes it possible to suppress the effect of light absorption due to the use of the black resin or the gray resin between the element structural bodies15. As a result, a light emitting device with good “light-dark boundary” is achieved by having a high contrast between a light emitting region and a non-light emitting region when the element structural bodies15are individually lit, which allows for suppression of a decrease of the light extraction efficiency of the light emitting surface.

Examples of the black resin or the gray resin include a resin containing a black pigment such as carbon black and graphite. If the black pigment and a white pigment such as the above-described reflective material are combined and each of added amounts is adjusted, a concentration of color such as black or gray can be adjusted. A red pigment, a blue pigment, a green pigment, and the like can be combined to achieve black, gray, and other desired colors.

In the light emitting device100, the plurality of element structural bodies15each including the light emitting surface are held by the first covering member51. With the first covering member51, the element structural bodies15can be each held in a desired arrangement, and thus, the plurality of light emitting surfaces can be highly densely disposed.

The support member60is a member that covers the lateral surface(s) of the first covering member51and is disposed along sides of the plurality of element structural bodies15in the one direction X. The support member60has a side that faces the plurality of element structural bodies15and is parallel to the one direction X. For example, the support member60can be a frame-shaped member surrounding the plurality of element structural bodies15. Here, the support member60is provided as a frame that surrounds the plurality of element structural bodies15and supports the first covering member51. The support member60is, for example, a substantially rectangular frame shape in a top view, and is provided around the plurality of element structural bodies15.

The support member60is formed of a member or a structure having rigidity greater than the first covering member51. Specifically, the support member60has a rigidity greater than a value of a stress (rigidity) that causes the first covering member51to warp. Here, “rigidity” indicates difficulty in deformation against a bending force or a tension force, and is expressed by a force required to cause a unit deformation (bending or tension), in other words, a force calculated by dividing load by a deformation amount. When the rigidity of each member is compared, a magnitude of a force required to apply the same amount of deformation in a range that can be considered as being an elastic deformation, is compared. The rigidity increases if a material having a high elastic modulus such as Young's modulus (tensile elastic modulus) is employed. In addition, the rigidity also increases by increasing a plate thickness if a thickness of the same material can be changed. In composite materials, the rigidity is compared by using a magnitude of a force required to cause a unit deformation (bending or tension), and is calculated by dividing load by deformation amount. For example, in a bending test, stresses at a bending strain of 0.05% and that of 0.25% can be evaluated in accordance with JIS K 7171:2016 to compare the rigidity.

The light emitting device100includes the support member60having a rigidity greater than a rigidity of the first covering member51, and thus, the first covering member51is suppressed from being warped. This may suppress the light emitting device100from being warped. As a result, a mounting surface of the light emitting device100is flat, and consequently, the light emitting device100can be precisely disposed at a desired position of the module substrate80. In the light emitting device100, the plurality of element structural bodies15are linked by the first covering member51. Therefore, if a resin is employed for the first covering member51, the light emitting device100may be warped due to shrinkage of the resin during curing, for example. However, if a material having a rigidity greater than the rigidity of the first covering member51, for example, a non-flexible material, is employed for the support member60, the occurrence of warping can be suppressed. As a result, the light emitting device100can be mounted favorably to the module substrate80, and the light emitting device100in which the plurality of light emitting surfaces are highly densely disposed can be more precisely disposed at a desired position of the module substrate80.

An electrically conductive member such as a metal, an alloy, or an insulating member such as a ceramic can be employed for the support member60. Examples of the electrically conductive member include a metal such as Fe, Cu, Ni, Al, Ti, or W, or an alloy including at least one element of Fe, Cu, Ni, Al, Ag, Au, Pt, Ti, W, Pd, or the like. Examples of the insulating material include ceramics such as alumina oxide or aluminum nitride, and a resin formed body formed of a phenol resin, an epoxy resin, a silicone resin, a polyimide resin, a BT resin, polyphthalamide, or the like. In a case in which a resin is used, inorganic fillers such as glass fibers, silicon oxide, titanium oxide, or aluminum oxide, can be mixed in the resin as necessary. Furthermore, a composite obtained by combining such an electrically conductive member and such an insulating member can be employed for the support member, and an example of the composite includes a support member in which a metal member is embedded into a resin molded body.

The support member60is preferably a frame-shaped member surrounding the plurality of element structural bodies15. Furthermore, the support member60is more preferably a frame-shaped member having a substantially rectangular opening in a top view including two sides parallel to the one direction X with the plurality of element structural bodies15being interposed therebetween and two sides perpendicular to the one direction X with the plurality of element structural bodies15being interposed therebetween. As a result, all of the lateral surface(s)s of the first covering member51being in contact with the support member60can be fixed by the support member60, and thus, an occurrence of warping can be more effectively suppressed.

A height H from the top surface to the bottom surface of the support member60is preferably lower than a height from the top surface to the bottom surface of the element structural body15. As a result, in the light emitting device100, the top surface of the support member60can be positioned lower than the top surface of the element structural body15(that is, on a bottom surface side of the light emitting device100relative to the top surface of the element structural body15). With such a configuration, creeping of the first covering member51onto the top surface of the light-transmissive member30during manufacturing of the light emitting device100is suppressed.

The height H of the support member60is preferably in a range from 0.1 mm to 1.0 mm. If the height H of the support member60is equal to or greater than 0.1 mm, the rigidity of the support member60itself can be ensured and an effect of suppressing the occurrence of the warpage of the light emitting device100is further enhanced, and as a result, the support member60can be disposed more precisely at a desired position. On the other hand, if the height H of the support member60is equal to or less than 1.0 mm, the light emitting device100can be further reduced in weight and size.

In the support member60, a width W of a portion disposed across the side of the plurality of element structural bodies15is preferably in a range from 0.5 mm to 2.0 mm. Here, the width W refers to the shortest length between an outer side and an inner side of the frame-shaped support member60in a direction perpendicular to the one direction X, on a side of the frame shape that is parallel to the one direction X and faces the element structural body15. If the width W is equal to or greater than 0.5 mm, the rigidity of the support member60itself can be ensured and an effect of suppressing the occurrence of the warpage of the light emitting device100is further enhanced, and as a result, the support member60can be disposed more precisely at a desired position. On the other hand, if the width W is equal to or less than 2.0 mm, the light emitting device100can be further reduced in weight and size.

