Method for manufacturing a light-emitting device

Abstract

The present invention provides a light-emitting device capable of increasing the brightness difference between the inner and outer sides of a light-emitting surface. The manufacturing method of the light-emitting device of the present invention includes: a mounting step of mounting a light-emitting element on a substrate; a light-shielding frame placement step of placing a light-shielding frame having an opening on a sheet; a light-reflective resin coating step of coating the light-shielding frame with a light-reflective resin; a light-guiding support member formation step of forming a first light-reflective member to produce a light-guiding support member in which the light-shielding frame and a light-transmitting member are supported by the first light-reflective member; and a light-guiding support member bonding step of bonding the upper surface of the mounted light-emitting element to the second surface to secure the light-guiding support member to the light-emitting element. The light-shielding frame includes a narrowed portion having a locally narrowed width when viewed from above, and in the light-reflective resin coating step, the light-reflective resin is disposed at least on the narrowed portion.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a light-emitting device. Background Art

[0002] In recent years, high-output light-emitting devices using light-emitting elements such as LEDs have begun to be used as light sources for automotive applications. For example, Patent Document 1 discloses a high-output light-emitting device used as an automotive light source in which a heat dissipation layer is formed to cover the periphery of the light-emitting surface of the light-emitting element, thereby enhancing heat dissipation.

[0003] Prior art literature

[0004] Patent Literature

[0005] Patent Document 1: Japanese Patent Application Laid-Open No. 2014-127679 Summary of the Invention

[0006] Problems to be solved by the invention

[0007] An object of the present invention is to provide a method for easily manufacturing a light-emitting device capable of increasing the brightness difference between the inner and outer sides of a light-emitting surface and efficiently outputting light emitted by a light-emitting element.

[0008] Solutions to Problems

[0009] A method for manufacturing a light-emitting device according to one embodiment of the present invention includes:

[0010] A mounting process, mounting the light emitting element on the substrate;

[0011] a light shielding frame placement step of placing a light shielding frame having an opening on the sheet;

[0012] a light-reflective resin coating step of coating the light-shielding frame with a light-reflective resin;

[0013] a light guide support member forming step of bringing a plate-shaped light-transmitting member into contact with the applied light-reflective resin at a position where a space is formed between the light-transmitting member and the opening, with a first surface of the light-transmitting member facing the sheet, and then pressing the plate to allow the light-reflective resin to flow into the space to form a first light-reflective member, and manufacturing a light guide support member in which the light-shielding frame and the light-transmitting member are supported by the first light-reflective member, the light-transmitting member having a first surface and a second surface opposite to the first surface, the outer periphery of the first surface being smaller than the inner periphery of the opening, and the second surface being larger than the first surface; and

[0014] a light guide supporting member bonding step of bonding the upper surface of the mounted light emitting element to the second surface to fix the light guide supporting member to the light emitting element;

[0015] in,

[0016] The light shielding frame has a narrow portion whose width is partially narrowed in a plan view, and in the light reflective resin coating step, the light reflective resin is disposed at least on the narrow portion.

[0017] Effects of the Invention

[0018] According to the method for manufacturing a light emitting device according to one embodiment of the present invention configured as described above, a light emitting device can be easily manufactured that can increase the brightness difference between the inner and outer sides of the light emitting surface and efficiently output light emitted by the light emitting element. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 This is an example of a plan view of a light emitting device according to an embodiment.

[0020] Figure 2A The light emitting device of the embodiment is Figure 1 An example of a cross-sectional view taken along line III-III is shown.

[0021] Figure 2B The light emitting device of the embodiment is Figure 1 An example of a cross-sectional view taken along line IV-IV is shown.

[0022] Figure 3 It is a three-dimensional schematic diagram of the shading frame.

[0023] Figure 4 yes Figure 3 A top view of the shading frame is shown.

[0024] Figure 5A This is a schematic perspective view showing a state in which a light-reflective resin is applied to a light-shielding frame having a narrow portion.

[0025] Figure 5B It is a schematic cross-sectional view showing a state of light-reflective resin applied to a light-shielding frame having a narrow portion.

[0026] Figure 6A It is a schematic cross-sectional view showing the installation process.

[0027] Figure 6B It is a schematic cross-sectional view showing the installation process.

[0028] Figure 7A It is a cross-sectional schematic diagram showing the light shielding frame placement process.

[0029] Figure 7B It is a schematic cross-sectional view showing the light-reflective resin coating step.

[0030] Figure 7C 2 is a schematic cross-sectional view illustrating a step of forming a light guide supporting member.

[0031] Figure 7D 2 is a schematic cross-sectional view illustrating a step of forming a light guide supporting member.

[0032] Figure 7E 2 is a schematic cross-sectional view illustrating a step of forming a light guide supporting member.

[0033] Figure 7F 2 is a schematic cross-sectional view illustrating a step of forming a light guide supporting member.

[0034] Figure 8A It is a schematic cross-sectional view showing the light guide supporting member bonding step.

[0035] Figure 8B It is a schematic cross-sectional view showing the second light reflecting member forming step.

[0036] Figure 9 It is a perspective schematic diagram showing an example of a light-transmitting member.

[0037] Figure 10A It is a schematic cross-sectional view showing an example of a manufacturing method according to the embodiment.

[0038] Figure 10B It is a schematic cross-sectional view showing an example of a manufacturing method according to the embodiment.

[0039] Figure 10C It is a schematic cross-sectional view showing an example of a manufacturing method according to the embodiment.

[0040] Figure 10D It is a schematic cross-sectional view showing an example of a manufacturing method according to the embodiment.

[0041] Figure 11 It is a schematic partial perspective view showing a state in which the light shielding frame and the light-transmitting member are combined.

[0042] Figure 12A This is a schematic perspective view for explaining repeated coating in a narrow width portion.

[0043] Figure 12B This is a schematic cross-sectional view for explaining repeated coating in a narrow width portion.

[0044] Figure 13A This is a perspective schematic diagram showing an example of repeated coating in a narrow width portion.

[0045] Figure 13B This is a perspective schematic diagram showing an example of repeated coating in a narrow width portion.

[0046] Figure 14A This is a perspective schematic diagram showing an example of repeated coating in a narrow width portion.

[0047] Figure 14B This is a perspective schematic diagram showing an example of repeated coating in a narrow width portion.

[0048] Figure 15 This is a perspective schematic diagram showing an example of repeated coating in a narrow width portion.

[0049] Explanation of symbols

[0050] 1 Light-emitting element

[0051] 3 Translucent components

[0052] 3a Surface 1 (light emitting surface of the light emitting device)

[0053] 3b Side 2

[0054] 3c 1st side

[0055] 3d Side 2

[0056] 3e Page 3

[0057] 30 Flange portion of light-transmitting member

[0058] 4 pieces

[0059] 5 Shading frame

[0060] 5a Opening

[0061] 5b Frame

[0062] 5b1 The outer edge of the frame

[0063] 50 Narrow width

[0064] 55 Non-narrow width portion

[0065] 57 Long side frame

[0066] 58 Short side frame

[0067] 9 Light reflective components

[0068] 9a First light reflecting member

[0069] 9a' Light reflective resin

[0070] 9b Second light reflecting member

[0071] 9b' Second light-reflective resin

[0072] 10 substrate

[0073] 11 Conductive bonding member

[0074] 13 Light guide components

[0075] 40 chuck

[0076] 60 Light guide support member

[0077] 71 1st coating

[0078] 71' Starting point of the first coating

[0079] 71” End point of the first coating

[0080] 72 2nd coating

[0081] 72' Starting point of the second coating

[0082] 72” End point of the second coating

[0083] 73 3rd coating

[0084] 73' Starting point of the third coating

[0085] 73” End point of the third coating DETAILED DESCRIPTION

[0086] In the manufacturing method according to the embodiment of the present invention, first, a substrate on which a light emitting element is mounted, and a light guide supporting member in which a light shielding frame and a light transmissive member are supported by a first light reflective member are prepared.

[0087] To form the light guide support member, a plate-shaped light-transmitting member is first prepared, having a first surface and a second surface opposite the first surface, the second surface being larger than the first surface. A light-shielding frame having an opening is placed on the sheet, and the light-transmitting member is positioned within the opening, creating a space between the light-transmitting member and the light-shielding frame's opening. When the light-transmitting member is positioned, its flange (more specifically, the flange formed by the second surface being larger than the first surface) presses against the light-reflecting resin disposed within the light-shielding frame, causing the light-reflecting resin to flow into the space between the light-transmitting member and the light-shielding frame's opening.

[0088] The light guide supporting member prepared in this manner is fixed to the light emitting element mounted on the substrate, and then a second light reflecting member is formed to surround the light emitting element.

[0089] In the case of this method, when manufacturing a plurality of light-emitting devices, a substrate on which light-emitting elements including a plurality of unit areas are mounted can be prepared, and a light-shielding frame and a light-guiding support member in a state in which a light-transmitting member is supported by a first light-reflecting member can be placed in each unit area of the substrate, thereby making it possible to manufacture the light-emitting devices more efficiently and simply.

[0090] In the light-emitting device obtained by this method, when viewed from above, the first light-reflecting member is sandwiched between the first surface of the translucent member, which serves as the light-emitting surface of the light-emitting device, and the light-shielding frame. The light-shielding frame, which serves to increase the brightness difference between the inner and outer sides of the light-emitting surface, has the property of absorbing light. Therefore, direct contact between the translucent member and the light-shielding frame poses a risk of reducing the light output efficiency of the light-emitting device. Therefore, in the light-emitting device of this embodiment, the reduction in light output efficiency is suppressed by the "first light-reflecting member sandwiched between the translucent member and the light-shielding frame." This results in a light-emitting device with suitable optical characteristics, a large brightness difference between the inner and outer sides of the light-emitting surface, and suppressed reduction in light output efficiency.

[0091] Furthermore, the manufacturing method of an embodiment of the present invention uses a shading frame having a narrow width portion whose width is locally narrowed when viewed from above. As a result, by using such a shading frame, the remaining of voids (bubbles) in the area of the first light reflective component between the translucent component and the shading frame can be eliminated or suppressed.

[0092] Below, with reference to the attached Figure 1 The following describes a manufacturing method according to an embodiment of the present invention and a light-emitting device obtained by the method (hereinafter sometimes referred to as a "light-emitting device according to an embodiment"). However, the embodiment described below is intended to embody the technical concept of the present invention and does not limit the present invention. The drawings referenced in the following description schematically illustrate embodiments of the present invention, and therefore the dimensions, spacing, and positional relationships of various components may be exaggerated, or some components may be omitted from the illustration.

