Patent Publication Number: US-2023134799-A1

Title: Method for manufacturing light-emitting device

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is based upon and claims priority to Japanese Patent Application No.2021-177467, filed on Oct. 29, 2021, and Japanese Patent Application No.2022-094309, filed on Jun. 10, 2022, the entire contents of which are incorporated herein by reference. 
     BACKGROUND 
     Embodiments relate to a method for manufacturing a light-emitting device. 
     JP-A 2016-149389 discusses a method for manufacturing a light-emitting device in which a light-emitting element is adhered to a support substrate, and a phosphor layer is formed by spraying phosphor particles or the like onto a semiconductor layer of the light-emitting element. 
     SUMMARY 
     According to one aspect of the present invention, a method for manufacturing a light-emitting device includes preparing a plurality of light-emitting elements. Each of the plurality of light-emitting elements includes a semiconductor structure body. The semiconductor structure body includes a first surface including a plurality of recesses, a second surface positioned at a side opposite to the first surface, and a lateral surface connecting the first surface and the second surface. The method includes disposing the plurality of light-emitting elements on a sheet member so that the second surfaces of the plurality of light-emitting elements face the sheet member and so that the lateral surfaces of the plurality of light-emitting elements are covered with the sheet member. The sheet member is adhesive. The method includes causing a first member to contact the first surfaces of the plurality of light-emitting elements so that the first member is located inside the plurality of recesses and located between the sheet member and a second member in a state in which the second member is located on the first member. The first member includes an uncured resin member that is transmissive. The second member includes a wavelength conversion material and has a higher hardness than the uncured resin member. The method includes curing the first member, and removing the sheet member from the plurality of light-emitting elements. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a cross-sectional view showing a light-emitting module according to a first embodiment; 
         FIG.  2 A  is an enlarged top view showing a portion of a first surface of a semiconductor structure body shown in  FIG.  1   ; 
         FIG.  2 B  is a top view showing the light-emitting module according to the first embodiment; 
         FIG.  3    is a flowchart showing a method for manufacturing the light-emitting module according to the first embodiment; 
         FIGS.  4 A to  7 C  are cross-sectional views illustrating the method for manufacturing the light-emitting module according to the first embodiment; 
         FIG.  8    is a cross-sectional view illustrating a method for manufacturing a light-emitting module according to a reference example; 
         FIG.  9    is a cross-sectional view illustrating a method for manufacturing a light-emitting module according to a first modification of the first embodiment; and 
         FIG.  10    is a cross-sectional view showing a light-emitting module according to a second embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Exemplary embodiments will now be described with reference to the drawings. 
     The drawings are schematic or conceptual, and the relationships between the thickness and width of portions, the proportional coefficients of sizes among portions, etc., are not necessarily the same as the actual values thereof. Furthermore, the dimensions and proportional coefficients may be illustrated differently among drawings, even for identical portions. 
     In the specification of the application and the drawings, components similar to those described in regard to a previously described drawing are marked with like reference numerals, and a detailed description is omitted as appropriate. 
     First Embodiment 
     First, a first embodiment will be described. 
       FIG.  1    is a cross-sectional view showing a light-emitting module  10  according to the embodiment. 
       FIG.  2 A  is an enlarged top view showing a portion of a first surface  121   s   1  of a semiconductor structure body  121  shown in  FIG.  1   . 
       FIG.  2 B  is a top view showing the light-emitting module  10  according to the embodiment. 
     The light-emitting module  10  according to the embodiment includes a wiring substrate  11 , a light-emitting device  12 , and a resin member  13 . The light-emitting device  12  includes a light-emitting element  120 , a first member  130 , and a second member  140 . The components of the light-emitting module  10  will now be elaborated. An XYZ orthogonal coordinate system is used for easier understanding of the following description. Hereinbelow, the direction in which the light-emitting element  120 , the first member  130 , and the second member  140  are arranged is taken as a “Z-direction.” A direction orthogonal to the Z-direction is taken as an “X-direction,” and a direction orthogonal to the Z-direction and the X-direction is taken as a “Y-direction.” When describing the structure of the light-emitting module  10 , among the Z-directions, the direction from the light-emitting element  120  toward the second member  140  is taken as the “upward direction,” and the opposite direction is taken as the “downward direction”; however, these directions are relative and are independent of the direction of gravity. 
     For example, the wiring substrate  11  includes an insulating layer and multiple interconnects located on the insulating layer. For example, the wiring substrate  11  has a flat plate shape. The upper surface and the lower surface of the wiring substrate  11  are substantially parallel to the X-Y plane. 
     The light-emitting element  120  is located on the wiring substrate  11 . The light-emitting element  120  includes the semiconductor structure body  121 , a light-reflective electrode  122 , an insulating film  123 , an n-side electrode  124 , and a p-side electrode  125 . 