The support member60preferably has at least one through hole to facilitate mounting to the module substrate80. For example, the support member60is a frame having a substantially rectangular opening in a top view including two sides parallel to the one direction X and two sides perpendicular to the one direction X, where through holes60a1and60a2are preferably provided at positions respectively corresponding to the two sides perpendicular to the one direction X. Here, the through holes60a1and60a2are provided on an extension line of a row of the element structural bodies15aligned in a single row along the one direction X. As a result of the support member60having the through holes60a1and60a2, when the light emitting device100is mounted on the module substrate80, as described below, if the through hole60a1is aligned with a hole80a1of the module substrate80and the through hole60a2is aligned with a hole80a2of the module substrate80, misalignment is suppressed, and as a result, a mounting accuracy is improved. This can facilitate mounting of the light emitting device100on the module substrate80. Further, for example, in a case in which the module substrate80on which the light emitting device100is mounted is further employed in a vehicle lighting appliance such as a headlight, the holes80a1and80a2of the module substrate80are aligned with positioning pins provided on a side of the lighting appliance to suppress misalignment. This can facilitate mounting of the light emitting module200into the vehicle lighting appliance.

Additionally, the through hole60a1being one of the through holes and the through hole60a2being another of the through holes are preferably different in size, for example, in diameter, from each other. If the through holes60a1and60a2different in size are provided, in a manufacturing process of the light emitting device100, when the element structural bodies15are disposed in each of the plurality of support members60disposed in two dimensions, erroneous recognition of the support members60in the left and right directions can be suppressed.

A shape of the through holes60a1and60a2is not limited to a circular shape, and can be an elliptical shape or a polygonal shape such as a triangle and a square. In addition, the through holes60a1and60a2can be positioned away from the lateral surface(s) of the support member in a top view, or can be open on the lateral surface(s). In other words, the through holes can have a shape such that, in a top view, a portion of an outer edge of the support member is notched in a semi-circular shape, a semi-elliptical shape, and the like. That is, as illustrated inFIG.5C, through holes60b1and60b2open on the lateral surface(s) of the support member can be adopted. Sizes of the through holes60a1and60a2can be appropriately adjusted according to the size and the like of the support member60. For example, a diameter of the through hole60a1is in a range from 1.5 mm to 2.5 mm, and a diameter of the through hole60a2is in a range from 0.5 mm to 1.5 mm. If the sizes of the through holes60a1and60a2are kept within this range, the through holes60a1and60a2are appropriately large, and thus, can be easily aligned with the holes80a1and80a2of the module substrate80, and the through holes60a1and60a2are appropriately small, and thus, the support member60can be increased in strength.

In addition, the support member60has an opening60a3in a center of the support member60. In the opening60a3, the element structural body15and the first covering member51are disposed. A planar shape of the opening60a3is, for example, a substantially rectangular shape longer in the one direction X. The opening60a3is preferably dimensioned so that a distance between the plurality of element structural bodies15disposed within the opening60a3along the one direction X and an inner lateral surface(s) of the opening60a3is at least equal to or greater than 0.4 mm. This can facilitate disposition of the element structural body15and the first covering member51into the opening60a3. The opening60a3preferably passes through the support member60. As a result, the top surface of the element structural body15(that is, the top surface of the light-transmissive member30) and the bottom surface thereof (that is, the bottom surface of the substrate10) can be exposed from the support member60and the first covering member51to allow them to serve as the light emitting surface and an external electrode surface of the light emitting device100.

The light emitting device100includes a plurality of the element structural bodies15. Here, 11 element structural bodies15aligned in a single row along the one direction X are held by the first covering member51. However, the light emitting device100can include 10 or fewer element structural bodies15, or can include 12 or more element structural bodies15. However, in the light emitting device100, at least three element structural bodies15are disposed along the one direction X. If three or more element structural bodies15are disposed along the one direction X without disposing the support member60, the light emitting device100undergoes shrinkage of the resin during curing of the first covering member51at a plurality of places. As the number of joint portions by the first covering member51in the one direction X increases, warping of the light emitting device is more likely to occur. In addition, the shrinkage of the resin can occur due to thermal history when mounting the cured light emitting device to the module substrate, and if warping occurs in the light emitting device during the mounting, it is difficult to mount the light emitting device. The light emitting device100according to the present embodiment includes the support member60, and thus, even if three or more element structural bodies15are disposed along the one direction X, the light emitting device100is suppressed from being warped, and thus, the light emitting device100can be precisely disposed at a desired position. In addition, the element structural bodies15can be disposed in a plurality of rows along the one direction X. In the present embodiment, the one direction X is a row direction, and a direction perpendicular to the one direction X is a column direction.

“Disposing the element structural bodies15along the one direction X” encompasses, in a top view, a case in which the element structural bodies15are disposed in parallel so that the upper and lower lateral surfaces of the plurality of element structural bodies15are aligned on a straight line, and a case in which the element structural bodies15are disposed so that the upper and lower lateral surfaces of adjacent element structural bodies15are offset from each other. That is, in the light emitting device, in a top view, it is only required that each of the element structural bodies15is partially disposed on the straight line in the one direction X. Preferably, a substantially center of the top surface of each of the element structural bodies15is positioned on the straight line in the one direction X. As described below, even if the element structural bodies15are disposed in a plurality of rows, it is only required that each of the element structural bodies15is partially disposed on each of a plurality of straight lines in the one direction X. Preferably, the top surface of the light-transmissive member30of the element structural body15is positioned in a matrix along one direction.

In the light emitting device100including the plurality of element structural bodies15, a plurality of light emitting surfaces can be precisely positioned at a desired location in the light emitting device100with high density.

Light Emitting Module

Next, the light emitting module200will be described.

The light emitting module200includes the light emitting device100having the above-described configuration, and the module substrate80on which the light emitting device100is mounted with the substrate10of the light emitting device100so that the substrate10faces the module substrate80.

If the light emitting device100does not include the protecting element25, a preferable configuration is such that the module substrate80includes protecting element25. Furthermore, the module substrate80can be configured to include other electronic components other than the protecting element25, such as a connector that supplies power to the light emitting device100.

The light emitting device100is configured as described above.

The module substrate80is a member on which the light emitting device100is mounted and that electrically connects the light emitting device100to the outside. The module substrate80is substantially rectangular in a top view, for example. The module substrate80includes a base member6and wiring parts7disposed on a surface of the base member6.