[0093] Light-emitting device according to an embodiment

[0094] The light emitting device of the embodiment includes at least a light emitting element, a light transmissive member, and a light shielding frame. Figure 1 、 Figure 2A and Figure 2B As shown, the light-emitting device includes: a substrate 10, a light-emitting element 1 arranged on the substrate 10, a translucent member 3 arranged in a manner opposite to the light-emitting surface of the light-emitting element 1, a first light-reflecting member 9a arranged on the side of the translucent member 3, and a light-shielding frame 5 arranged around the translucent member 3 and in contact with the first light-reflecting member 9a.

[0095] More specifically, the light-emitting device includes a substrate 10, a light-emitting element 1 disposed on the substrate 10, and a plate-shaped translucent member 3 disposed with its second surface 3b facing the light-emitting surface of the light-emitting element 1. Furthermore, in the light-emitting device, the first surface 3a of the translucent member 3, which constitutes the light-emitting surface of the light-emitting device, is exposed. A first light-reflecting member 9a is provided to join the light-shielding frame 5 to at least a portion of the side surface of the translucent member 3. A second light-reflecting member 9b is provided between the first light-reflecting member 9a and the substrate 10 to cover the side surface of the light-emitting element 1. Hereinafter, the first light-reflecting member 9a and the second light-reflecting member 9b may be collectively referred to as the "light-reflecting member 9."

[0096] In the light-emitting device of the embodiment, the translucent member 3 is positioned in the opening 5a of the light-shielding frame 5. Specifically, the translucent member 3 is positioned such that the first surface 3a of the translucent member 3 is positioned in the opening 5a of the light-shielding frame 5, with the first light-reflecting member 9a interposed therebetween. As shown in the figure, the first surface 3a of the translucent member 3 is exposed from the first light-reflecting member 9a and the light-shielding frame 5. The first surface 3a of the translucent member 3 can be positioned at substantially the same height as the upper surface of the light-shielding frame 5 (i.e., they can be flush with each other).

[0097] In the light-emitting device of the embodiment, when viewed from above (i.e., from the light-emitting surface side of the light-emitting device), the inner periphery of the opening 5a is located away from the outer periphery of the first surface 3a of the light-transmitting member 3, which constitutes the light-emitting surface of the light-emitting device. The first light-reflecting member 9a is located between the inner periphery of the opening 5a of the light-shielding frame 5 and the outer periphery of the first surface 3a of the light-transmitting member 3. In other words, the frame portion of the light-shielding frame 5 and the first surface 3a of the light-transmitting member 3 are separated from each other via the first light-reflecting member 9a. Thus, the light-emitting device separates the light-transmitting member 3 and the light-shielding frame 5 by interposing the first light-reflecting member 9a.

[0098] The light emitting device of the embodiment configured in this manner can increase the brightness difference between the light emitting surface and the region surrounding the light emitting surface, and can efficiently output light emitted by the light emitting element.

[0099] In the light-emitting device of the embodiment, in order to take into account both increasing the brightness difference between the inner and outer sides of the first surface 3a of the light emitting surface and efficiently outputting the light emitted by the light-emitting element, the distance between the inner periphery of the opening 5a and the outer periphery of the first surface 3a can be greater than 5 μm and less than 150 μm, for example, can be greater than 40 μm and less than 60 μm.

[0100] In the light-emitting device of the embodiment, the light-shielding frame has a narrowed portion whose width is locally narrowed when viewed from above. Specifically, the frame portion of the light-shielding frame does not have a constant width, but rather has a locally narrowed width. For example, if the light-shielding frame has a frame shape when viewed from above, the light-shielding frame may have a narrowed region in the frame portion corresponding to one side of the rectangular shape, serving as the narrowed portion.

[0101] Figure 3 and Figure 4 An example of a light-shielding frame 5 used in the embodiments is shown. The light-shielding frame 5 is provided on the upper surface of the light-emitting device to reduce the brightness of the portion excluding the light-emitting surface. The light-shielding frame 5 of the light-emitting device of the embodiment includes an opening 5a and a frame portion 5b forming the opening. The light-transmitting member 3 is positioned in the opening 5a. The frame portion 5b of the light-shielding frame 5 is the area where the light-reflective resin is applied during the light guide support member formation step during manufacturing, and assists in forming the first light-reflecting member 9a.

[0102] The narrow portion 50 of the light-shielding frame 5 plays a role in eliminating or reducing the generation of voids during the formation of the light-guiding support member. In particular, by applying the reflective resin at least to the narrow portion 50 during the light-reflective resin coating step performed prior to the light-guiding support member formation step, a light-emitting device can be obtained in which voids (air bubbles) are eliminated or minimized in the region where the first light-reflective member 9a is formed between the light-transmitting member 3 and the light-shielding frame 5. As will be explained in detail later, the presence of such voids can reduce the reduction in light output efficiency achieved by the first light-reflective member sandwiched between the light-transmitting member and the light-shielding frame. Furthermore, residual voids can reduce the bonding strength between the components of the light-emitting device. More specifically, voids in the region where the first light-reflective member 9a is formed between the light-transmitting member 3 and the light-shielding frame 5 can reduce the bonding strength between the first light-reflective member 9a and the light-transmitting member 3 and / or between the first light-reflective member 9a and the light-shielding frame 5. The light emitting device of the embodiment includes the light shielding frame 5 having the narrow width portion 50 as a component, and suppresses the remaining voids that may adversely affect the light extraction efficiency and / or bonding strength.

[0103] The narrow width portion 50 is a portion of the frame region of the light shielding frame 5 where the width dimension is relatively smaller than that of other frame regions. Figure 4 As shown in FIG. 1 , the narrow width portion 50 is a portion where the width dimension is relatively reduced in a frame portion extending in a certain direction when viewed from above. When such a light shielding frame is coated with a light reflective resin, the height of the light reflective resin 9a' on the light shielding frame 5 will not be uniform due to the narrow width portion 50 (see FIG. 1 ). Figure 5A and Figure 5BThat is, the light-reflective resin on the light-shielding frame has locally varying heights. By having the light-reflective resin on the light-shielding frame have locally varying heights, the formation of voids can be suppressed during the formation of the first light-reflective member. Specifically, during the light-guiding support member formation process, the light-reflective member is brought into contact with and pressed against the light-reflective resin to fill the space between the light-transmitting member and the opening of the light-shielding frame. During this pressing process, the locally varying heights of the light-reflective resin cause a time difference in the contact between the light-transmitting member and the light-reflective resin. This time difference in contact facilitates the escape of air from this space, thereby suppressing the formation of voids.

[0104] Hereinafter, the overall structure and each structural member of the light emitting device according to the embodiment will be described in detail.

[0105] In the light emitting device of the embodiment, the light transmissive member 3 has a first surface 3a which is substantially the light emitting surface of the light emitting device, and a second surface 3b on the opposite side of the first surface. When viewed from above, the area of the second surface 3b of the light transmissive member 3 is larger than the area of the first surface 3a of the light transmissive member 3 (see FIG. Figure 1 ).

[0106] By making the area of the first surface 3a of the translucent member 3 smaller than the second surface 3b, the emitted light from the light-emitting element 1 that enters from the second surface 3b of the translucent member 3 can be emitted from the first surface 3a with a smaller area. That is, by reducing the area of the light-emitting surface through the translucent member 3, it is possible to illuminate farther with high brightness. Light-emitting devices with high front brightness are particularly suitable for vehicle-mounted lighting such as headlights. It should be noted that in vehicle-mounted lighting, there are various regulations for the color of this type of light. For example, the color of the light of a headlight is determined to be white or light yellow, and all headlights are the same.

[0107] It should be noted that the first surface 3a and the second surface 3b of the translucent member 3 are different in size, and a flange portion is provided on the translucent member 3. Specifically, the flange portion is provided on the translucent member 3 because the area of the second surface 3b is larger than the area of the first surface 3a.

[0108] When viewed from above, it is preferred that at least a portion of the outer periphery of the second surface 3b of the light-transmitting member 3 is located outside the inner periphery of the opening 5a of the light-shielding frame 5. Figure 1 In the light-emitting device of the illustrated embodiment, a portion of the outer periphery of the second surface 3b (particularly at least a portion of the flange outline of the light-transmitting member 3) is located outside the inner periphery of the opening 5a when viewed from above. When the outer periphery of the second surface 3b of the light-transmitting member 3 has a rectangular shape, for example, it is preferably configured such that at least one side of the outer periphery, for example two opposing sides, preferably two opposing long sides, is located outside the inner periphery of the opening 5a of the light-shielding frame 5.

[0109] Thus, in a preferred embodiment, part or all of the outer periphery of the second surface 3b of the translucent member 3 is located outside the inner periphery of the opening 5a when viewed from above, and the outer periphery of the first surface 3a of the translucent member 3 is located inside the inner periphery of the opening 5a when viewed from above.

[0110] Specifically, in the light-emitting device of this embodiment, when viewing the light-emitting device from above (i.e., the light-emitting surface of the light-emitting device), the first surface 3a of the translucent member 3 and the upper surface of the first light-reflecting member 9a surrounding the outer periphery of the first surface 3a can be observed and confirmed inside the opening 5a of the light-shielding frame 5. In this case, in the region inside the opening 5a, the translucent member 3 is located at least partially below the first light-reflecting member. Consequently, even if cracks and / or peeling occur in the first light-reflecting member 9a, light leaking from the portion of the translucent member 3 located inside the opening 5a is easily limited to light emitted from the translucent member 3. To enhance this effect, when the outer periphery of the second surface 3b of the translucent member 3 is rectangular with long and short sides, it is preferable to configure the structure so that at least the long sides of the outer periphery of the second surface 3b are located outside the inner periphery of the opening 5a of the light-shielding frame 5, as described above.

[0111] In addition, in the area covered by the light-shielding frame 5, since the leakage light from the light-reflecting member 9 is blocked, even if the second light-reflecting member 9b located on the side of the light-emitting element 1 develops cracks and / or peels off, it is possible to more effectively suppress the light emitted from the side of the light-emitting element 1 from leaking to the light-emitting surface through the cracks and / or peeling parts.