     The semiconductor structure body  121  is, for example, a structure body in which multiple semiconductor layers made of a nitride semiconductor are stacked. Here, “nitride semiconductor” includes all compositions of semiconductors of the chemical formula In x Al y Ga 1-x-y N (0 ≤ x ≤ 1, 0 ≤ y ≤ 1, and x + y ≤ 1) for which the composition ratios x and y are changed within the ranges respectively. The semiconductor structure body  121  includes an n-side semiconductor layer  126 , an active layer  127 , and a p-side semiconductor layer  128  in this order downward from above. 
     The upper surface of the n-side semiconductor layer  126  corresponds to the upper surface of the semiconductor structure body  121 . Hereinbelow, the upper surface of the semiconductor structure body is called the “first surface  121   s   1 .” Multiple recesses  121   a  are provided in the first surface  121   s   1 . A region  121   b  of the first surface  121   s   1  between the multiple recesses  121   a  is, for example, a region that is substantially parallel to the X-Y plane. The multiple recesses  121   a  are surrounded with the region  121   b  in a top-view. 
     The multiple recesses  121   a  are arranged in a staggered configuration in a top-view. However, the arrangement pattern of the multiple recesses  121   a  is not limited to such a pattern. For example, the multiple recesses  121   a  may be arranged in a matrix configuration. 
     As shown in  FIGS.  1  and  2 A , each recess  121   a  is substantially circular conic. A depth L1 of each recess  121   a  is not particularly limited. It is favorable for the depth L1 of each recess  121   a  to be, for example, not less than 0.5 µm and not more than 3 µm. A diameter L2 of each recess  121   a  is not particularly limited. It is favorable for the diameter L2 of each recess  121   a  to be, for example, not less than 1 µm and not more than 6 µm. However, the shape and size of each recess  121   a  is not particularly limited to the shapes and sizes described above. For example, each recess  121   a  may be a truncated pyramid, circular cone, polygonal pyramid, hemisphere, etc. 
     As shown in  FIG.  1   , the lower surface of the n-side semiconductor layer  126  includes an outer perimeter region  126   a , a covered region  126   b , and multiple contact regions  126   c . The outer perimeter region  126   a  is within a constant range from the outer perimeter edge of the lower surface of the n-side semiconductor layer  126 . The outer perimeter region  126   a  is substantially parallel to the X-Y plane. The covered region  126   b  is positioned inward of the outer perimeter region  126   a . The covered region  126   b  is substantially parallel to the X-Y plane. The position of the covered region  126   b  in the Z-direction is lower than the position of the outer perimeter region  126   a . Each contact region  126   c  is positioned inward of the outer perimeter edge of the covered region  126   b . Each contact region  126   c  is substantially parallel to the X-Y plane. The positions of the contact regions  126   c  in the Z-direction are higher than the position of the covered region  126   b  and substantially the same as the position of the outer perimeter region  126   a . 
     The active layer  127  covers substantially the entire region of the covered region  126   b  of the lower surface of the n-side semiconductor layer  126 . The p-side semiconductor layer  128  covers substantially the entire region of the lower surface of the active layer  127 . The active layer  127  and the p-side semiconductor layer  128  leave exposed the contact regions  126   c  and the outer perimeter region  126   a  of the lower surface of the n-side semiconductor layer  126 . 
     The surface of the semiconductor structure body  121  positioned inward of the outer perimeter edge of the lower surface of the n-side semiconductor layer  126 , i.e., the outer perimeter edge of the outer perimeter region  126   a , is called a “second surface  121   s   2 .” The second surface  121   s   2  is positioned at the side opposite to the first surface  121   s   1 . A surface that is positioned between the first surface  121   s   1   and the second surface  121   s   2  and connected to the first and second surfaces  121   s   1  and  121   s   2  is called a “lateral surface  121   s   3 .” 
     The light-reflective electrode  122  is located at the lower surface of the p-side semiconductor layer  128 . The light-reflective electrode  122  covers at least a portion of the lower surface of the p-side semiconductor layer  128 . The light-reflective electrode  122  contacts the p-side semiconductor layer  128 . Thereby, the light-reflective electrode  122  is electrically connected to the p-side semiconductor layer  128 . The light-reflective electrode  122  can include, for example, silver (Ag), aluminum (Al), nickel (Ni), titanium (Ti), platinum (Pt), an alloy that includes such a metal as a major component, etc. 
     The insulating film  123  is located below the semiconductor structure body  121  and the light-reflective electrode  122 . The insulating film  123  partially covers the lower surface of the light-reflective electrode  122  and the second surface  121   s   2  of the semiconductor structure body  121 . Multiple through-holes  123   a  that expose the multiple contact regions  126   c  of the n-side semiconductor layer  126  and a through-hole  123   b  that exposes the lower surface of the light-reflective electrode  122  are provided in the insulating film  123 . 
     The insulating film  123  can include an insulating material such as silicon oxide (SiO 2 ), silicon nitride (SiN), etc. The insulating film  123  may have a single-layer structure or a multilayer structure. 
     The n-side electrode  124  is located below the insulating film  123 . The n-side electrode  124  contacts the contact regions  126   c  of the n-side semiconductor layer  126  via the through-holes  123   a . Thereby, the n-side electrode  124  is electrically connected to the n-side semiconductor layer  126 . The n-side electrode  124  is electrically connected to one interconnect of the wiring substrate  11  via a conductive member. The conductive member can include, for example, a metal bump, solder, etc. 