Examples of a material of the base member6include the examples described with respect to the material employed in the base1of the substrate10. Examples of a material of the wiring parts7include the examples described with respect to the material employed for the wiring of the substrate10.

The module substrate80includes the holes80a1and80a2that pass through the module substrate80at positions facing the through holes60a1and60a2of the support member60. The hole80a1is substantially the same in shape and size as the through hole60a1, in a top view, and the hole80a2is substantially the same in shape and size as the through hole60a2in a top view. The light emitting device100is mounted on the top surface of the module substrate80so that the through holes60a1and60a2respectively overlap the holes80a1and80a2. Further, the light emitting device100is mounted on the top surface of the module substrate80so that the external connection electrodes3and the wiring parts7are joined via an electrically conductive adhesive9. Examples of the electrically conductive adhesive9include the examples described with respect to the electrically conductive adhesive8described above.

In the light emitting module200, the support member60is joined to the module substrate80via the electrically conductive adhesive9. As a result, heat generated from the light emitting device100is dissipated to the module substrate80via the support member60. Therefore, the light emitting module200has good heat dissipation. The support member60can be joined onto the module substrate80via an electrically insulating adhesive instead of the electrically conductive adhesive9. Additionally, the module substrate80can be positioned away from or placed on the support member60in contact with the support member60, without the support member60being fixed to the module substrate80.

Operation of Light Emitting Module

When the light emitting module200is driven, a current is supplied to the light emitting element20from an external power source, and as a result, the light emitting element20emits light. Of the light emitted from the light emitting element20, a portion of light traveling upward is extracted to the outside above the light emitting device100via the light-transmissive member30. Further, light traveling downward is reflected by the substrate10or the third covering member53, and is extracted to the outside of the light emitting device100via the light-transmissive member30. Light traveling in a lateral direction is reflected by at least one of the first covering member51, the second covering member52, and the third covering member53, and extracted to the outside of the light emitting device100via the light-transmissive member30. At this time, if a space between the light-transmissive members30is narrowed (for example, narrowed to equal to or less than 0.2 mm), for example, when the light emitting module200is employed for a light source of a vehicle headlight, a configuration of an optical system can be simplified and reduced in size. Furthermore, the light emitting module200has good heat dissipation and can be suppressed from deforming due to heat because of a presence of the support member60.

Method of Manufacturing Light Emitting Device

First, an example of a method of manufacturing the light emitting device100will be described.FIG.2is a flowchart of a method of manufacturing the light emitting device according to the embodiment.

The method of manufacturing the light emitting device100includes an element structural body provision step S101, a support member provision step S102, an element structural body disposition step S103, a first covering member formation step S104, and a sheet member removal step S105.

The material, arrangement, and the like of each of the members are as in the description of the light emitting device100, and thus descriptions thereof will be omitted as appropriate.

Element Structural Body Provision Step

The element structural body provision step S101is a step of providing a plurality of the element structural bodies15each including the substrate10, the light emitting element20, the light-transmissive member30, the light-guiding member40, the third covering member53, and the second covering member52.

The plurality of element structural bodies15can be provided by being purchased, for example, or provided by preparing the substrate10, the light emitting element20, the light-transmissive member30, the light-guiding member40, the third covering member53, and the second covering member52and then going through some or all of the steps described below.

The element structural body provision step S101includes, for example, a substrate assembly provision step S101a, a light emitting element mounting step S101b, a light-transmissive member disposition step S101c, a light-guiding member disposition step S101d, a third covering member formation step S101e, a second covering member formation step S101f, and an element structural body division step S101g.

Substrate Assembly Provision Step

The substrate assembly provision step S101ais a step of providing a substrate assembly11including a plurality of first regions12serving as the substrates10after the substrate assembly11is divided.

The substrate assembly11is a single substrate including the plurality of first regions12on which the light emitting element20is mounted. InFIG.4A, for convenience, the substrate assembly11including two of the first regions12is illustrated, but the number of the first regions12can be adjusted as appropriate.

Light Emitting Element Mounting Step

FIG.4Ais a schematic cross-sectional view illustrating a step of mounting the light emitting element.

The light emitting element mounting step S101bis a step of mounting the light emitting elements20in the plurality of first regions12.

In the step S101b, each of a plurality of the light emitting elements20is mounted in each of the plurality of first regions12. The mounting surface of the light emitting element20is a surface on which an electrode is formed, and the light emitting element20is flip-chip mounted on the top surface wiring2disposed in each of the first regions12by the electrically conductive adhesive8.

The light emitting element20can be provided through some or all of the manufacturing steps, such as through a step of growing a semiconductor, or can be purchased and provided.

The step S101bincludes a step of mounting the protecting elements25in the plurality of first regions12. That is, in the step S101b, each of the plurality of protecting elements25is mounted in each of the plurality of first regions12.

Light-Transmissive Member Disposition Step

FIG.4Ais a schematic cross-sectional view illustrating a step of disposing the light-transmissive member.

The light-transmissive member disposition step S101cis a step of disposing the light-transmissive member30above each of the light emitting elements20.

In the step S101c, for example, the light-transmissive member30having a predetermined shape is joined to a top surface opposite to an electrode formation surface of the light emitting element20(that is, on a primary light extraction side).

In the step S101c, for example, the light-transmissive member30is disposed on the light emitting element20disposed with a light-transmissive adhesive member thereon. As a result, the light-transmissive member30is joined to the top surface of the light emitting element20via the adhesive member. As described below, the adhesive member is pressed by the light-transmissive member30to form the light-guiding member40having a predetermined thickness. The bottom surface of the light-transmissive member30is preferably wider than the top surface of the light emitting element20. As a result, the adhesive member can easily extend to the lateral surface of the light emitting element20. The light-transmissive member30can be mounted on the light emitting element20so that the adhesive member is disposed on the light-transmissive member30, after which the adhesive member on the light-transmissive member30is disposed on the top surface of the light emitting element20.

When the light-transmissive member30is joined to the light emitting element20, a direct joint method can be employed without using the adhesive member.

Light-Guiding Member Disposition Step

The light-guiding member disposition step S101dis a step of disposing the light-guiding member40to the lateral surface(s) of each of the light emitting elements20.