[0112] For example, when using a light-emitting device that emits white light by mixing blue light emitted from light-emitting element 1 with yellow light obtained by wavelength conversion of a portion of the blue light as vehicle lighting, if blue light emitted from light-emitting element 1 leaks out in addition to the white light emitted from the light-emitting surface, a chromaticity difference will occur within opening 5a, potentially causing uneven light color within the illuminated area. Furthermore, if blue light leakage is observed, the aforementioned requirements for vehicle lighting are not met, potentially compromising vehicle safety.

[0113] In one mode of the light emitting device of the embodiment, at least a portion of the outer periphery of the first surface 3a of the light transmissive member 3 is located inside the outer periphery of the light emitting element 1 when viewed from above (see FIG. Figure 1 For example, when the periphery of the first surface 3a of the light-transmitting member 3 has a rectangular shape, the long side of the rectangle may be located further inward than the long side of the periphery of the light-emitting element 1. Figure 1As shown, when the periphery of the light-emitting element 1 is mentioned in a light-emitting device including a plurality of light-emitting elements 1, the periphery is defined by considering the plurality of light-emitting elements 1 as a whole, and does not include the peripheries of the light-emitting elements facing each other between adjacent light-emitting elements.

[0114] Thus, light emitted from the plurality of light-emitting elements 1 can be collected and emitted from the first surface 3a of the translucent member 3. Therefore, light emitted from the light-emitting elements 1 can be emitted from the first surface 3a of the translucent member 3, which serves as the light-emitting surface of the light-emitting device, with a higher luminous flux density.

[0115] (Substrate)

[0116] The substrate 10 is a member that supports the light-emitting element 1 and other components, and has wiring on at least its surface that is electrically connected to the external electrodes of the light-emitting element 1. The main material of the substrate 10 is preferably an insulating material that is not easily permeable to light from the light-emitting element 1 and external light. Specifically, examples include ceramics such as aluminum oxide and / or aluminum nitride, and at least one resin selected from phenolic resin, epoxy resin, silicone resin, polyimide resin, BT resin, and polyphthalamide. It should be noted that when using a resin, at least one inorganic filler selected from glass fiber, silicon oxide, titanium oxide, and aluminum oxide may be mixed into the resin as needed. This can improve mechanical strength, reduce thermal expansion coefficient, and / or increase light reflectivity. Alternatively, the substrate 10 may be a metal component formed with an insulating material formed on the surface. Wiring is formed in a predetermined pattern on the insulating material. The wiring material may be at least one selected from gold, silver, copper, titanium, palladium, nickel, and aluminum. The wiring can be formed by plating, vapor deposition, and / or sputtering.

[0117] (Light-emitting element)

[0118] As the light emitting element 1, a light emitting diode is preferably used. The light emitting element 1 can be an element of any wavelength. For example, as a blue or green light emitting element, a nitride semiconductor (In X Al Y Ga 1-X-Y N, 0≤X, 0≤Y, X+Y≤1), at least one of ZnSe and GaP. In addition, as a red light-emitting element, GaAlAs and / or AlInGaP can be used. In addition, a semiconductor light-emitting element formed of materials other than the above can also be used. The composition, luminous color, size, and / or number of the light-emitting elements used can be appropriately selected according to the purpose. In the case of making a light-emitting device with a phosphor, a nitride semiconductor (In2O3) that can emit short-wavelength light that can efficiently excite the phosphor can be preferably cited. X Al Y Ga1-X-Y N, 0≤X, 0≤Y, X+Y≤1). Various emission wavelengths can be selected according to the material of the semiconductor layer and / or its mixed crystal degree.

[0119] The light emitting element 1 used in the light emitting device of the embodiment has positive and negative electrodes on the same side, for example. Figure 2A As shown in FIG, the light emitting element 1 can be flip-chip mounted on the substrate 10 via the conductive bonding member 11. Figure 2A In the figure, the conductive bonding member 11 connected to the positive and negative electrodes of the light-emitting element 1 is simplified. In fact, it is provided in a manner of being connected to the positive and negative electrodes provided on the same side of the surface. The positive and negative electrodes of the light-emitting element 1 are connected to the positive and negative wiring (not shown) provided on the substrate 10 via the conductive bonding member 11, respectively. In addition, the light-emitting element 1 is mounted on the substrate with the surface on which the electrodes are formed as the lower surface, and the upper surface opposite to the lower surface is used as the main light emitting surface. As described above, such a light-emitting element 1 is connected to the substrate using a conductive bonding member such as a bump and / or a conductive paste. Therefore, compared with a light-emitting element connected using a metal wire, etc., the contact area between the electrode and the substrate can be increased, and the connection resistance can be reduced.

[0120] The light-emitting element 1 is, for example, a light-emitting element formed by stacking a nitride semiconductor layer on a light-transmitting support substrate. The support substrate is the upper surface side of the light-emitting element 1 and serves as the main light-emitting surface. It should be noted that the support substrate can be removed, for example, by polishing and / or laser lift-off.

[0121] (Light-transmitting member)

[0122] The translucent member 3 transmits light emitted from the light-emitting element 1 and emits it to the outside. The translucent member 3 includes a first surface 3a, which essentially serves as the light-emitting surface of the light-emitting device, and a second surface 3b opposite the first surface. The area of the second surface 3b of the translucent member 3 is larger than the area of the first surface 3a of the translucent member 3. As described above, the translucent member 3 includes a flange portion 30 on its side surface.

[0123] The translucent member 3 may include a light-diffusing material or a phosphor capable of wavelength-converting at least a portion of incident light. The translucent member 3 may be formed, for example, from resin, glass, and / or an inorganic material. Examples of translucent members containing a phosphor include a fired phosphor, or a member containing a phosphor in a resin, glass, ceramic, or other inorganic material. Alternatively, a resin layer containing the phosphor may be formed on the surface of a molded body such as a resin, glass, and / or ceramic. The total thickness of the translucent member 3 may be, for example, approximately 50 to 300 μm.

[0124] like Figure 2AAs shown, the light-transmitting member 3 and the light-emitting element 1 can be bonded, for example, via the light-guiding member 13. Alternatively, the light-transmitting member 3 and the light-emitting element 1 can be bonded without using the light-guiding member 13, and a direct bonding method such as press bonding, firing, surface-activated bonding, atomic diffusion bonding, and / or hydroxyl bonding can be used.

[0125] The light-transmitting member 3 may contain a phosphor. As the phosphor that may be contained in the light-transmitting member 3, a phosphor that can be excited by the light emitted from the light-emitting element 1 can be used. For example, as a phosphor that can be excited by a blue light-emitting element or an ultraviolet light-emitting element, at least one of the following phosphors can be exemplified: cerium-activated yttrium / aluminum / garnet phosphor (YAG:Ce); cerium-activated lutetium / aluminum / garnet phosphor (LAG:Ce); europium and / or chromium-activated nitrogen-containing calcium aluminosilicate phosphor (CaO-Al2O3-SiO2:Eu); europium-activated silicate phosphor ((Sr,Ba)2SiO4:Eu); nitride phosphors such as β-sialon phosphor, CASN phosphor represented by CaAlSiN3:Eu, and SCASN phosphor represented by (Sr,Ca)AlSiN3:Eu; KSF phosphor represented by K2SiF6:Mn; sulfide phosphor; and quantum dot phosphor, etc. By combining these phosphors with a blue light-emitting element or an ultraviolet light-emitting element, a light-emitting device having a desired light-emitting color (for example, a white light-emitting device) can be manufactured.

[0126] Although it is just an example, the light-transmitting member 3 may be a plate material called a so-called “YAG plate”.

[0127] The light-transmitting member may have a quadrilateral shape when viewed from above. In particular, the first main surface of the light-transmitting member may have a quadrilateral shape when viewed from above. That is, when viewed from above, the light-transmitting member may have a quadrilateral shape. The term "quadrilateral" here refers to a substantially quadrilateral shape and can be broadly interpreted to include squares, rectangles (rectangles), parallelograms, trapezoids, and the like. For example, when a plurality of light-emitting elements 1 are provided on a single light-transmitting member, the light-transmitting member 3 may have a quadrilateral shape and size that is consistent with all of the plurality of light-emitting elements 1.

[0128] When the first main surface of the light-transmitting member has a quadrilateral shape as a plan view, flanges may be provided in pairs on opposite sides of the quadrilateral. In other words, flanges may be provided on a pair of opposite sides of the quadrilateral. Figure 1 As shown, for example, the first and second principal surfaces of the light-transmitting member 3 may have a rectangular (long) shape in a plan view. When the first and second principal surfaces of the light-transmitting member have a rectangular shape in a plan view, flange portions may be provided in pairs on the opposing long sides of the rectangle.

[0129] (Shading frame)

[0130] The light-shielding frame 5 is provided to reduce the brightness of the portion of the light-emitting device's upper surface excluding the light-emitting surface. To reduce the brightness of the portion excluding the light-emitting surface, it is necessary to block light that leaks from the translucent member 3, excluding the first surface 3a. Considering this function, the light-shielding frame 5 is preferably made of a material that does not transmit light but reflects and / or absorbs it, or has a film formed on its surface from a material that reflects and / or absorbs light.

[0131] The light shielding frame 5 used in the light emitting device of the embodiment includes a portion where the frame width is non-constant. In other words, the light shielding frame is provided with a narrow portion where the width is locally narrowed in a plan view.

[0132] The material constituting the light-shielding frame 5 can be selected from resin (including fiber-reinforced resin), ceramic, glass, paper, metal, and composite materials formed from two or more of these materials. Specifically, the light-shielding frame 5 can be formed from a material with good light-shielding properties and not easily deteriorated. For example, the light-shielding frame 5 can be formed using a metal frame formed from metal or a frame having a metal film on the surface. Examples of metal materials include copper, iron, nickel, chromium, aluminum, gold, silver, titanium, or alloys thereof.

[0133] In addition, it is more preferred that the light-shielding frame 5 not only suppresses light leakage from the inside of the light-emitting device, but also has the function of suppressing the reflection of light from the outside. As the function of suppressing the reflection of light from the outside, for example, the surface on the light-emitting side has fine concave-convex parts, and materials with high light absorption rate are used. As fine concave-convex parts, for example, the average arithmetic roughness Ra is greater than 0.5 μm and less than 1.0 μm. It should be noted that when the surface of the light-shielding frame has fine concave-convex parts, the wettability of the surface of the light-shielding frame to the liquid increases, and the uncured resin material is easy to wet and spread on the surface of the light-shielding frame. Therefore, for example, it is preferred not to perform fine concave-convex processing on the edge of the upper surface of the light-shielding frame. In addition, as materials with high light absorption rate, black nickel plating and / or black chrome plating can be exemplified.