     The p-side electrode  125  is located below the insulating film  123  and separated from the n-side electrode  124 . The p-side electrode  125  contacts the light-reflective electrode  122  via the through-hole  123   b . Thereby, the p-side electrode  125  is electrically connected to the p-side semiconductor layer  128 . The p-side electrode  125  is electrically connected to another interconnect of the wiring substrate  11  via a conductive member. 
     The n-side electrode  124  and the p-side electrode  125  can include aluminum (Al), nickel (Ni), titanium (Ti), platinum (Pt), an alloy that includes such a metal as a major component, etc. 
     However, the configuration of the light-emitting element  120  is not limited to the configuration described above as long as the semiconductor structure body  121  is included and the multiple recesses  121   a  are provided in the first surface  121   s   1  of the semiconductor structure body  121 . For example, the position at which the n-side semiconductor layer  126  and the n-side electrode  124  contact and the position at which the p-side semiconductor layer  128  and the light-reflective electrode  122  contact are not particularly limited to the positions shown in  FIG.  1   . It is sufficient for the n-side electrode  124  and the n-side semiconductor layer  126  to be electrically connected; one or more conductive members may be interposed between the n-side electrode  124  and the n-side semiconductor layer  126 . It is sufficient for the p-side electrode  125  and the light-reflective electrode  122  to be electrically connected; one or more conductive members may be interposed between the p-side electrode  125  and the light-reflective electrode  122 . The p-side electrode  125  may contact the p-side semiconductor layer  128  without including the light-reflective electrode  122  in the light-emitting element  120 . 
     The second member  140  is located above the light-emitting element  120 . For example, the second member  140  has a flat plate shape. The surfaces of the second member  140  include an upper surface  141  and a lower surface  142  positioned at the side opposite to the upper surface  141 . The upper surface  141  and the lower surface  142  are substantially parallel to the X-Y plane. 
     According to the embodiment, when viewed along the Z-direction, the outer perimeter edge of the second member  140  is positioned outward of the outer perimeter edge of the first surface  121   s   1  of the light-emitting element  120 . However, the outer perimeter of the second member  140  may align with the outer perimeter edge of the first surface  121   s   1  when viewed along the Z-direction. 
     The second member  140  is, for example, a sintered body of a wavelength conversion material. The wavelength conversion material performs a wavelength conversion of a portion of the light emitted by the light-emitting element  120  and emits light of a different light emission peak wavelength from the light emission peak wavelength of the light emitted by the light-emitting element  120 . The light-emitting device  12  emits mixed light of the light emitted by the semiconductor structure body  121  and the light emitted by the second member  140 . However, the greater part of the light emitted by the semiconductor structure body  121  may undergo wavelength conversion by the second member  140 , and the light that is emitted from the light-emitting device  12  may be mainly the light emitted by the second member  140 . The wavelength conversion material can include, for example, phosphor particles. As the phosphor, an yttrium-aluminum-garnet-based phosphor (e.g., Y 3 (Al, Ga) 5 O 12 :Ce), a lutetium-aluminum-garnet-based phosphor (e.g., Lu 3 (Al, Ga) 5 O 12 :Ce), a terbium-aluminum-garnet-based phosphor (e.g., Tb 3 (Al, Ga) 5 O 12 :Ce), a CCA-based phosphor (e.g., Ca 10 (PO 4 ) 6 Cl 2 : Eu), an SAE-based phosphor (e.g., Sr 4 Al 14 O 25 : Eu), a chlorosilicate-based phosphor (e.g., Ca s MgSi 4 O 16 Cl 2 :Eu), an oxynitride-based phosphor such as a β-sialon-based phosphor (e.g., (Si, AI) 3 (O, N) 4 :Eu), an α-sialon-based phosphor (e.g., Ca(Si, AI) 12 (O, N) 16 :Eu), or the like, a nitride-based phosphor such as an SLA-based phosphor (e.g., SrLiAl 3 N 4 : Eu), a CASN-based phosphor (e.g., CaAlSiN 3 : Eu), a SCASN-based phosphor (e.g., (Sr, Ca)AlSiN 3 :Eu), or the like, a fluoride-based phosphor such as a KSF-based phosphor (e.g., K 2 SiF 6 : Mn), a KSAF-based phosphor (e.g., K 2 Si 0.99 Al 0.01 F 5.99 :Mn), a MGF-based phosphor (e.g., 3.5MgO·0.5MgF 2 ·GeO 2 :Mn), or the like, a phosphor having a perovskite structure (e.g., CsPb(F, Cl, Br, I) 3 ), a quantum dot phosphor (e.g., CdSe, InP, AgInS 2 , or AgInSe 2 ), etc., can be used. 
     The thickness of the second member  140  is greater than the thickness of the first member  130 . The thickness of the second member  140  can be, for example, not less than 30 µm and not more than 200 µm. 