The light-guiding member disposition step S101dcan be performed as the same step as the light-transmissive member disposition step S101c. An amount and a viscosity of the adhesive member used in the light-transmissive member disposition step S101ccan be adjusted. This can form the light-guiding member40by extending the adhesive member disposed between the light emitting element20and the light-transmissive member30to the lateral surface(s) of the light emitting element20.

If the light-transmissive member disposition step S101cis followed by the light-guiding member disposition step S101d, the light-guiding member40is disposed on the lateral surface(s) of the light emitting element20after the light emitting element20and the light-transmissive member30are joined by using the adhesive member or by a direct joint method.

If a light-transmissive adhesive member for joining the light emitting element20and the light-transmissive member30is employed for the light-guiding member40in the light-transmissive member disposition step S101c, the light-transmissive member disposition step S101cand the light-guiding member disposition step S101dare preferably performed as the same step. This can simplify the steps.

Third Covering Member Formation Step

FIG.4Cis a schematic cross-sectional view illustrating a step of forming the third covering member.

The third covering member formation step S101eis a step of forming the third covering member53that covers the lateral surface(s) of each of the light emitting elements20, onto the substrate assembly11.

In the step S101e, via the light-guiding member40disposed on the lateral surface(s) of the light emitting element20, the third covering member53that covers the lateral surface(s) of each of the light emitting elements20is formed on the substrate assembly11. In addition, the third covering member53can also be disposed between the light emitting element20and the substrate assembly11, and in the step S101e, the third covering member53is preferably provided so as to cover the bottom surface of each of the light emitting elements20.

In the step S101e, an uncured resin to be the third covering member53is applied onto the substrate assembly11by potting, spraying, and the like. If there is a gap between the light emitting element20and the substrate assembly11, the resin applied on the substrate assembly11spreads into the gap and creeps up and covers the lateral surface(s) of the light emitting element20and/or the light guide member40. Thereafter, the resin is cured to form the third covering member53that covers the lateral surface(s) of the light emitting element20.

Second Covering Member Formation Step

FIG.4Dis a schematic cross-sectional view illustrating a step of forming the second covering member.

The second covering member formation step S101fis a step forming the second covering member52that covers the lateral surface(s) of each of the light emitting elements20and the lateral surface(s) of each of the light-transmissive members30, on the substrate assembly11.

In the step S101f, the lateral surface(s) of each of the light emitting elements20is covered via the light-guiding member40disposed on the lateral surface(s) of the light emitting element20, and the second covering member52that covers the lateral surface(s) of each of the light-transmissive members30is formed on the substrate assembly11.

In the step S101f, an uncured resin to be the second covering member52is applied onto the substrate assembly11by potting, spraying, and the like. The resin applied on the substrate assembly11creeps up and covers the lateral surface(s) of the light emitting element20, the light guide member40, and/or the light-transmissive member30by a surface tension. Thereafter, the resin is cured to from the second covering member52that covers the lateral surface(s) of the light emitting element20and the lateral surface(s) of the light-transmissive member30.

In the step S101f, the second covering member52is formed so that the lateral surface(s) of the light emitting element20and the lateral surface(s) of the light-transmissive member30are covered and the top surface of the light-transmissive member30is exposed. The second covering member52can be formed by injection molding, transfer molding, compression molding, and the like by using a mold and the like. Formation of the second covering member52can be performed by covering the top surface of the light-transmissive member30and thereafter removing a part of the second covering member52by polishing, grounding, and severing, for example, so that the top surface of the light-transmissive member30is exposed.

Element Structural Body Division Step

FIG.4Eis a schematic cross-sectional view illustrating a step of individualizing the element structural body.

The element structural body division step S101gis a step of dividing the substrate assembly11into each of the first regions12to obtain a plurality of the element structural bodies15.

In the step S101g, the substrate assembly11is divided at predetermined positions to achieve the plurality of element structural bodies15.

In the method of manufacturing the light emitting device100, the plurality of divided element structural bodies15are combined to manufacture the light emitting device100. That is, a sorting step can be performed after the division into each of the element structural bodies15, and thus, the light emitting device100can be formed in such a way that an element structural body15having a light emitting property within a predetermined range is sorted from the divided element structural bodies15, after which the divided element structural bodies15are combined as desired. As a result, the light emitting device100providing a desired light emission color with little color deviation can be obtained.

In addition, each of the element structural bodies15includes the third covering member53, and thus, even if a light emission color of the element structural body15and a light emission color of the light emitting element20differ from each other, such as in a case in which the light-transmissive member30includes a wavelength conversion member, only the element structural body15having a light emitting property within a predetermined range can be easily sorted.

In addition, in the manufacturing process, when a defect occurs in some of the element structural bodies15, only the defective element structural body15can be discarded before the first covering member51is disposed. In a light emitting device in which a plurality of light emitting elements are mounted on a single substrate, when a defect occurs in some of the members, the entire light emitting device needs to be discarded. Therefore, the method of manufacturing the light emitting device according to the present embodiment allows for reduction of an amount of waste members when a defect occurs during the step.

Support Member Provision Step

FIG.4Fis a schematic top view illustrating a support member assembly in a support member provision step.FIG.4Gis a schematic cross-sectional view illustrating a state in which the support member is disposed on a sheet member.

The support member provision step S102is a step of providing the support member60.

As illustrated inFIG.4F, the support member60can be provided as a support member assembly65in which, for example, the frame-shaped support member60having the opening60a3is connected in a matrix with a link member61.

As illustrated inFIG.4G, when the support member assembly65is fixed on the sheet member70, for example, the element structural bodies15can be mounted on the sheet member70, based on the position of the support member60. As a result, the element structural body15can be precisely mounted on the sheet member70even without an alignment mark for mounting the element structural body15. Additionally, using the support member60having the through holes60a1and60a2different in diameter can suppress erroneous recognition in the left and right directions of the support member assembly65. InFIG.4G, for convenience, a state in which one support member60is disposed on the sheet member70is illustrated.

Element Structural Body Disposition Step

FIG.4His a schematic cross-sectional view illustrating a step of disposing the element structural body on a sheet. InFIG.4H, for convenience, the element structural bodies15disposed on one support member60is illustrated.

The element structural body disposition step S103is a step of disposing the plurality of element structural bodies15on the sheet member70so that the substrate10of each of the element structural bodies15faces the sheet member70.