[0134] In addition, while maintaining the strength when used as a light-emitting device, taking into account the degree of lightness and / or non-deformability, the thickness of the shading frame 5 (i.e., the height from the lower surface to the upper surface of the shading frame 5) can be set to about 20μm to 200μm, for example, about 30 to 80μm.

[0135] The light shielding frame 5 can be arranged so that its outer periphery coincides with the outer periphery of the light emitting device when viewed from above, or it can be arranged so that the outer periphery of the light shielding frame 5 is located inside the outer periphery of the light emitting device. As a result, in the segmentation process of segmenting the light emitting device into each unit area (i.e., each light emitting device) described later, the light shielding frame 5 is not arranged on the segmentation line, thereby suppressing positional deviation of the light shielding frame 5 during segmentation.

[0136] It should be noted that setting the shading frame 5 in a manner such that the outer periphery of the shading frame 5 is located inside the outer periphery of the light-emitting device includes the case where the shading frame 5 is set in a manner such that a part of the outer periphery of the shading frame 5 is located inside the outer periphery of the light-emitting device.

[0137] In order to increase the brightness difference between the inner and outer sides of the light exit surface of the first surface 3a, the width of the light shielding frame 5 in a plan view may be at least 130 μm or more. In particular, considering ease of handling during the manufacturing process, it may be, for example, 500 μm or more.

[0138] (Light reflecting member)

[0139] The light-reflecting member may include a first light-reflecting member 9a and a second light-reflecting member 9b, wherein the first light-reflecting member 9a is arranged in a manner that joins the opening 5a of the light-shielding frame 5 with a portion of the side surface of the light-transmitting member 3, and the second light-reflecting member 9b is arranged in a manner that covers the side surface of the light-emitting element 1 between the first light-reflecting member 9a and the substrate 10.

[0140] The first and second light-reflecting members 9a and 9b cover the side surfaces of the light-emitting element 1 and the side surfaces of the translucent member 3, reflecting light emitted from the side surfaces of the light-emitting element 1 and the translucent member 3 so that it exits from the first surface 3a of the translucent member 3, which serves as the light-emitting surface of the light-emitting device. Providing the light-reflecting members 9 covering the side surfaces of the light-emitting element 1 and the translucent member 3 in this manner can improve light output efficiency. The light-reflecting members are formed, for example, from a light-reflecting material with a high light reflectivity. Specifically, the light-reflecting members can be formed from a light-reflecting material having a reflectivity of 60% or greater, for example, 80% or 90% or greater, for light from the light-emitting element. The light-reflecting material is formed, for example, from a resin containing a light-reflective substance. As described in detail below, the first and second light-reflecting members 9a and 9b are formed separately and can be formed from different light-reflecting materials or the same light-reflecting material.

[0141] The resin forming the matrix of the light-reflecting member 9 can be silicone resin, modified silicone resin, epoxy resin, modified epoxy resin, acrylic resin, or a mixed resin containing at least one of these resins. The matrix formed from this resin contains a light-reflecting substance. The light-reflecting substance can be at least one selected from titanium oxide, silicon oxide, zirconium oxide, magnesium oxide, yttrium oxide, yttria-stabilized zirconium oxide, calcium carbonate, calcium hydroxide, calcium silicate, niobium oxide, zinc oxide, barium titanate, potassium titanate, magnesium fluoride, aluminum oxide, aluminum nitride, boron nitride, and mullite. For example, titanium dioxide (TiO2) can be used. Furthermore, particles having a different refractive index from that of the matrix resin can be dispersed in the matrix resin as the light-reflecting substance. Since the amount of light reflected and transmitted varies depending on the concentration and density of the light-reflecting substance, the concentration and / or density can be appropriately adjusted according to the shape and / or size of the light-emitting device. Furthermore, the light-reflecting member can contain other pigments and / or phosphors in addition to the light-reflecting substance. In particular, when the light-transmitting member 3 contains a fluorescent substance, the second light-reflecting member 9b covering the side surface of the light-emitting element also contains the same fluorescent substance, thereby suppressing leakage of light emitted from the light-emitting element from the side surface of the light-emitting device.

[0142] (Light guide member)

[0143] In the light-emitting device, the light-transmitting member 3 and the light-emitting element 1 can be joined via a light-guiding member 13. As shown in FIG2 , the light-guiding member 13 can cover a part or all of the side surface of the light-emitting element 1. In the case where a part of the second surface 3b of the light-transmitting member 3 is not opposite to the upper surface of the light-emitting element 1 which serves as the main light-emitting surface, the light-guiding member 13 can cover a part of the light-transmitting member 3 that is not opposite to the upper surface of the light-emitting element. It should be noted that the light-guiding member 13 is also sandwiched between the light-emitting element 1 and the light-transmitting member 3 to join the two. The light-guiding member 13 constructed as described above can efficiently guide the emitted light from the upper surface and side surface of the light-emitting element 1 to the light-transmitting member 3.

[0144] For ease of handling and processing, the light guide member 13 is preferably made of a resin material. Examples of the resin material include a resin or a mixed resin containing at least one selected from silicone resin, modified silicone resin, epoxy resin, modified epoxy resin, acrylic resin, and fluororesin. The light guide member 13 can be formed into the aforementioned shape by appropriately adjusting the viscosity of the resin material and / or the wettability of the resin material with the light-emitting element 1.

[0145] (Other components)

[0146] The light emitting device may optionally include other elements such as a protective element, electronic components, etc. These elements and electronic components are preferably embedded in the light reflecting member.

[0147] Method for manufacturing a light-emitting device according to an embodiment

[0148] The manufacturing method of the light-emitting device of the embodiment includes: a mounting step of mounting a light-emitting element on a substrate; a light-shielding frame placement step of placing a light-shielding frame having an opening on a sheet; a light-reflective resin coating step of coating the light-shielding frame with a light-reflective resin; a light-guiding support member forming step of bringing a plate-shaped light-transmitting member into contact with the coated light-reflective resin at a position where a space is formed between the light-transmitting member and the opening, with a first surface of the light-transmitting member facing the sheet, and pressing the light-reflective resin so that the light-reflective resin flows into the space to form a first light-reflective member, and manufacturing a light-guiding support member in which the light-shielding frame and the light-transmitting member are supported by the first light-reflective member, the light-transmitting member having a first surface and a second surface opposite to the first surface, the outer periphery of the first surface being smaller than the inner periphery of the opening, and the second surface being larger than the first surface; and a light-guiding support member bonding step of bonding the upper surface of the mounted light-emitting element to the second surface to fix the light-guiding support member to the light-emitting element.

[0149] According to the manufacturing method of this embodiment, for example, Figure 1 、 Figure 2A and 2B Hereinafter, a manufacturing method of the embodiment will be described with reference to the accompanying drawings.

[0150] (Installation process)

[0151] Here, a light emitting element is mounted on a substrate. Figure 6A and 6B As shown, at least one light emitting element 1 is mounted on the main surface of the substrate 10. For example, the light emitting element 1 can be flip-chip mounted on the substrate 10. Specifically, for example, the light emitting element 1 having positive and negative electrodes on the lower surface of the same side is bonded by a conductive bonding member 11, so that the positive electrode is opposite to the positive wiring provided on the substrate 10, and the negative electrode is opposite to the negative wiring provided on the substrate 10. It should be noted that Figure 2A Likewise, in Figure 6B In the figure, the positive and negative electrodes of the light emitting element 1 and the conductive bonding member 11 connected to the positive and negative wirings provided on the substrate 10 are simplified and drawn without distinction.

[0152] (Light-shielding frame placement process)

[0153] Here, a light shielding frame having an opening is placed on the sheet. Figure 7A As shown, the light shielding frame 5 in which the opening 5 a is formed by the frame portion 5 b is placed on the main surface of the sheet 4 .

[0154] The light-shielding frames can be pre-processed into the desired shape and placed one by one on the sheet. Alternatively, multiple light-shielding frames can be connected in rows and / or columns according to the unit area and placed all at once on the sheet. A heat-resistant sheet with an adhesive surface can be used. The sheet substrate can be, for example, polyimide.

[0155] (Light-reflective resin coating step)

[0156] Here, a light-reflecting resin is applied to the light-shielding frame. Figure 7B As shown, the frame portion 5b of the light shielding frame is coated with a light reflective resin 9a'. In particular, the light reflective resin 9a' is coated on the frame portion 5b of the light shielding frame 5 so as to be coated at least on the narrow portion.

[0157] The amount of light-reflective resin 9a' applied can be such that, in the subsequent light guide support member forming step, the first light-reflective member 9a can be formed without a gap between the light-transmitting member 3 and the light-shielding frame 5. It should be noted that, in order to prevent light from being emitted from the first surface 3a of the light-transmitting member 3, which serves as the light-emitting surface of the light-emitting device, the amount of light-reflective resin 9a' applied and its viscosity can be adjusted so that the light-reflective resin 9a' does not adhere to the first surface 3a of the light-transmitting member 3.

[0158] The light-reflective resin 9a' can be applied to the light-shielding frame 5 by, for example, being discharged from the tip of a resin dispensing device using a nozzle. For example, the light-reflective resin 9a' can be applied to the light-shielding frame 5 in a linear pattern using the nozzle. More specifically, the light-reflective resin 9a' can be applied to the light-shielding frame 5 in a linear pattern by reciprocating the nozzle while dispensing the light-reflective resin 9a'. This allows the light-reflective resin 9a' to be applied to the light-shielding frame 5 in such a manner that it is applied to narrow portions of the light-shielding frame 5.

[0159] As described later, by bringing the light-transmitting member 3 into contact with the light-reflective resin 9a' coated on the light-shielding frame 5, the uncured light-reflective resin 9a' moves along the surface of the light-shielding frame 5 and the light-transmitting member 3, covering the inner side surface of the opening 5a of the light-shielding frame 5 and the side surface of the light-transmitting member 3, while filling the space between the light-transmitting member 3 and the opening 5a with the light-reflective resin 9a'.

[0160] The viscosity of the uncured light reflective resin 9a' can be, for example, 5 Pa·s to 15 Pa·s, thereby ensuring the flow of the resin material into the space between the light transmissive member 3 and the opening 5a and suppressing the wetting and diffusion of the resin material onto the first surface 3a of the light transmissive member 3.