     The first member  130  is located between the semiconductor structure body  121  and the second member  140 . According to the embodiment, the first member  130  covers substantially the entire region of the first surface  121   s   1  of the semiconductor structure body  121  and the lower surface  142  of the second member  140 . Specifically, the first member  130  is located inside the recesses  121   a  of the first surface  121   s   1  of the semiconductor structure body  121  and on the region  121   b  between the multiple recesses  121   a . In the Z-direction, the first member  130  covers the region of the lower surface  142  of the second member  140  positioned outward of the first surface  121   s   1  of the semiconductor structure body  121 . 
     The first member  130  includes a resin member  131  that is transmissive. Here, “transmissive” means transmissive to not less than 70%, and favorably not less than 80% of the incident light. The resin member  131  is formed by curing an uncured resin. The resin member  131  can include a thermosetting resin, a resin cured by irradiating ultraviolet light, etc. According to the embodiment, the hardness of the second member  140  is greater than the hardness of the resin member  131  in the cured state. However, the magnitude relationship between the hardness of the second member  140  and the hardness of the resin member  131  in the cured state is not limited to such a magnitude relationship. 
     The first member  130  further includes a wavelength conversion material  132  located inside the resin member  131 . The wavelength conversion material  132  of the first member  130  can include the same wavelength conversion material used in the second member  140 . However, the wavelength conversion material  132  may be omitted from the first member  130 . 
     The thickness of the first member  130  can be, for example, not less than 10 µm and not more than 100 µm. The thickness of the first member  130  located in the recess  121   a  is less than the thickness of the first member  130  located at a region  121   b   1 . The thickness of the first member  130  located in the recess  121   a  is, for example, not less than 1 µm and not more than 10 µm. The thickness of the first member  130  located at the region  121   b   1  is, for example, not less than 3 µm and not more than 50 µm. 
     The resin member  13  is located on the wiring substrate  11 . The resin member  13  surrounds the light-emitting device  12  when viewed along the Z-direction. Specifically, the resin member  13  covers the lateral surface  121   s   3  of the semiconductor structure body  121  of the light-emitting element  120 , the regions of the lateral surface and the lower surface of the exposed first member  130 , and the lateral surface of the second member  140 . As shown in  FIG.  2 B , the resin member  13  surrounds the insulating film  123  and the n-side electrode  124  of the light-emitting element  120  when viewed along the Z-direction. 
     The resin member  13  is light-reflective. The resin member  13  includes, for example, a light-diffusing material that can diffusely reflect the light emitted by the second member  140 . For example, a silicone resin, an epoxy resin, an acrylic resin, etc., are examples of the resin included in the resin member  13 . For example, particles of titania, silica, alumina, zinc oxide, magnesium oxide, zirconia, yttria, calcium fluoride, magnesium fluoride, niobium pentoxide, barium titanate, tantalum pentoxide, barium sulfate, glass, etc., are examples of the light-diffusing agent included in the resin member  13 . 
     However, the configuration of the light-emitting module  10  is not limited to the configuration described above. For example, the light-emitting module  10  may include multiple light-emitting devices  12 . In such a case, the resin member  13  may be provided to surround each light-emitting device  12 . The light-emitting module  10  may include the light-emitting device  12  and the resin member  13  without the wiring substrate  11 . 
     An example of a method for manufacturing the light-emitting module  10  including the light-emitting device  12  according to the embodiment will now be described. 
       FIG.  3    is a flowchart showing the method for manufacturing the light-emitting module  10  according to the embodiment. 
       FIGS.  4 A to  7 C  are cross-sectional views illustrating the method for manufacturing the light-emitting module  10  according to the embodiment. 
     As shown in  FIG.  3   , the method for manufacturing the light-emitting device  12  according to the embodiment includes a step S 11  of preparing the multiple light-emitting elements  120 , a step S 12  of disposing the multiple light-emitting elements  120  on the sheet member  920 , a step S 13  of removing a substrate  910  from the semiconductor structure body  121 , a step S 14  of preparing the first member  130  and the second member  140 , a step S 15  of causing the first member  130  to contact the first surfaces  121   s   1  of the multiple light-emitting elements  120 , a step S 16  of curing the first member, a step S 17  of removing the sheet member  920  from the multiple light-emitting elements  120 , and a step S 18  of dividing into the multiple light-emitting devices  12 . The steps S 11  to S 18  will now be elaborated. 
     First, the step S 11  of preparing the multiple light-emitting elements  120  is performed. 
     Specifically, as shown in  FIG.  4 A , the semiconductor structure body  121  is epitaxially grown on the substrate  910  including multiple protrusions  911  in the surface. At this time, the n-side semiconductor layer  126 , the active layer  127 , and the p-side semiconductor layer  128  are formed in this order. The surface of the semiconductor structure body  121  facing the substrate  910  is the first surface  121   s   1 . 