In the step S102, the plurality of element structural bodies15are disposed along the one direction X within the opening60a3of the frame-shaped support member60having the opening60a3. The plurality of element structural bodies15are mounted on the sheet member70so that the bottom surface of the substrate10(that is, a surface opposite the surface on which the light emitting element20is mounted) contacts the top surface of the sheet member70. In the sheet member70, an adhesive agent72is provided on a support71. In a case in which the element structural body15includes the external connection electrode3on the bottom surface, the element structural body15is preferably disposed on the sheet member70to press the bottom surface into the adhesive agent72so that the external connection electrode3is embedded in the adhesive agent72of the sheet member70. As a result, in the first covering member formation step S104described below, intrusion of the first covering member51to the surface of the external connection electrode3can be suppressed.

In the step S102, the divided element structural bodies15can be disposed on the sheet member70, and thus, for example, if a blade is used for division, the element structural bodies15can be disposed at a distance shorter than a width of the blade. As a result, the light emitting device100having a narrow space between the light emitting surfaces can be provided. In addition, in the step S102, the divided element structural bodies15are disposed on the sheet member70, and thus, the plurality of light emitting surfaces can be precisely positioned at a desired location within a frame of the support member60with high density.

Examples of the sheet member70include a heat-resistant resin sheet and a UV cured sheet, known in the art.

First Covering Member Formation Step

FIG.4Iis a schematic cross-sectional view illustrating a step of forming the first covering member.

The first covering member formation step S104is a step of forming the first covering member51on the sheet member70exposed from the opening60a3. The first cover member51covers lateral surface(s) of the substrate10, the light emitting element20, and the light-transmissive member30of each of the element structural bodies15.

In the step S104, an uncured resin to be the first covering member51is disposed on the sheet member70so that the first covering member51is provided up to the lateral surface(s) of the element structural bodies15in the frame of the support member60by potting or spraying, for example. The resin disposed within the opening60a3creeps up a space between the adjacent element structural bodies15due to a capillary action. As a result, the lateral surface(s) of the light-transmissive member30of the element structural body15can be covered. In the case in which the height of the top surface of the support member60disposed on the sheet member70is made lower than the top surface of the element structural body15, creeping of the first covering member51onto the top surface of the light-transmissive member30can be suppressed.

In the step S104, the first covering member51is provided so that the lateral surface(s) of the element structural body15(that is, the lateral surface(s) of the substrate10, the lateral surface(s) of the light emitting element20, and the lateral surface(s) of the light-transmissive member30) are covered and the top surface of the light-transmissive member30is exposed. The first covering member51can be disposed so that the top surface of the element structural body15is covered, after which a part of the first covering member51is removed by being polished, ground, or severed, for example, so that the top surface of the element structural body15is exposed.

Note that the first covering member51can be formed by molding, printing, or the like.

Sheet Member Removal Step

FIG.4Jis a schematic cross-sectional view illustrating a step of removing the sheet member. The sheet member removal step S105is a step of removing the sheet member70.

In the step S105, the sheet member70on which the element structural body15and the like is mounted is peeled off to form the light emitting device100.

I practice, the light emitting devices100are linked with each other with the link member61of the support member assembly65, and the link member61is cut to obtain individual light emitting devices100.

The light emitting device100thus obtained has a narrow space between the light emitting surfaces, and thus, coordination of a light distribution by an optical system such as a lens is facilitated. Additionally, the plurality of light emitting surfaces can be disposed precisely at a desired position in the light emitting device100with high density. In addition, the light emitting device100is suppressed from being warped, and thus, the light emitting device100can be precisely disposed at a desired position of the module substrate80.

Method of Manufacturing Light Emitting Module

Next, an example of a method of manufacturing the light emitting module200will be described.FIG.3is a flowchart of the method of manufacturing the light emitting module according to the embodiment.

The method of manufacturing the light emitting module200includes a light emitting device provision step S11and a light emitting device mounting step S12.

The module substrate80preferably has the holes80a1and80a2at positions respectively facing the through holes60a1and60a2of the support member60. As illustrated inFIG.4K, in the light emitting device mounting step S12, the through holes60a1and60a2of the support member60are aligned with the holes80a1and80a2of the module substrate80to mount the light emitting device100on the module substrate80.

The material, arrangement, and the like of each of the members are as in the description of the light emitting module200, and thus descriptions thereof will be omitted as appropriate.

Light Emitting Device Provision Step

The light emitting device provision step S11is a step of providing the above-described light emitting device100.

In the step S11, the light emitting device100is manufactured by, for example, performing the above-described steps S101to S105.

Light Emitting Device Mounting Step

FIG.4Kis a schematic cross-sectional view illustrating a step of mounting the light emitting device.

The light emitting device mounting step S12is a step of mounting the light emitting device100so that the substrate10of the light emitting device100faces the module substrate80.

In the step S12, the light emitting device100is mounted on the top surface of the module substrate80. In the light emitting device100, a side closer to the substrate10is a mount surface, and the light emitting device100is mounted on the top surface of the module substrate80via the electrically conductive adhesive9.

In the step S12, the through hole60a1of the support member60is aligned with the hole80a1of the module substrate80and the through hole60a2of the support member60is aligned with the hole80a2of the module substrate80, and fastener91aof positioning jigs90is inserted into the through hole60a1and the hole80a1and fastener91bis inserted into the through hole60a2and the hole80a2. Thus, the light emitting device100is aligned with the module substrate80to mount the light emitting device100on the module substrate80.

Thus, the light emitting device and the light emitting module, and the method of manufacturing the light emitting device and the method of manufacturing the light emitting module have been specifically described in DESCRIPTION OF EMBODIMENTS, but the spirit of the present invention is not limited to these descriptions, and should be broadly construed based on the claims. Various modifications, variations, and the like based on these descriptions are also included within the spirit of the present invention.

Modifications

FIGS.5A to5Gare schematic top views each illustrating an example of a light emitting module including a light emitting device according to a first modification to a seventh modification.FIG.5His a schematic cross-sectional view illustrating an example of a method of manufacturing a light emitting module according to an eighth modification.

In each of the drawings, the size, the positional relationship, and the like of the members are simplified as appropriate.

In the first modification, in a light emitting module200A and a light emitting device100A, a support member60A is a single bar-shaped member. The bar-shaped support member60A is disposed along the side of the plurality of element structural bodies15in the one direction X.