[0161] (Light Guide Support Member Forming Step)

[0162] Here, a light guide support member is fabricated in which the light shielding frame 5 and the light transmissive member 3 are supported by the first light reflective member 9a. Specifically, using the light transmissive member 3, a light reflective resin 9a' disposed on the light shielding frame 5 is poured between the light transmissive member 3 and the opening 5a of the light shielding frame 5, and then cured to form the first light reflective member 9a. This results in a light guide support member 60 in which the light shielding frame 5 and the light transmissive member 3 are supported by the first light reflective member 9a.

[0163] like Figures 7C to 7F As shown, in the light guide support member forming step, a plate-shaped light-transmitting member 3 having a flange 30 on its side is used. At a position where a space is formed between the light-transmitting member 3 and the opening 5a of the light-shielding frame 5, the flange 30 is brought into contact with a light-reflective resin 9a', with the second surface 3b of the light-transmitting member 3 facing the sheet 4. The flange 30 is then pressed against the sheet 4, causing the light-reflective resin 9a' to flow into the space, thereby forming the first light-reflecting member 9a. This results in a light guide support member 60 in which the light-shielding frame 5 and the light-transmitting member 3 are supported by the first light-reflecting member 9a.

[0164] The light-transmitting member 3 used in the light guide support member forming step is, for example, Figure 9 As shown, the light-transmitting member 3 comprises a first surface 3a, a second surface 3b opposite the first surface, a first side surface 3c continuous with the first surface 3a, a second side surface 3d located further outward from the first side surface 3c and continuous with the second side surface 3b, and a third surface 3e continuous with both the first side surface 3c and the second side surface 3d. In the light-transmitting member 3, the first surface 3a has an outer circumference smaller than the inner circumference of the opening 5a of the light-shielding frame 5, and the second surface 3b has an area larger than that of the first surface 3a. Due to the difference in area between the first surface 3a and the second surface 3b, a flange 30 is provided on the light-transmitting member 3. Here, the first surface 3a is a rectangle having long and short sides, and the flange 30 is provided on the side surface of the rectangle along the long side.

[0165] like Figures 7C to 7FAs shown, when the light-transmitting member 3 is placed on the sheet 4, the flange portion 30 of the light-transmitting member 3 comes into contact with the light-reflecting resin 9a' before the first surface 3a of the light-transmitting member 3 comes into contact with the light-reflecting resin 9a' on the light-shielding frame 5. Specifically, at a position where a space is formed between the light-transmitting member 3 and the opening 5a of the light-shielding frame 5, the light-transmitting member 3 is brought into contact with the light-reflecting resin 9a' on the light-shielding frame 5 so that the first surface 3a of the light-transmitting member 3 faces the sheet 4. As a result, the light-reflecting resin 9a' flows, as shown in FIG. Figure 7F As shown, the light-reflective resin 9 a ′ is filled in the space between the frame portion 5 b of the light-shielding frame and the light-transmitting member 3 .

[0166] More specifically, if the translucent member 3 is arranged so that at least a portion of the outline of the flange portion 30 is located outside the inner periphery of the opening portion 5a of the light shielding frame 5 (see Figure 7C ), the flange portion 30 of the light-transmitting member 3 is brought into contact with the light-reflecting resin 9a' coated on the light-shielding frame 5 (see Figure 7D ), the contact point becomes the starting point, and the light reflective resin 9a' flows from the flange portion 30 of the light-transmitting member 3 to the side (refer to Figure 7E ), the light reflective resin 9a' can be filled in the space between the side surface of the light-transmitting member 3 and the opening 5a of the light-shielding frame 5 (refer to Figure 7F ). When the opening 5a of the light-shielding frame 5 and the second surface 3b of the light-transmitting member 3 are both rectangular with long sides and short sides, the light-transmitting member 3 and the light-shielding frame 5 can be arranged so that the distance between the long side of the second surface 3b and the long side of the opening 5a is equal to the distance between the short side of the second surface 3b and the short side of the opening 5a when viewed from above.

[0167] In the light guide support member forming step, a suction device such as a chuck may be used to place the light transmissive member 3 on the sheet 4. For example, the light transmissive member 3 may be placed on the sheet 4 while being picked up by a suction device such as a chuck 40, and the light reflective resin 9a' in contact with the flange portion 30 of the light transmissive member 3 may be made to flow by pressing the light transmissive member 3 with such a suction device (see FIG. Figures 7C to 7F It should be noted that when the flange portion 30 of the light-transmitting member 3 is in contact with the light-reflecting resin 9a' on the light-shielding frame 5 (see Figure 7D ), the flange portion 30 of the translucent member 3 will start to contact the highest level portion of the light reflective resin 9a', and then contact other portions of the light reflective resin 9a' according to a time difference (the relevant details will be described later).

[0168] (Light guide supporting member bonding step)

[0169] Here, as Figure 8AAs shown, the light guide support member 60 is fixed to the light emitting element 1 by bonding the light emitting surface (ie, the upper surface) of the mounted light emitting element 1 to the second surface 3 b of the light transmissive member 3 .

[0170] The translucent member 3 of the light guide supporting member 60 obtained as described above is aligned with the light emitting element 1 , and the translucent member 3 is bonded to the light emitting surface of the light emitting element 1 using, for example, the light guide member 13 .

[0171] In getting Figure 1 、 Figure 2A and 2B In the case of the light emitting device of the embodiment shown, the light guide support member 60 is aligned in the following manner, for example,

[0172] (i) the outer periphery of the second surface 3b of the light-transmitting member 3 is positioned outside the outer periphery of the light-emitting element 1 when viewed from above,

[0173] (ii) At least one side of the outer periphery of the first surface 3 a of the translucent member 3 is positioned inside the outer periphery of the light emitting element 1 when viewed from above.

[0174] When bonding the second surface 3b of the translucent member 3 of the light guide support member 60 to the upper surface of the light emitting element 1, the translucent member 3 having the light guide member 13 pre-applied on the second surface 3b may be placed on the light emitting element 1, or the translucent member 3 of the light guide support member 60 may be placed on the light emitting element 1 after the light guide member 13 is applied to the upper surface of the light emitting element 1. The amount of light guide member 13 applied, the load applied when the translucent member 3 is placed on the light emitting element 1 and pressed, and, if a resin material is used as the light guide member 13, the viscosity of the resin material applied when the light guide member 13 is applied, etc., can be appropriately set in consideration of the desired shape of the light guide member 13 after the translucent member 3 of the light guide support member is bonded to the light emitting element 1.

[0175] (Sheet removal process)

[0176] The sheet 4 can be removed in a sheet removing step after the light guide supporting member bonding step or after the second light reflecting member forming step.

[0177] (Second Light Reflective Member Forming Step)

[0178] Here, another light reflecting member, that is, the second light reflecting member 9b is formed. Specifically, the uncured second light reflecting resin 9b' forming the second light reflecting member 9b is filled into the space between the substrate 10 and the light shielding frame 5, thereby forming the second light reflecting member 9b surrounding the light emitting element 1 and the light transmissive member 3 between the substrate 10 and the light shielding frame 5 (see Figure 8B). The second light reflecting member 9b can constitute an integrated light reflecting member 9 together with the first light reflecting member 9a. It should be noted that, Figure 8B This is an example in which the sheet 4 is removed before the second light reflecting member forming step.

[0179] For example, a light shielding frame 5 that is slightly smaller than the substrate 10 (ie, with its outer edge enclosed within the substrate 10 in a plan view) may be used, and the second light reflective resin 9b' may be filled from the outer periphery of the light shielding frame into the space between the substrate 10 and the light shielding frame 5.

[0180] After the space between the substrate 10 and the light shielding frame 5 is filled with the second light reflective resin 9b', the filled second light reflective resin 9b' is cured, thereby forming the second light reflective member 9b.

[0181] As described above, the light-emitting device of the embodiment is manufactured.

[0182] The above description has been made with reference to the drawings showing a single light emitting device.

[0183] However, in the manufacturing method of the light-emitting device of the embodiment, a substrate and a light-shielding frame divided into a plurality of unit areas corresponding to the respective light-emitting devices can be used as the substrate and the light-shielding frame to manufacture a plurality of light-emitting devices at one time and then separate them into the respective light-emitting devices.

[0184] For example, as the substrate and the light shielding frame, a substrate including a plurality of (n×m) unit regions in a manner forming a plurality of rows (n rows) and a plurality of columns (m columns) can be used.

[0185] Furthermore, for example, as a light shielding frame, a light shielding frame including a plurality of (n×m) unit regions may be used so as to form a plurality of rows (n rows) and a plurality of columns (m columns) corresponding to the substrate. Alternatively, for example, as a light shielding frame, a plurality of (n×m) light shielding frames may be used so as to form a plurality of rows (n rows) and a plurality of columns (m columns) corresponding to the substrate, with each light shielding frame serving as a unit region.

[0186] More specifically, a plurality of light-emitting devices can be produced as follows.

[0187] (1) In the light emitting element mounting step, one or two or more light emitting elements are mounted on each of the unit areas.

[0188] (2) In the light guide supporting member forming step, light guide supporting members are formed in the unit regions.

[0189] (3) In the light guide supporting member bonding step, the light guide supporting members are bonded so as to cover the one or two or more light emitting elements mounted in the unit area at a time.

[0190] (4) In the second light reflective member forming step, the space between the substrate and the light shielding frame in each unit area is filled with the second light reflective resin.

[0191] Next, after the second light reflective member forming step, the light reflective member and the substrate are divided into unit regions in a dividing step to separate the light emitting devices. The dividing step can be performed by cutting using a dicing blade or the like, for example.

[0192] Considering the division into unit areas, it is preferable that the division positions for each unit area be away from the outer periphery of the light-shielding frame. In other words, the light-shielding frame is preferably slightly smaller than the outer shape of the light-emitting device. In this case, for example, multiple light-shielding frames slightly smaller than the outer shape of the light-emitting device can be used as the light-shielding frames.

[0193] According to the above method for manufacturing a light-emitting device, a plurality of light-emitting devices are manufactured at once and then separated into individual light-emitting devices, so that the light-emitting devices can be manufactured simply.

[0194] The following details the effects of the narrowed portion of the light-shielding frame. In embodiments of the present invention, a light-shielding frame is provided with a narrowed portion, where the width is locally narrowed when viewed from above. Specifically, during the light-reflective resin coating step, when applying the light-reflective resin to the light-shielding frame, the light-reflective resin is applied at least to the narrowed portion.