     The substrate  910  is, for example, a transmissive substrate such as a sapphire substrate, etc. The multiple protrusions  911  are arranged in a staggered configuration. Each protrusion  911  is substantially circular conic. A region  912  between the multiple protrusions  911  at the surface of the substrate  910  is substantially parallel to the X-Y plane. Therefore, the first surface  121   s   1  includes the multiple recesses  121   a  that correspond to the multiple protrusions  911 . The region  121   b  of the first surface  121   s   1  between the multiple recesses  121   a  is substantially parallel to the X-Y plane to correspond to the region  912  between the multiple protrusions  911  of the substrate  910 . However, the arrangement pattern of the multiple protrusions is not limited to the arrangement pattern described above. For example, multiple protrusions may be arranged in a matrix configuration. The shape of each protrusion is not particularly limited to such shapes. For example, each protrusion may be a truncated pyramid, circular cone, polygonal pyramid, hemisphere, etc. 
     Then, the multiple contact regions  126   c  and the outer perimeter region  126   a  of the n-side semiconductor layer  126  are exposed from under the active layer  127  and the p-side semiconductor layer  128  by etching a portion of the semiconductor structure body  121 . 
     Continuing, the light-reflective electrode  122  is formed on the p-side semiconductor layer  128 . Then, the insulating film  123  is formed to cover the semiconductor structure body  121 . Then, the n-side electrode  124  that is positioned on the insulating film  123  and electrically connected with the n-side semiconductor layer  126  and the p-side electrode  125  that is positioned on the insulating film  123  and electrically connected with the p-side semiconductor layer  128  are formed. Then, the structure is divided into the multiple light-emitting elements  120  by exposing the substrate  910  by removing the semiconductor structure body  121  positioned between the regions used to form the light-emitting element  120 . Thus, the multiple light-emitting elements  120  are obtained. The sequence of the sub-steps in the step of preparing the multiple light-emitting elements  120  is not particularly limited to the sequence described above. 
     Then, the step S 12  of disposing the multiple light-emitting elements  120  on the sheet member  920  is performed. 
     Specifically, as shown in  FIG.  4 B , the multiple light-emitting elements  120  are disposed on the adhesive sheet member  920  so that the second surfaces  121   s   2  of the light-emitting elements  120  face the sheet member  920  and so that the lateral surfaces  121   s   3  of the light-emitting elements  120  are covered with the sheet member  920 . At this time, the multiple light-emitting elements  120  may be buried inside the sheet member  920 , and the substrate  910  may contact the sheet member  920 . 
     The sheet member  920  can include a material that is heat-resistant and adhesive such as polyimide, etc. 
     Then, as shown in  FIG.  4 C , the step S 13  of removing the substrate  910  from the semiconductor structure body  121  is performed. Examples of methods of removing the substrate  910  from the semiconductor structure body  121  include, for example, laser lift-off (LLO) in which the substrate  910  is removed from the semiconductor structure body  121  by irradiating a laser from the substrate  910  side to concentrate the laser at the vicinity of the interface between the semiconductor structure body  121  and the substrate  910 , etc. The first surface  121   s   1  of the semiconductor structure body  121  is exposed thereby. Thus, the surface of the semiconductor structure body  121  exposed by removing the substrate  910  is the first surface  121   s   1 . The first surface  121   s   1  may be cleaned with hydrochloric acid, etc. The first surface  121   s   1  may be roughened by wet etching. The light extraction efficiency can be increased by roughening the first surface  121   s   1 . 
     Continuing, the step S 14  of preparing the first member  130  and the second member  140  is performed. Specifically, as shown in  FIG.  5 A , the second member  140  that includes a wavelength conversion material and has a higher hardness than the uncured resin member  131  is disposed on the first member  130  that includes the transmissive uncured resin member  131 . According to the embodiment, the wavelength conversion material  132  is located inside the uncured resin member  131 . The hardness of the second member  140  is, for example, a Vickers hardness of not less than 10 GPa and not more than 20 GPa. Here, “uncured” refers to the state before a curing reaction progresses, that is, the state before an operation for causing the curing reaction to progress is performed. Examples of operations for causing the curing reaction to progress include heating, light irradiation, etc. Although there are cases where the curing reaction slightly progresses before the operation for causing the curing reaction to progress, the uncured state also includes such a state. 
     Then, as shown in  FIGS.  5 A and  5 B , the step S 15  of causing the first member  130  to contact the first surfaces  121   s   1  of the multiple light-emitting elements  120  is performed. Specifically, the first member  130  is caused to contact the first surfaces  121   s   1  of the multiple light-emitting elements  120  so that the first member  130  is located inside the multiple recesses  121   a  and located between the sheet member  920  and the second member  140 . At this time, the first member  130  is interposed between the second member  140  and the region  121   b  between the multiple recesses  121   a . 
     At this time, the first member  130  is caused to contact the first surface  121   s   1  in a heated state. For example, the first member  130  is caused to contact the first surface  121   s   1  and is pressed onto the first surface  121   s   1 . Thereby, the first member  130  easily flows, and the first member  130  is easily disposed inside the recesses  121   a . For example, the first member  130  is brought to the heated state by placing the members on a hotplate and heating, and then a load is applied. The temperature when heating can be, for example, not less than 150° C. and not more than 200° C. The applied load can be, for example, not less than 70 N and not more than 150 N. It is sufficient to perform the step S 14  of preparing the first member  130  and the second member  140  before the step S 15  of the contact, and it is unnecessary to perform the step S 14  after the step S 13  of removing the substrate  910  from the semiconductor structure body  121 . 