In the second modification, in a light emitting module200B and a light emitting device100B, a support member60B includes two bar-shaped support members60B. The two support members60B are disposed in parallel along the sides of the plurality of element structural bodies15in the one direction X so that the bar-shaped support members60B sandwich the plurality of element structural bodies15.

As illustrated in the first modification and the second modification, even if the bar-shaped support member is employed in the light emitting device, using the configuration in which the support members are disposed along the sides of the plurality of element structural bodies15in the one direction X can suppress warping of the light emitting device. Furthermore, if the bar-shaped support member is employed, the support member can be reduced in size, and thus, the light emitting modules200A and200B and the light emitting devices100A and100B can be reduced in size and weight. In the first modification and the second modification, the support member may have or may not have a through hole to be aligned with the module substrate.

In the third modification, in a light emitting module200C and a light emitting device100C, a support member60C includes the through holes60b1and60b2having a shape obtained by partially cutting an external edge in a semi-elliptical shape, at both lateral surface(s)s facing in the one direction X. The through holes60b1and60b2differ in size. In this manner, if the through holes60b1and60b2are through holes open on the lateral surface(s), a length in the one direction X of the support member60C can be shortened, and thus, the light emitting module200C and the light emitting device100C can be reduced in size and weight. The shapes of the through holes60b1and60b2open on the lateral surface(s) are not limited to a semi-elliptical shape, and can be a semicircular shape or a quadrangular shape.

In the fourth modification, in a light emitting module200D and a light emitting device100D, a plurality of the element structural bodies15are disposed in a matrix of 2 rows and 11 columns. In the fifth modification, in a light emitting module200E and a light emitting device100E, a plurality of the element structural bodies15are disposed in a matrix of 2 rows and 11 columns. In the fifth modification, the element structural bodies15located at both ends of each row are disposed so that a distance from the element structural body15at one end to the adjacent element structural body15in a row direction is longer than a distance between the other element structural bodies15in the row direction.

In the sixth modification, in a light emitting module200F and a light emitting device100F, the element structural bodies15that are different in a size of the light emitting surface are combined. In this modification, the element structural bodies15having small light emitting surfaces are disposed in a matrix of two rows and six columns at a center portion of the light emitting device100F. In addition, the three element structural bodies15having large light emitting surfaces are each disposed in line at both ends in the row direction of an assembly of the element structural bodies15having small light emitting surfaces. In this manner, in the light emitting module200F and the light emitting device100F, the plurality of element structural bodies15different in light emitting surface are disposed along the one direction. In this manner, in the light emitting module200and the light emitting device100, some of the plurality of element structural bodies15can be disposed in a plurality of rows while being disposed along the one direction. In the light emitting module200F and the light emitting device100F, in the case in which the element structural body15having a small light emitting surface is disposed at the center portion, a large number of element structural bodies15can be densely disposed at the center portion, as compared to a case in which the element structural body15having a large light emitting surface is disposed. In the light emitting module200F and the light emitting device100F, in the case in which the element structural bodies15are densely disposed at the center portion, in a case in which the light emitting module200F is employed for a light source of a vehicle headlight, for example, it is possible to emit light onto the center portion (mainly, on a road) with higher definition.

In the seventh modification, in a light emitting module200G and a light emitting device100G, the element structural bodies15are disposed in two rows in a staggered pattern. In this modification, the element structural bodies15in the first row and the element structural bodies15in the second row are disposed to be shifted in a row direction so that a gap in the row direction between the element structural bodies15in the first row and the element structural bodies15in the second row is equal to or less than 0. In this manner, in the light emitting module200G and the light emitting device100G, the plurality of element structural bodies15are disposed in two rows along the one direction. In the light emitting module200G and the light emitting device100G, the gap in the row direction can be equal to or less than 0, for example, in a case in which the light emitting module200G is employed for a light source of a vehicle headlight, it is possible to emit light in a lateral direction with higher definition.

Thus, in the light emitting module and the light emitting device, the number of rows and the number of columns are not limited, and the number of element structural bodies in each row and each column can be adjusted as appropriate in accordance with a desired light distribution pattern. Furthermore, in the light emitting module and the light emitting device, a combination of element structural bodies different in size of the light emitting surface, a disposition of the element structural bodies, or the like can be adjusted as appropriate in accordance with a light distribution pattern.

In the light emitting device, the plurality of element structural bodies can include at least two types of element structural bodies different in light emission color. Here, the light emission color of the element structural body refers to an emission color of the light emitted from the top surface of the light-transmissive member. For example, the light emitting element and the element structural body can be the same in light emission color. If light emitting elements different in light emission color are employed, for example, at least two types of element structural bodies having different light emission colors can be obtained. In addition, if the plurality of element structural bodies using the light emitting elements same in light emission color include the light-transmissive members containing phosphors different from each other, the plurality of element structural bodies different in light emission color can be obtained.

In the light emitting device and the light emitting module described above, the second covering member may or may not cover the bottom surface of the light emitting element.

Furthermore, various types of colorants, fillers, wavelength conversion members, or the like serving as an additive can be contained in each member of the first covering member, the second covering member, the third covering member, the light-guiding member, and the like to obtain a desired light emission color, a desired color of a surface of a member, a desired light distribution characteristic, or the like.

Additionally, the substrate and the module substrate can be a substantially square in a top view, and the support member can also be a substantially square frame body in a top view. The substrate, the module substrate, and the support member can be formed in other shapes. In addition, if the support member is a frame body, the frame can include an intermittently disposed portion. The support member can be formed in a shape in which one side of a polygon is missing (for example, a concave shape), a U shape, and the like, for example.

In the eighth modification, a light emitting module200H includes the light emitting device100and a module substrate80A. The module substrate80A has holes80c1and80c2at positions respectively facing the through holes60a1and60a2of the support member60. Additionally, the module substrate80A has holes80d1an80d2into which fasteners91Aa and91Ab of positioning jigs90A are inserted. In the eighth modification, the holes80c1and80c2and the holes80d1and80d2are holes that are provided on the top surface of the module substrate80A and do not pass through the module substrate80A.