[0195] Figure 3 and Figure 4 An example of a light shielding frame 5 is shown. The light shielding frame 5 includes an opening 5a and a frame portion 5b. The frame portion 5b extends to form a quadrilateral when viewed from above, with the opening 5a formed inside. Specifically, the light shielding frame 5 has a form in which a portion corresponding to the opening 5a is removed from a flat plate member. For example, the light shielding frame 5 shown in the figure has a form in which a quadrilateral portion corresponding to the opening 5a is removed from a quadrilateral flat plate member.

[0196] like Figure 3 and Figure 4 As shown, the width of the frame portion 5b of the light shielding frame 5 used in the embodiment of the present invention is not constant, and has a partially reduced width. That is, the narrow width portion 50 makes the frame portion 5b of the light shielding frame 5 narrow in a plan view.

[0197] The light shielding frame 5 having the narrowed portion 50 helps suppress the formation of voids during the manufacture of the light-emitting device. More specifically, the presence of the narrowed portion 50 on the light shielding frame 5 can suppress or eliminate the formation of voids in the region of the first light reflective member between the light-transmitting member and the light shielding frame when forming the light guide support member.

[0198] Voids during the formation of the light-guiding support member are bubbles or similar particles that form when light-reflective resin flows into the space between the light-transmitting member and the opening of the light-shielding frame. During the formation of the light-guiding support member, the light-reflective resin is placed on the light-shielding frame, and then the light-transmitting member is placed on the sheet. When placing the light-transmitting member, the flange of the light-transmitting member presses against the light-reflecting resin on the light-shielding frame, causing this pressure to flow into the space between the light-transmitting member and the light-shielding frame opening. Voids can sometimes form as a result of this flow into the space. This is believed to be primarily due to the fact that, when the light-transmitting member is placed, the flange of the light-transmitting member and the light-reflective resin come into contact over a wide area all at once. In particular, this wide contact causes the light-reflective resin to flow all at once into the space between the light-transmitting member and the light-shielding frame opening, which can easily lead to voids. If the light-reflective resin is cured to form the first light-reflecting member while voids are present, voids may remain in the light-guiding support member. In particular, it is considered that voids (air bubbles) are likely to remain in the region of the first light reflecting member between the light-transmitting member and the light-shielding frame in a plan view.

[0199] Such residual holes in the light-guiding support member are undesirable for the optical characteristics of the light-emitting device. For example, there is a risk that the effect of "suppressing the reduction in light output efficiency" brought about by the first light-reflecting member sandwiched between the light-transmitting member and the light-shielding frame will be reduced due to the holes. The light-shielding frame, which increases the brightness difference between the inner and outer sides of the light-emitting surface, has the property of absorbing light. Therefore, if the light-transmitting member is in direct contact with the light-shielding frame, there is a risk of reducing the light output efficiency of the light-emitting device. Therefore, in the light-emitting device of this embodiment, the "first light-reflecting member sandwiched between the light-transmitting member and the light-shielding frame" is used to suppress the reduction in the light output efficiency. Therefore, if there are holes (bubbles) in the area of the first light-reflecting member, the effect of "suppressing the reduction in light output efficiency" in the light-emitting device will be reduced. The manufacturing method of the embodiment of the present invention can reduce or eliminate such residual holes in the light-guiding support member, and can manufacture a light-emitting device exhibiting desired optical characteristics.

[0200] In addition, the residual holes in the light-guiding support member pose a risk of reducing the bonding strength between its components. In the light-guiding support member, the first light-reflecting member is sandwiched between the light-transmitting member and the light-shielding frame to bond the light-transmitting member and the light-shielding frame to each other. If there are holes (bubbles) in the area of such a first light-reflecting member, there is a risk of reducing the bonding. More specifically, if there are holes in the area of the first light-reflecting member, there is a risk of reducing the bonding strength between the first light-reflecting member and the light-transmitting member and / or the bonding strength between the first light-reflecting member and the light-shielding frame. The manufacturing method of an embodiment of the present invention can reduce or eliminate such residual holes, and thus can more appropriately maintain the bonding strength of the components of the light-guiding support member.

[0201] The suppression of residual voids is described in detail. In the manufacturing method of the embodiment of the present invention, due to the narrow width portion of the light-shielding frame, the height of the light-reflective resin applied to the light-shielding frame is locally different. That is, in the light-guiding support member forming process, the light-reflective resin on the light-shielding frame has a portion that is relatively high and a portion that is relatively low in height from the light-guiding support member. It is preferred that the height of the light-reflective resin on the frame area other than the narrow width portion is relatively lowered so that the portion of the light-reflective resin located on the narrow width portion is relatively increased (relevant details will be described later). Therefore, in the light-guiding support member forming process, the contact between the light-reflective resin and the light-transmitting member is accompanied by a time difference due to the height of the light-reflective resin, and residual voids can be suppressed in the obtained light-guiding support member.

[0202] Figure 5A and Figure 5BThe diagram schematically illustrates the shape of light-reflective resin 9a' applied to the light-shielding frame 5 during the light-reflective resin application process. As shown, during the light-reflective resin application process, the topmost portion 9a1' of the light-reflective resin 9a' is located above the narrow portion 50. Specifically, if the height of the light-reflective resin 9a1' applied to the portion of the light-shielding frame 5 directly above the narrow portion 50 is H1, and the height of the light-reflective resin 9a2' applied to the portion of the light-shielding frame 5 other than the narrow portion is H2, then H1 is preferably greater than H2. The reason for the topmost portion of the light-reflective resin being located above the narrow portion is believed to be as follows. When a light-shielding frame having a narrow portion is coated with a fluid light-reflective resin, the light-reflective resin wets and spreads across the light-shielding frame. Regarding the wet spreading of the resin on the light-shielding frame, the frame area outside the narrow portion is relatively wide, so the light-reflective resin spreads more widely. On the other hand, the frame area within the narrow portion is relatively narrow, so the light-reflective resin spreads less widely. Since the height of the applied light-reflective resin decreases as it spreads over the light-shielding frame, the height of the light-reflective resin decreases further in the frame area outside the narrow portion, which is a relatively wide area. As a result, the area of light-reflective resin located above the narrow portion becomes relatively taller.

[0203] When the height of the light-reflective resin located above the narrow portion is relatively high, voids are less likely to form during the light guide support member formation process. During the light guide support member formation process, the light-reflective resin disposed on the light-shielding frame flows into the space between the light-transmitting member and the opening of the light-shielding frame by pressing against it with the translucent member. When the translucent member is pressed, the light-reflective resin on the light-shielding frame and the translucent member come into contact with each other. Here, assuming the height of the light-reflective resin applied to the light-shielding frame is constant, the translucent member's pressing against the light-reflective resin facilitates simultaneous, extensive contact between the flange of the translucent member and the light-reflective resin. This extensive, simultaneous contact easily leads to further entrapment or entrapment of air between the translucent member and the light-reflective resin, making it difficult for air to escape when the light-reflective resin flows into the space between the translucent member and the opening of the light-shielding frame. This means that voids are more likely to remain during the formation of the light guide support member. On the other hand, in the manufacturing method of the embodiment of the present invention, since the height of the light-reflective resin applied to the light-shielding frame is locally different (see Figure 5B), so there is a time difference between the contact between the flange of the light-transmitting member and the light-reflective resin. Specifically, in the light-reflective resin applied to the light-shielding frame, since the top of the light-reflective resin located on the narrow width portion is relatively the highest, the light-reflective resin on the narrow width portion starts to contact the flange of the light-transmitting member. That is, when the flange of the light-transmitting member contacts the light-reflective resin, the narrow width portion becomes the starting point of the contact. In this way, when the narrow width portion becomes the starting point of contact and there is a time difference in the contact, when the light-reflective resin is filled into the "space between the light-transmitting member and the opening of the light-shielding frame", the air in the space easily escapes to the outside. That is, the light-guiding support member is obtained by curing the light-reflective resin filled into the gap between the light-transmitting member and the opening of the light-shielding frame, and the generation of voids can be suppressed before the curing. Therefore, in the embodiment of the present invention, the narrow width portion of the light-shielding frame has the effect of improving the filling characteristics of the light-reflective resin in a manner that suppresses the generation of voids during the light-guiding support member formation process.

[0204] For the contact between the light-transmitting member and the light-reflecting resin with a time difference, use Figures 10A to 10D The schematic diagram is explained in detail. Figures 10A to 10D The left figure shows the temporal change of the light-guiding support member forming process. The left figure shows the temporal change of the topmost portion of the light-reflective resin, and the right figure shows the temporal change of the non-topmost portion of the light-reflective resin. That is, the left figure shows the temporal relationship between the light-reflective resin 9a' on the narrow width portion 50 and the flange portion 30 of the light-transmitting member 3, and the right figure shows the temporal relationship between the light-reflective resin 9a' on the non-narrow width portion 55 and the flange portion 30 of the light-transmitting member 3. As shown in the figure, when the light-transmitting member 3 is arranged on the sheet 4, first, as shown in FIG. Figure 10A As shown in the left figure in FIG, the light reflective resin 9a' on the narrow width portion 50 is in contact with the flange portion 30 of the light transmissive member 3. Then, as the light transmissive member 3 is further lowered, as shown in FIG. Figure 10C As shown in the right-hand side of the figure, the light-reflective resin 9a' on the non-narrow portion 55 contacts the flange 30 of the translucent member 3. Therefore, when the translucent member 3 and the light-reflective resin 9a' on the light-shielding frame 5 come into contact with each other, the flange 30 of the translucent member 3 first contacts the highest portion of the light-reflective resin 9a' (i.e., the light-reflective resin on the narrow portion 50), and then gradually contacts other portions of the light-reflective resin 9a' with a time lag.

[0205] like Figures 10A to 10DAs shown, during the light guide support member formation process, the light shielding frame 5 is positioned opposite the flange 30 of the light transmissive member 3. Specifically, the flange 30 is positioned so as to overlap the light shielding frame when viewed from above. By arranging the narrow width portion 50 and the non-narrow width portion 55 in the region of the light shielding frame that faces the flange 30 of the light transmissive member 3, contact between the first surface of the light transmissive member 3 and the light reflective resin can be initiated, starting with the light reflective resin 9a' on the narrow width portion. Specifically, by providing the narrow width portion 50 and the non-narrow width portion 55 on the edge that overlaps with the second surface of the light transmissive member among the edges that form the light shielding frame's top view shape, the surface of the light reflective resin on the narrow width portion can be made the starting point for contact between the light transmissive member and the light reflective resin.