     Then, the step S 16  of curing the first member  130  is performed. The hardness of the first member  130  after curing is, for example, a Vickers hardness of not less than 0.5 GPa and not more than 2 GPa. 
     Continuing as shown in  FIG.  6 A , the step S 17  of removing the sheet member  920  from the multiple light-emitting elements  120  is performed. 
     Here, a method for manufacturing a reference example will be described with reference to  FIG.  8   . 
       FIG.  8    is a cross-sectional view illustrating a method for manufacturing a light-emitting module according to the reference example. In the reference example, the first member  130  contacts the multiple light-emitting elements  120  located on a support substrate  930  instead of the sheet member  920 . 
     As shown in  FIG.  8   , when the multiple light-emitting elements  120  are located on the support substrate  930  instead of the sheet member  920 , the lateral surfaces  121   s   3  of the light-emitting elements  120  are not covered with the support substrate  930 . When the second member  140  is caused to contact the multiple light-emitting elements  120  in this state, a portion of the first member  130  is pushed out from between the second member  140  and the light-emitting elements  120   and contacts the lateral surfaces  121   s   3 . In such a case, the first member  130  that is pushed out may flow over the lateral surfaces  121   s   3  of the light-emitting elements  120  and adhere to the support substrate  930 . When the first member  130  is cured while a portion of the first member  130  is adhered to the support substrate  930 , the first member  130  is adhered to the support substrate  930 , and it may be difficult to remove the support substrate  930  from the multiple light-emitting elements  120  by peeling, etc. Also, there is a possibility that the multiple light-emitting elements  120  and the second member  140  may be damaged when forcibly removing the support substrate  930  from the multiple light-emitting elements  120 . 
     In contrast, according to the embodiment as shown in  FIG.  5 B , the multiple light-emitting elements  120  are located on the sheet member  920 , and the sheet member  920  covers the lateral surfaces  121   s   3  of the multiple light-emitting elements  120 . Therefore, the portion of the first member  130  pushed out when the second member  140  is caused to contact the multiple light-emitting elements  120  flows around to the lateral surface of the second member  140  without flowing over the lateral surfaces  121   s   3  of the semiconductor structure bodies  121 . In other words, the part of the first member  130  that is pushed out covers at least a portion of the lateral surface of the second member  140 . Thus, the first member  130  that is adhered to the lateral surfaces  121   s   3  of the semiconductor structure bodies  121  can be reduced. Therefore, the sheet member  920  can be more easily removed from the multiple light-emitting elements  120  by peeling, etc. As a result, damage of the multiple light-emitting elements  120  and the second member  140  when removing the sheet member  920  can be reduced. It is favorable for the sheet member  920  to be flexible. Thereby, the sheet member  920  can be easily removed from the multiple light-emitting elements  120 . 
     Then, as shown in  FIG.  6 B , the step S 18  of dividing into the multiple light-emitting devices  12  is performed. Specifically, the first member  130  and the second member  140  that are positioned between the multiple light-emitting elements  120  in a top-view are removed using a cutting machine such as a dicing saw, etc. The multiple light-emitting devices  12  that each include the light-emitting element  120 , the first member  130 , and the second member  140  are obtained thereby. 
     After the step S 18 , as shown in  FIG.  3   , a step S 21  of disposing the multiple light-emitting devices  12  on the wiring substrate  11 , a step S 22  of forming the resin member  13 , and a step S 23  of dividing into the multiple light-emitting modules  10  may be performed. The steps S 21  to S 23  will now be elaborated. 
     In the step S 21  of disposing the multiple light-emitting devices  12  on the wiring substrate  11  as shown in  FIG.  7 A , the light-emitting devices  12  are disposed so that the wiring substrate  11  and the second surfaces  121   s   2  of the light-emitting elements  120  face each other. The n-side electrode  124  of each light-emitting element  120  and one interconnect of the wiring substrate  11  are connected by a conductive member. Also, the p-side electrode  125  of each light-emitting element  120  and another interconnect of the wiring substrate  11  are connected by a conductive member. Thereby, the light-emitting elements  120  are flip-chip mounted to the wiring substrate  11 . 
     As shown in  FIG.  9   , a reflecting member  150  may be formed on the lateral surface of the first member  130  and the lateral surface of the second member  140 .  FIG.  9    is a cross-sectional view illustrating the method for manufacturing the light-emitting module according to a modification of the embodiment. The reflecting member  150  is a member for reflecting the light from the first and second members  130  and  140 . The reflecting member  150  can include, for example, aluminum, nickel, titanium, platinum, an alloy that includes such a metal as a major component, etc. The reflecting member  150  may include a dielectric multilayer film that includes multiple dielectric layers. When such a reflecting member  150  is formed, the step of forming the resin member  13  may be omitted. 