In the light emitting device mounting step S12, the through hole60a1of the support member60is aligned with the hole80c1of the module substrate80A, and the through hole60a2of the support member60is aligned with the hole80a2of the module substrate80A, and the fasteners91aof the positioning jigs90A are inserted into the through hole60a1and the hole80c1, and the fastener91bis inserted into the through hole60a2and the hole80c2. The fastener91Aa is inserted into the hole80d1, and the fastener91Ab is inserted into the hole80d2. Thus, the light emitting device100is aligned with the module substrate80A to mount the light emitting device100on the module substrate80A.

FIG.6Ais a schematic top view illustrating an example of a light emitting module including a light emitting device according to a ninth modification.FIG.6Bis a schematic bottom view illustrating an example of the light emitting device according to the ninth modification.FIG.6Cis a schematic cross-sectional view taken along line VIC-VIC ofFIG.6A.FIG.6Dis a schematic top view illustrating an example of a module substrate used in the light emitting module according to the ninth modification.FIG.6Eis a schematic top view illustrating, in a partially expanded manner, an example of the light emitting module according to the ninth modification, and is a schematic top view illustrating a positional relationship between the module substrate ofFIG.6Dand the light emitting device ofFIG.6A.FIG.6Fis a schematic top view illustrating an example of a module substrate used in a light emitting module according to a tenth modification.FIG.6Gis a schematic top view illustrating, in a partially expanded manner, an example of the light emitting module according to the tenth modification, and is a schematic top view illustrating a positional relationship between the module substrate ofFIG.6Fand the light emitting device ofFIG.6A.FIGS.6E and6Gillustrate the light emitting device in a see-through manner.

In the ninth modification, a light emitting module200I and a light emitting device100H include heat dissipation terminals. In the light emitting device100H, the substrate10provided in an element structural body15A includes a first heat dissipation terminal5, and a pair of external connection electrodes3A on the bottom surface opposite to the top surface on which the light emitting element20is mounted. The substrate10has a substantially rectangular parallelepiped shape having a longitudinal direction and a lateral direction in a top view. The substrate10includes the pair of external connection electrodes3A at a first end in the longitudinal direction of the bottom surface and the first heat dissipation terminal5at a second end opposite to the first end. The first heat dissipation terminal5faces positive and negative external connection electrodes (that is, an anode electrode3Aa and a cathode electrode3Ab) in the longitudinal direction. Thus, the light emitting device100H includes the pair of external connection electrodes3A having a shorter length in the longitudinal direction of the substrate10, than the external connection electrode3of the light emitting device100.

The first heat dissipation terminal5having a substantially rectangular shape is disposed on the bottom surface of the substrate10. In the element structural body15A, the first heat dissipation terminal5is disposed immediately beneath the light emitting element20.

Examples of a material of the first heat dissipation terminal5include the examples described with respect to the material employed for the external connection electrode3. The first heat dissipation terminal5is electrically insulated from the pair of external connection electrodes3A. That is, the first heat dissipation terminal5and the light emitting element20are electrically insulated.

The light emitting device100H differs from the light emitting device100in a size of an opening63aof a support member60D.

The light emitting device100H is similar to the light emitting device100in other aspects.

The top surface of the module substrate80B on which the light emitting device100H is mounted includes positive and negative wiring parts7A disposed at positions facing positive and negative external connection electrodes3A, and a second heat dissipation terminals17disposed at position facing the first heat dissipation terminals5.

In the module substrate80B, a shape and a position of each of the wiring parts7A joined to the light emitting device100H match a shape and a position of each of the pair of external connection electrodes3A. Specifically, the module substrate80B includes the wiring parts7A each having a shape substantially matching shapes of the anode electrode3Aa and the cathode electrode3Ab of the light emitting device100H (an anode electrode-side wiring part7Aa and a cathode electrode-side wiring part7Ab).

The module substrate80B includes the second heat dissipation terminals17disposed to respectively face the first heat dissipation terminals5of the element structural bodies15A. The second heat dissipation terminals17are disposed continuously in a top view from a position facing the first heat dissipation terminal5to a position facing the bottom surface of the support member60in a Y direction perpendicular to the one direction X. As a result, heat dissipation can be further improved.

In the tenth modification, in a light emitting module200J, the second heat dissipation terminal of a module substrate80C differs in shape from the module substrate80B.

The module substrate80C on which the light emitting device100H is mounted is provided with one second heat dissipation terminal17A having a size including a plurality of regions facing the first heat dissipation terminal5of each of the plurality of element structural bodies15A. That is, the module substrate80C includes one second heat dissipation terminal17A collectively connected with a plurality of the first heat dissipation terminals5provided in the light emitting device100H. The second heat dissipation terminal17A is disposed continuously in a top view from a position facing the first heat dissipation terminals5to a position facing the bottom surface of the support member60D in a Y direction perpendicular to the one direction X. As a result, heat dissipation can be further improved.

The module substrate80C is similar to the module substrate80B in other aspects.

In the module substrate80B and the module substrate80C, the second heat dissipation terminals17and17A are different in shape and position from the first heat dissipation terminal5, but a module substrate in which the second heat dissipation terminals17and17A match in shape and position with the first heat dissipation terminal5can be used.

FIG.7Ais a schematic top view illustrating an example of a light emitting module including a light emitting device according to an eleventh modification.FIG.7Bis a schematic bottom view illustrating an example of the light emitting device according to the eleventh modification.FIG.7Cis a schematic top view illustrating an example of a module substrate used in the light emitting module according to the eleventh modification.FIG.7Dis a schematic top view illustrating, in a partially expanded manner, an example of the light emitting module according to the eleventh modification, and is a schematic top view illustrating a positional relationship between the module substrate ofFIG.7Cand the light emitting device ofFIG.7A.FIG.7Eis a schematic top view illustrating an example of a module substrate used in a light emitting module according to a twelfth modification.FIG.7Fis a schematic top view illustrating, in a partially expanded manner, an example of the light emitting module according to the twelfth modification, and is a schematic top view illustrating a positional relationship between the module substrate ofFIG.7Eand the light emitting device ofFIG.7A.FIGS.7D and7Feach illustrate the light emitting device in a transparent manner.

In the eleventh modification, in a light emitting module200K and a light emitting device100I, the plurality of element structural bodies15A are disposed in a matrix of 2 rows and 11 columns along the one direction X. The plurality of element structural bodies15A are disposed in two rows and linearly symmetrical with respect to a symmetry axis of a straight line parallel to the one direction X. That is, the plurality of element structural bodies15A are disposed in two rows along the one direction X and are disposed so as to be linearly symmetrical with respect to the straight line passing between the two rows.