[0206] Regarding the application of the light-reflective resin before the formation of the light-guiding support member, the light-reflective resin is applied to the narrow portion as well as to the frame portion outside the narrow portion. In particular, in the frame portion outside the narrow portion, it is preferable to apply the light-reflective resin in such a manner that an area for wet diffusion of the light-reflective resin remains on the light-shielding frame 5. This is because, when the light-reflective resin wets and diffuses in the frame portion outside the narrow portion, the portion of the light-reflective resin located on the narrow portion becomes relatively higher. From this point of view, in the narrow portion, it is preferable to apply the light-reflective resin in such a manner that substantially no area for wet diffusion remains, or even if any area remains, it is less than the area of the frame portion outside the narrow portion. For example, in the narrow portion, the light-reflective resin can be applied in such a manner that substantially the entire area in the width direction thereof is covered.

[0207] In the light shielding frame 5, the frame portion 5b extends in a quadrilateral shape, for example, so as to form the opening 5a in a plan view (see FIG. Figure 4 ). It can be considered that the top view shape of the frame portion 5b is a quadrilateral. In an embodiment of the present invention, a narrow width portion 50 can be provided in the frame portion 5b corresponding to at least one side of the quadrilateral. It is preferred to provide only one narrow width portion 50 for the frame portion 5b corresponding to one side of the quadrilateral. That is, it is preferred that the number of narrow width portions 50 provided for the frame portion 5b corresponding to the one side is one rather than multiple. Thus, in the light-guiding support member forming process, when the light-reflective resin is filled in the "space between the light-transmitting member and the opening portion of the light-shielding frame", air can escape to the outside more easily. It should be noted that the so-called "quadrilateral" here refers to a basic quadrilateral, and can therefore be broadly interpreted to include squares, rectangles (rectangles), parallelograms, trapezoids, and the like.

[0208] The narrow portion 50 is the area where the width of the frame portion 5b of the light-shielding frame 5 is relatively narrowed. Due to the narrow portion 50, the light-shielding frame has a concave or cutout shape when viewed from above (hereinafter, the concave or cutout portion is also referred to as the "concave portion"). When viewed from above, the outline of the concave portion of the narrow portion 50 can be formed by straight lines, curves, or a combination thereof. For example, the shape of such a concave portion can be substantially quadrilateral when viewed from above. The term "substantially quadrilateral" here is not limited to a perfect quadrilateral and can be broadly interpreted to include shapes that can be considered modified from such shapes by those skilled in the art. Therefore, for example, "substantially quadrilateral" includes squares, rectangles (rectangles), parallelograms, and trapezoids. In such shapes, the corners (such as corners) do not necessarily need to be sharp corners and can also have a curvature (specifically, the corners forming the outline can have an R).

[0209] For example, the narrow width portion has a shape in which the outer area of the light shielding frame is recessed or cut out when viewed from above. That is, the outer contour of the light shielding frame may be recessed in the narrow width portion. Figure 3 and Figure 4 In the illustrated light-shielding frame 5, the outer edge 5b1 of the frame portion 5b is partially recessed inward. The recessed outer contour of the light-shielding frame in the narrow portion facilitates the formation of the desired light-guiding support member. Specifically, it facilitates the desired amount of the first light-reflecting member sandwiched between the light-transmitting member and the light-shielding frame. If the narrow portion is recessed not in the outer contour of the light-shielding frame but in its inner contour, the presence of the narrow portion will result in a difference in the width of the first light-reflecting member between the light-transmitting member and the light-shielding frame. Specifically, when viewing the light-emitting device from above, the first light-reflecting member will be relatively more present in the area containing the narrow portion, while relatively less in areas not containing the narrow portion. This poses the risk of causing local variations in the effect of "suppressing a decrease in light output efficiency." In other words, there is the risk of locally uneven brightness between the light-emitting surface and the surrounding area. In contrast, when the outer contour of the light-shielding frame is recessed to form the narrow portion, as in the manufacturing method of the embodiment, this disadvantage is easily avoided.

[0210] The narrow width portion corresponds to a portion where the frame width of the light shielding frame is reduced, but does not need to be reduced significantly beyond what is necessary. For example, the width of the narrow width portion may be more than half of the frame width of the light shielding frame. More specifically, when the width of the narrow width portion 50 of the light shielding frame 5 is set to w and the frame width of the light shielding frame other than the narrow width portion is set to W (refer to Figure 4), preferably 0.50W≤w≤0.95W, and can be, for example, 0.60W≤w≤0.95W, 0.70W≤w≤0.95W, or 0.80W≤w≤0.95W. If the width dimension w of the narrow portion is less than 0.5W, it can be difficult to retain the applied light-reflective resin on the light-shielding frame, depending on the coating amount, and may easily overflow from the frame portion of the light-shielding frame. On the other hand, if the width dimension w of the narrow portion is greater than 0.95W, it is difficult to form the topmost portion of the light-reflective resin on the narrow portion. In other words, it is difficult to achieve the effect of the light-reflective resin being relatively elevated in the portion located on the narrow portion. It should be noted that the "width dimension w" referred to in this specification, when it varies depending on the sampling point, refers to the dimension of the portion of the narrow portion that reaches its maximum value. Similarly, the "width dimension W" referred to in this specification, when it varies depending on the sampling point, refers to the dimension of the portion of the frame portion corresponding to "one side" that reaches its maximum value.

[0211] In one embodiment, a narrow width portion is provided in the central area of the light shielding frame. Figure 3 and Figure 4 As shown, a narrow portion 50 is provided at the center of the extended length of the light-shielding frame 5 when viewed from above. The narrow portion 50 can be provided in the center of a portion corresponding to one side of the quadrilateral formed by the light-shielding frame 5 when viewed from above (i.e., the area that divides the side into two substantially equal parts). When the narrow portion is provided in the central region of the light-shielding frame, the light-reflective resin in this central region forms the topmost portion. Therefore, during the light-guide support member formation process, when the flange of the translucent member and the light-reflective resin come into contact with each other with a time lag, the translucent member and the light-reflective resin gradually contact each other from the center toward the outside (particularly in two opposing outward directions). In other words, when the light-reflective resin flows into the space between the translucent member and the opening of the light-shielding frame, air in this space easily escapes from the center toward the outside. In particular, air easily escapes from the central portion in relatively balanced, mutually opposing directions, thereby further reducing the occurrence of voids in the light-guide support member.

[0212] The narrow width portion can be provided at positions opposite to each other in the frame portion of the light shielding frame. For example, the narrow width portion 50 can be provided at the sides opposite to each other among the sides of the quadrilateral formed by the frame portion 5b of the light shielding frame when viewed from above (see FIG. Figure 4 That is, when the light shielding frame has a four-sided frame shape as a top view, for example, narrowed portions may be provided in pairs on the frame portions corresponding to opposing sides of the quadrilateral. A light shielding frame having narrowed portions in such a manner that oppose each other can more widely suppress remaining voids.

[0213] like Figure 3 and Figure 4 As shown, when the light shielding frame has a rectangular shape as a plan view (i.e., when the shape of the frame portion 5b is a rectangle when viewed from above), the narrow width portions 50 may be provided in pairs on the long sides thereof. For example, the narrow width portions 50 may be provided in pairs only on the long sides of the rectangle, without providing the narrow width portions 50 on the short sides (see FIG. Figure 3 and Figure 4 ). Here, the portion of the rectangular light-shielding frame corresponding to the long side is a portion that is particularly prone to residual voids. This is because the portion of the light-shielding frame corresponding to the long side is a portion where the light-transmitting member and the light-reflective resin are in contact with a longer surface when the light-transmitting member is configured, and when the light-reflective resin flows into the "space between the light-transmitting member and the opening of the light-shielding frame", the air in the space is difficult to escape to the outside. In this regard, the light-shielding frame used in the light-emitting device of the embodiment can be provided with a narrow width portion on the "long side" where the air is difficult to escape, which can more effectively suppress the generation of voids. In other words, when the narrow width portion is provided at the portion of the light-shielding frame corresponding to the long side, the effect of suppressing the generation of voids is more easily exhibited.

[0214] It should be noted that, when the light shielding frame 5 has a rectangular shape as its top view shape (that is, when the top view shape of the light shielding frame is formed by long sides and short sides), it is preferred that the first surface 3a of the light transmissive member 3 also has a rectangular shape as its top view shape. Figure 9 As shown, the translucent member 3 preferably has a flange portion 30 on the long side of the rectangular first surface 3a. On the other hand, the flange portion 30 may not be provided on the short side. In this case, when observed and confirmed from the upper surface 3a side of the translucent member 2, the frame portion 57 of the light-shielding frame 5 corresponding to the long side (hereinafter also referred to as the "long side frame portion") is arranged so as to overlap with the translucent member 3, but the frame portion 58 of the light-shielding frame 5 corresponding to the short side (hereinafter also referred to as the "short side frame portion") does not overlap with the translucent member 3. In this case, the voids generated between the long side frame portion 57 and the flange portion 30 can easily escape to the outside through the short side frame portion 58 of the light-shielding frame 5 during the light guide support member formation process.

[0215] Regarding the size of the narrow width portion, the width dimension w thereof may be half or more of the frame width dimension W of the light shielding frame as described above. On the other hand, the size l of the narrow width portion of the frame portion 5b in the extending direction (refer to Figure 4) As shown in the figure, for example, it can be larger than the width dimension w (hereinafter, this dimension l is also referred to as the "extension dimension"). That is, the extension dimension l of the narrow width portion in the direction perpendicular to the width dimension w when viewed from above can be larger than the width dimension w. When the extension dimension l of the narrow width portion is larger than the width dimension w, it is easy to more clearly show the local height difference of the light-reflective resin applied to the light-shielding frame. That is, when the extension dimension l of the narrow width portion is larger than the width dimension w, it is easy to further promote the effect of "suppressing the generation of voids when the light-guiding support member is formed due to the topmost part of the light-reflective resin located on the narrow width portion". For example, the extension dimension l of the narrow width portion can be more than 2 times, more than 3 times, more than 5 times, or more than 10 times the width dimension w. The extension dimension l of the narrow width portion can be, for example, less than 50 times or less than 40 times the width dimension w. It should be noted that the so-called "extension dimension l" in this specification refers to the dimension of the portion where each narrow width portion reaches the maximum value, when there are differences depending on the sampling point.