     Then, as shown in  FIG.  7 B , the step S 22  of forming the resin member  13  is performed. Specifically, the light-reflective resin member  13  is formed to cover the lateral surface  121   s   3  of the light-emitting element  120 , the exposed regions of the lateral surface and the lower surface of the first member  130 , and the lateral surface of the second member  140 . For example, in the step S 22  of forming the resin member  13 , the resin member  13  is formed by forming a resin material to cover the upper surface of the second member  140  and then by exposing the upper surface of the second member  140  from under the resin material by removing a portion of the resin material. By reducing the amount of the first member  130  adhered to the lateral surface  121   s   3  of the light-emitting element  120  in the step S 15  of the contact, the resin member  13  can be formed to cover the lateral surface  121   s   3  of the light-emitting element  120 . The resin member  13  is connected not only to the second member  140  that is the sintered body of the wavelength conversion material but also to the first member  130  that includes the resin member  131 . Therefore, the bonding strength between the resin member  13  and the light-emitting device  12  can be increased. 
     Continuing as shown in  FIG.  7 C , the step S 23  of dividing into multiple light-emitting modules is performed. Specifically, the resin member  13  and the wiring substrate  11  that are positioned between the multiple light-emitting devices  12  in a top-view are removed using a cutting machine such as a dicing saw, etc. The multiple light-emitting modules  10  that each include the wiring substrate  11 , the light-emitting device  12 , and the resin member  13  are obtained thereby. However, a module that includes the wiring substrate  11 , the multiple light-emitting devices  12 , and the resin member  13  shown in  FIG.  7 B  may be used as the light-emitting module  10  without performing the step S 23 . Also, in the step S 21 , instead of the wiring substrate  11 , the multiple light-emitting devices  12  may be disposed on a support substrate that does not include interconnects, and the support substrate may be removed from the multiple light-emitting devices  12  after the step S 22  of forming the resin member  13 . 
     A usage example of the light-emitting module  10  will now be described. 
     The active layer  127  is caused to emit light by applying a voltage between the n-side electrode  124  and the p-side electrode  125  of the light-emitting element  120  via the wiring substrate  11 . The greater part of the light emitted by the active layer  127  is incident on the second member  140 . Therefore, the second member  140  emits light. According to the embodiment, the first member  130  includes the wavelength conversion material  132 ; therefore, the wavelength conversion material  132  of the first member  130  also emits light. 
     Effects of the embodiment will now be described. 
     The method for manufacturing the light-emitting device  12  according to the embodiment includes the step S 11  of preparing the multiple light-emitting elements  120 , the step S 12  of disposing the multiple light-emitting elements  120  on the sheet member  920 , the step S 15  of causing the first member  130  to contact the first surfaces  121   s   1  of the multiple light-emitting elements  120 , the step S 16  of curing the first member  130 , and the step S 17  of removing the sheet member  920  from the multiple light-emitting elements  120 . In the step S 11 , the multiple light-emitting elements  120  that include the semiconductor structure bodies  121  that includes the first surfaces  121   s   1  including the multiple recesses  121   a , the second surfaces  121   s   2  positioned at the side opposite to the first surfaces  121   s   1 , and the lateral surfaces  121   s   3  connecting the first surfaces  121   s   1  and the second surfaces  121   s   2  are prepared. In the step S 12 , the second surfaces  121   s   2  of the light-emitting elements  120  are caused to face the adhesive sheet member  920 , and the multiple light-emitting elements  120  are disposed on the sheet member  920  so that the lateral surfaces  121   s   3  of the light-emitting elements  120  are covered with the sheet member  920 . In the step S 15 , the first member  130  is caused to contact the first surfaces  121   s   1  of the multiple light-emitting elements  120  so that the first member  130  is located inside the multiple recesses  121   a  and located between the sheet member  920  and the second member  140  in a state in which the second member  140  that includes a wavelength conversion material and has a higher hardness than the uncured resin member  131  is located on the first member  130  that includes the transmissive uncured resin member  131 . 
     Thus, according to the method for manufacturing the light-emitting device  12  according to the embodiment, the substrate  910  that is used to epitaxially grow the semiconductor structure body  121  is not located between the light-emitting element  120  and the second member  140 , and the second member  140  and the semiconductor structure body  121  of the light-emitting element  120  are connected by the first member  130 . Therefore, the light extraction efficiency of the light-emitting device  12  can be increased. 
     The multiple recesses  121   a  are provided in the first surface  121   s   1 . Therefore, the total internal reflections at the first surface  121   s   1  of the light emitted by the active layer  127  can be reduced. Thereby, the light that is emitted by the active layer  127  is easily incident on the second member  140 , and the light extraction efficiency of the light-emitting device  12  can be increased. 
     The first member  130  is caused to contact the multiple light-emitting elements  120  in a state in which the lateral surfaces  121   s   3  of the light-emitting elements  120  are covered with the sheet member  920 . Therefore, the amount of the first member  130  adhered to the lateral surfaces  121   s   3  of the light-emitting elements  120  can be reduced. The sheet member  920  can be easily removed thereby. As a result, damage of the second member  140  when removing the sheet member  920  can be reduced, and the yield can be increased. 