In the light emitting device100I, in a top view, the element structural body15A in the first row and the element structural body15A in the second row are disposed so that the lateral surface(s) on the other end side where the first heat dissipation terminals5are disposed face each other. That is, the first heat dissipation terminals5included in the plurality of element structural bodies15A are disposed inward of the pair of external connection electrodes3A in a direction Y perpendicular to the one direction X in a top view.

The light emitting device100I is similar to the light emitting device100H in other aspects except for a size of the opening63aof the support member.

The top surface of the module substrate80D on which the light emitting device100I is mounted includes positive and negative wiring parts7A disposed at a position facing a positive and negative external connection electrodes3A, and a second heat dissipation terminal17B disposed at positions facing the first heat dissipation terminals5.

The module substrate80D includes one second heat dissipation terminal17B having a size including a plurality of regions facing the first heat dissipation terminal5of each of the plurality of element structural bodies15A.

In the module substrate80D, the second heat dissipation terminal17B is disposed continuously in a top view from a position facing at least one of the first heat dissipation terminals5to a position facing the bottom surface of the support member60in the one direction X. The second heat dissipation terminal17B is positioned away from the through holes60a1and60a2in a top view.

That is, in the module substrate80D, the plurality of first heat dissipation terminals5provided in the light emitting device100I are collectively mounted, and the one second heat dissipation terminal17B extends to a predetermined position facing the bottom surface of the support member60in the one direction X, in a top view. As a result, heat dissipation can be further improved.

The module substrate80D is similar to the module substrate80B in other aspects.

In the twelfth modification, in a light emitting module200L, a second heat dissipation terminal of a module substrate80E differs in shape from that of the module substrate80D.

The module substrate80E of the light emitting module200L according to the twelfth modification is mounted thereon with the light emitting device100I including the plurality of element structural bodies15A disposed in a plurality of rows along the one direction X. The module substrate80E includes a plurality of second heat dissipation terminals17C corresponding to the plurality of rows in which the element structural bodies15A are disposed. Each of the plurality of second heat dissipation terminals17C is joined with the first heat dissipation terminals5.

Specifically, the module substrate80E includes, as the second heat dissipation terminals17C, a second heat dissipation terminal17Ca disposed to face the first heat dissipation terminal5of each of the element structural bodies15A disposed in the first row, and a second heat dissipation terminal17Cb disposed to face the first heat dissipation terminal5of each of the element structural bodies15A disposed in the second row.

In addition, in the module substrate80E, a pair of the second heat dissipation terminals17C is disposed to extend to a position facing the bottom surface of the support member60in the one direction X, in a top view. As a result, heat dissipation can be further improved. The second heat dissipation terminal17C is positioned away from the through holes60a1and60a2of the support member60in a top view.

The module substrate80E is similar to the module substrate80D in other aspects.

In the module substrate80D and the module substrate80E, the second heat dissipation terminals17B and17C are different in shape and position from the first heat dissipation terminal5, but a module substrate in which the second heat dissipation terminals17B and17C match in shape and position with the first heat dissipation terminals5can be used.

Further, as long as the above-described steps are not adversely affected, the method of manufacturing the light emitting device and the method of manufacturing the light emitting module can include another step during, before, or after any of the steps.

FIG.8is a flowchart of another method of manufacturing a light emitting device according to the embodiment.

For example, in the method of manufacturing the light emitting device according to the embodiment, in a case in which a thermosetting resin is employed for the first covering member51in the first covering member formation step S104, an adhesive agent curing step S500, which is a step of curing an adhesive resin, that is, the adhesive agent72, of the sheet member70can be performed after the element structural body disposition step S103is performed, and before the first covering member formation step S104is performed. Due to thermal history when the resin is cured and/or the time elapsed until the resin is cured, the light emitting device100may not easily be peeled from the sheet member70or a part of the adhesive agent72of the sheet member70may adhere to a rear surface of the light emitting device100after the peeling. In particular, in a case in which the element structural body15includes the external connection electrode3on the bottom surface of the substrate10, once the adhesive agent72of the sheet member70adheres to the surface of the external connection electrode3, an electrical connection may not be performed during mounting on the module substrate. To avoid this, when the adhesive agent72of the sheet member70is cured before the first covering member51is formed, the adhesive agent of the sheet member70is less likely to remained on the external connection electrode3of the light emitting device100after the sheet member70is removed. A curing condition and the like of the resin are ordinarily managed so that the above-described disadvantage do not occur, but the adhesive agent curing step S500can be performed to further ensure suppression of adhesion and the like of the adhesive agent72.

In addition, in the element structural body disposition step, the element structural body is disposed on the sheet member70so that the external connection electrode3is embedded in the adhesive agent72of the sheet member70. However, the element structural body can be disposed on the sheet member70so that the external connection electrode3is not embedded in the adhesive agent72of the sheet member70. In this case, in the first covering member formation step, the first covering member can cover the bottom surface of the substrate10and the lateral surface(s) of the external connection electrode3.

For example, a step of removing a foreign matter mixed during manufacturing can be included.

Furthermore, in the method of manufacturing the light emitting device and the method of manufacturing the light emitting module, the order of some steps is not limited, and the order can be reversed. For example, in the element structural body provision step, after the plurality of light emitting elements20are mounted on the substrate10, the light-transmissive member30is provided on each of the light emitting elements20. However, after the light-transmissive member30is provided above the light emitting element20, the light-transmissive member30can be mounted on the substrate10. Furthermore, after the substrate assembly11is divided, the light emitting element20and the light-transmissive member30can be mounted on the substrate10.

In addition, for example, in the method of manufacturing the light emitting device described above, the support member provision step is performed before the element structural body disposition step. However, the support member provision step can be performed before the first covering member formation step and after the element structural body disposition step. The support member provision step can be performed before the element structural body provision step.

The light emitting device and the light emitting module according to embodiments of the present disclosure can be suitably utilized for an adoptive driving beam headlight light source serving as a vehicle lighting appliance. In addition, the light emitting device and the light emitting module according to embodiments of the present disclosure can be utilized for a backlight light source of a liquid crystal display, various types of lighting fixtures, a large display, various types of display devices for advertisements, destination information, or the like, and further, a digital video camera, an image reading device in a facsimile, a copy machine, a scanner, and the like, and a projector device.