[0216] like Figure 4 As shown, the extension length L of the narrow portion 50 is less than the total length L of the straight portion of the frame portion 5b. Specifically, the narrow portion 50, when viewed from above, has an extension length L that is shorter than the extension length L of the frame portion 5b corresponding to one side of the quadrilateral formed by the light-shielding frame 5. While this is merely an example, the extension length L of the narrow portion can be, for example, less than 1 / 2, less than 1 / 3, less than 1 / 5, or less than 1 / 10 of the extension length L of the frame portion 5b. There is no particular lower limit; the extension length L of the narrow portion can be, for example, greater than 1 / 30, greater than 1 / 20, or greater than the extension length L of the frame portion 5b. This allows for a more optimal formation of a non-narrow portion in the frame portion 5b corresponding to one side of the quadrilateral, allowing for wet diffusion of the light-reflective resin. This further facilitates creating localized height differences in the light-reflective resin applied to the light-shielding frame. It should be noted that the "extension length L" referred to in this specification, while varying depending on the location, refers to the maximum dimension of the portion of the frame portion corresponding to one side.

[0217] In one embodiment, during the light-reflective resin coating step, the light-reflective resin coating includes at least a first coating and a second coating, with the first and second coatings overlapping at the narrow portion. This makes it easier and more reliable to position the topmost portion of the light-reflective resin above the narrow portion. For example, the starting point or end point of the first coating can overlap with the starting point or end point of the second coating at the narrow portion. By overlapping the light-reflective resin coatings at the narrow portion, the portion of the light-reflective resin located above the narrow portion can be relatively elevated.

[0218] Reference Figure 12A and 12BLet's take an example. When a first coating 71 is applied to the light-shielding frame 5 along the frame portion 5b, and a second coating 72 is also applied to the light-shielding frame 5 along the frame portion 5b, the light-reflective resin applied by the first coating 71 and the second coating 72 overlap in the narrow portion 50. It is preferable to apply the light-reflective resin so that the first coating 71 and the second coating 72 overlap only in the narrow portion 50 of the light-shielding frame 5, while avoiding overlap in the non-narrow portion 55 of the light-shielding frame 5. In this case, the overlapping of the applied light-reflective resin facilitates the formation of a higher layer of light-reflective resin in the narrow portion. This, combined with the "relatively narrow wetting and spreading" effect of the narrow portion, makes it easier to form the topmost layer of light-reflective resin in the narrow portion. Therefore, in the process of forming the light-guiding support member, the contact between the flange of the translucent member and the light-reflective resin is more likely to produce a time difference, and when the light-reflective resin fills the "space between the translucent member and the opening of the light-shielding frame", the air in the space is more likely to escape to the outside.

[0219] The same light-reflective resin can be used for the first and second coatings. In addition, the first and second coatings are preferably applied to one side of the light-shielding frame including the narrow portion. Figure 13A and 13B 、 Figure 14A and 14B Various combinations of the first coating 71 and the second coating 72 are exemplified. Figure 13A In the embodiment, the light reflective resin is applied so that the starting point 71' of the first coating 71 applied to the light shielding frame 5 along the frame portion 5b and the starting point 72' of the second coating 72 applied to the light shielding frame 5 along the frame portion 5b overlap each other at the narrow width portion 50. Figure 13B In the embodiment, the light reflective resin is applied so that the end point 71'' of the first coating 71 applied to the light shielding frame 5 along the frame portion 5b and the end point 72'' of the second coating 72 applied to the light shielding frame 5 along the frame portion 5b overlap each other at the narrow width portion 50. Figure 14A In the embodiment, the light reflective resin is applied so that the starting point 71' of the first coating 71 applied to the light shielding frame 5 along the frame portion 5b and the end point 72" of the second coating 72 applied to the light shielding frame 5 along the frame portion 5b overlap each other at the narrow width portion 50. Figure 14B In the process, the light reflective resin is applied so that the end point 71 ″ of the first coating 71 applied along the frame portion 5 b of the light shielding frame 5 and the starting point 72 ′ of the second coating 72 applied along the frame portion 5 b of the light shielding frame 5 overlap with each other in the narrow width portion 50.

[0220] The application of the light reflective resin is not limited to the first and second applications, and may include further applications. For example, in the light reflective resin application step, the application of the light reflective resin includes the first, second, and third applications, and the first, second, and third applications may overlap each other in the narrow width portion. Figure 15 As shown, the light reflective resin can be applied in a manner such that the starting point 71' of the first coating 71, a part of the second coating 72 and the end point 73" of the third coating 73 applied to the light shielding frame 5 along the frame portion 5b overlap at the narrow width portion 50. Even so, the number of overlapping coatings at the narrow width portion is greater than that at the non-narrow width portion, so it is easy to form the top of the light reflective resin at the narrow width portion. It should be noted that the first coating 71, the second coating 72 and the third coating 73 can be performed as a continuous coating process in a so-called "one-stroke" manner. That is, the coating can be performed in a manner such that the light reflective resin is continuously and integrally formed on the light shielding frame. This is because it can be further improved. High process efficiency. It should be noted that, in this case, the light-reflective resin coating process also includes a first coating pass, a second coating pass, and a third coating pass. Specifically, in the light-reflective resin coating process, the light-reflective resin coating includes a first coating pass, a second coating pass in which the nozzle advances in a different direction than the first coating pass, and a third coating pass in which the nozzle advances in a different direction than the second coating pass. Each coating process is continuous, and the light-reflective resin is continuously discharged from the resin discharge device during each coating process. In the resin discharge device, the amount of resin discharged tends to increase at the start and end points of coating. However, by not arranging the start and end points on non-narrow width portions, the height of the light-reflective resin in non-narrow width portions can be easily suppressed.

[0221] Finally, the method for forming the narrow width portion will be described. In an embodiment of the present invention, the narrow width portion of the light-shielding frame 5 can be made by any method. For example, the "narrow width portion" of the light-shielding frame 5 can be formed by etching. In this case, a light-shielding frame having a constant width dimension of the frame portion 5b can be obtained by a conventional method, and then the light-shielding frame is subjected to an etching process to form the narrow width portion 50 in the frame portion 5b. It should be noted that the narrow width portion can be formed by mechanical processing methods such as pressing. That is, by cutting off the area corresponding to the "recessed portion" from the light-shielding frame having a constant width dimension of the frame portion 5b, a narrow width portion can be formed on the frame portion 5b. In addition, the above-mentioned processing method can be used to simultaneously form the opening portion 5a and the narrow width portion from a plate-shaped light-shielding member.

[0222] In particular, when the narrow width portion is formed by etching, the concave portion in the narrow width portion may have a profile that gradually narrows toward the inside of the frame portion when viewed from above. Figure 3 or Figure 4As shown, when the narrow portion is formed by recessing the outer contour of the light-shielding frame 5, the recessed portion can have a profile that gradually narrows from the outside of the light-shielding frame 5 toward the opening 5a. In other words, when viewed from above, the narrow portion can have a tapered outer contour. Furthermore, when the narrow portion is formed through etching, the corners of the narrow portion's contour are likely to be curved, forming an arc (R).

[0223] While the embodiments of the present invention have been described above, these are merely typical examples, and the present invention is not limited thereto, and it is readily apparent to those skilled in the art that various embodiments are conceivable.

[0224] For example, while the light-reflective resin coating process has been described above, the present invention does not necessarily require coating all sides of the light-shielding frame with light-reflective resin. For example, if the light-shielding frame has a rectangular top-view shape (i.e., if the frame portion 5b is rectangular when viewed from above), light-reflective resin may be applied only to the frame portion 5b corresponding to its long sides. In this case, when the light-reflective resin is applied to the light-shielding frame and / or when the flange of the light-transmitting member presses the light-reflective resin on the light-shielding frame, causing it to flow into the space between the light-transmitting member and the opening of the light-shielding frame, the light-reflective resin on the "long sides" flows toward the "short sides" in a circumferential manner. In other words, the light-reflective resin on the long sides of the frame flows toward the "short sides" in a circumferential manner, filling the space between the light-transmitting member and the opening of the light-shielding frame. In this method, narrowed portions may be provided only in the portions of the light-shielding frame corresponding to the "long sides."

Claims

1. A method for manufacturing a light-emitting device, the method comprising: A mounting process, mounting the light emitting element on the substrate; a light shielding frame placement step of placing a light shielding frame having an opening on the sheet; a light-reflective resin coating step of coating the light-shielding frame with a light-reflective resin; a light guide support member forming step of bringing a plate-shaped light-transmitting member into contact with the applied light-reflective resin at a position where a space is formed between the light-transmitting member and the opening, with a first surface of the light-transmitting member facing the sheet, and then pressing the plate to allow the light-reflective resin to flow into the space to form a first light-reflective member, and manufacturing a light guide support member in which the light-shielding frame and the light-transmitting member are supported by the first light-reflective member, the light-transmitting member having a first surface and a second surface opposite to the first surface, the outer periphery of the first surface being smaller than the inner periphery of the opening, and the second surface being larger than the first surface; and a light guide supporting member bonding step of bonding the upper surface of the mounted light emitting element to the second surface to fix the light guide supporting member to the light emitting element; in, The light shielding frame has a narrow portion whose width is partially narrowed in a plan view, and in the light reflective resin coating step, the light reflective resin is disposed at least on the narrow portion.

2. The method for manufacturing a light emitting device according to claim 1, wherein: In the narrow width portion, the outer contour of the light shielding frame is recessed.

3. The method for manufacturing a light-emitting device according to claim 1 or 2, wherein: In the light-reflective resin coating step, the topmost portion of the light-reflective resin is positioned on the narrow portion.

4. The method for manufacturing a light emitting device according to claim 3, wherein: In the light guide supporting member forming step, the light reflective resin and the light transmissive member come into contact with each other with a time difference depending on the height of the light reflective resin.

5. The method for manufacturing a light-emitting device according to claim 1 or 2, wherein: The narrow width portions are provided at positions facing each other in the light shielding frame.

6. The method for manufacturing a light-emitting device according to claim 1 or 2, wherein: The narrow portion is provided at the center of the extended length of the light shielding frame when viewed from above.

7. The method for manufacturing a light-emitting device according to claim 1 or 2, wherein: In the light-reflective resin coating step, the coating of the light-reflective resin includes at least a first coating and a second coating, and the first coating and the second coating overlap each other in the narrow width portion.

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