     In the step S 11  of the preparation, the semiconductor structure body  121  is epitaxially grown on the substrate  910  that includes the multiple protrusions  911  in the surface of the substrate  910 . The step S 13  of removing the substrate  910  from the semiconductor structure body  121  is further included before the step S 15  of the contact. In the step S 13  of removing the substrate  910  from the semiconductor structure body  121 , the surface of the semiconductor structure body  121  that is exposed by removing the substrate  910  is the first surface  121   s   1 , and the shape of the multiple recesses  121   a  of the first surface  121   s   1  corresponds to the multiple protrusions  911 . It is therefore unnecessary to pattern the surface of the semiconductor structure body  121  to form the multiple recesses  121   a  after removing the substrate  910 , and the steps can be simplified. 
     The first surface  121   s   1  includes the region  121   b  positioned between the multiple recesses  121   a . In the step S 15  of the contact, the first member  130  is caused to contact the first surface  121   s   1  so that the first member  130  is interposed between the second member  140  and the region  121   b . Therefore, the light-emitting element  120  can be securely adhered to the second member  140  via the first member  130 . 
     The second member  140  is a sintered body of a wavelength conversion material. Therefore, the hardness of the second member  140  can be higher than when the second member  140  includes a resin member and a wavelength conversion material inside the resin member. The deformation of the second member  140  in the step S 15  of the contact and the step S 17  of removing the sheet member  920  from the multiple light-emitting elements  120  can be reduced thereby. 
     In the step S 15  of the contact, the first member  130  is caused to contact the first surface  121   s   1  in a heated state. The fluidity of the first member  130  is increased thereby, and the first member  130  is easily disposed inside the recesses  121   a  of the semiconductor structure body  121 . 
     The first member  130  includes the wavelength conversion material  132 . Thereby, the light conversion efficiency of the wavelength conversion material can be higher than when only the second member  140  includes the wavelength conversion material. 
     Also, the step S 18  of dividing into the multiple light-emitting devices  12  by removing the first member  130  and the second member  140  positioned between the multiple light-emitting elements  120  in a top-view is performed after the step S 16  of curing the first member  130 . Thus, the light-emitting devices  12  can be manufactured with a high yield by dividing into the multiple light-emitting devices  12  after the multiple light-emitting elements  120  are connected to the second member  140  via the first member  130 . 
     Also, a step S 19  of forming the light-reflective resin member  13  to cover the lateral surface  121   s   3  of the light-emitting element  120 , the lateral surface of the first member  130 , and the lateral surface of the second member  140  is performed after the step S 18  of dividing into the multiple light-emitting devices  12 . Therefore, the light traveling toward the lateral surfaces  121   s   3  of the light-emitting elements  120  is reflected toward the second member  140  by the resin member  13 . The light extraction efficiency of the light-emitting device  12  can be increased thereby. The resin member  13  is connected not only to the second member  140 , i.e., the sintered body of the wavelength conversion material, but also to the first member  130  that includes the resin member  131 . The bonding strength between the resin member  13  and the light-emitting device  12  can be increased thereby. 
     The first member  130  is caused to contact the lateral surface of the second member  140  in the step S 15  of the contact. Specifically, in the step S 15  of the contact, the second member  140  is caused to contact the multiple light-emitting elements  120  in a state in which the lateral surfaces  121   s   3  of the light-emitting elements  120  are covered with the sheet member  920 . Thereby, a portion of the first member  130  is pushed out from between the light-emitting element  120  and the second member  140  while the first member  130  is located inside the multiple recesses  121   a  so that the portion of the first member  130  contacts the lateral surface of the second member  140 . The bonding strength between the first member  130  and the second member  140  can be increased thereby, while reducing the portion of the first member  130  that is pushed out to be adhered to the lateral surfaces  121   s   3  of the light-emitting elements  120 . 
     Second Embodiment 
     A second embodiment will now be described. 
       FIG.  10    is a cross-sectional view showing a light-emitting module  20  according to the embodiment. 
     As a general rule in the following description, only the differences with the first embodiment are described. Other than the items described below, the embodiment is similar to the first embodiment. 
     A light-emitting device  22  of the light-emitting module  20  according to the embodiment differs from the light-emitting device  12  according to the first embodiment in that the second member  140  contacts the region  121   b  between the multiple recesses  121   a  at the first surface  121   s   1 . Such a light-emitting device  22  can be obtained by causing the second member  140  to approach the multiple light-emitting elements  120  until the second member  140  contacts the first surface  121   s   1  in the step S 15  of the contact according to the first embodiment. 
     Effects of the embodiment will now be described. 
     The first surface  121   s   1  includes the region  121   b  positioned between the multiple recesses  121   a , and in the step S 15  of the contact, the first member  130  is caused to contact the first surface  121   s   1  so that the second member  140  contacts the region  121   b . Therefore, fluctuation between positions along the X-Y plane of the distance between the second member  140  and the light-emitting element  120  can be reduced. By causing the second member  140  to contact the region  121   b , the heat dissipation can be improved because the heat dissipation path from the second member  140  toward the semiconductor structure body  121  can be better ensured than when the first member  130  is located between the second member  140  and the region  121   b .