Light source, light source device, and method for manufacturing light source

Abstract

The present invention provides a light source, a light source device and a method for manufacturing a light source having excellent luminous properties during partial illumination. The light source comprises a plurality of light emitting units (51) arranged in one dimension or two dimensions and a light shielding component (60), each light emitting unit comprises a light emitting element (20) having an exit surface, a wavelength conversion component (30) arranged on the exit surface, and a light transmissive component (40) arranged on the upper surface of the wavelength conversion component, the wavelength conversion component being larger than the exit surface of the light emitting element when viewed from above, the light shielding component covering the side surface of the light emitting element and the side surface of the wavelength conversion component of each light emitting unit, and being continuously arranged between the plurality of light emitting units, the light transmissive component comprising a first region located above the light emitting element and a second region located outside the first region and having a thickness less than the first region, and at least a portion of the side surface of the light transmissive component of each light emitting unit is exposed from the light shielding component.

Description

Technical Field

[0001] The invention relates to a light source, a light source device and a method for manufacturing a light source. Background Art

[0002] Light sources with multiple light-emitting elements arranged in an array are used in various fields. Such light sources can perform partial illumination with a variable illumination area by driving any part of the multiple light-emitting elements. If such characteristics are utilized, lamps with functions that were not previously available can be realized. For example, Patent Document 1 discloses a light source that can be used for a variable light distribution headlamp for a vehicle.

[0003] Patent Document 1: (Japanese) Patent Publication No. 2016-219637 Summary of the invention

[0004] The present invention provides a light source, a light source device and a method for manufacturing a light source having excellent light emission characteristics during partial irradiation.

[0005] A light source in one embodiment of the present invention has a plurality of light-emitting units and shading components arranged in one dimension or two dimensions, each light-emitting unit having: a light-emitting element having an exit surface; a wavelength conversion component arranged on the exit surface; and a light-transmitting component arranged on the upper surface of the wavelength conversion component. When observed from above, the wavelength conversion component is larger than the exit surface of the light-emitting element. The shading component covers the side surfaces of the light-emitting element and the side surfaces of the wavelength conversion component of each light-emitting unit, and is continuously arranged between the plurality of light-emitting units. The light-transmitting component includes a first region located above the light-emitting element and a second region located outside the first region and having a thickness less than that of the first region. At least a portion of the side surfaces of the light-transmitting component of each light-emitting unit is exposed from the shading component.

[0006] A light source device according to one embodiment of the present invention includes the light source and a lens placed at a predetermined distance from the light source. A method for manufacturing a light source according to one embodiment of the present invention has the following steps: on the wavelength conversion layer of a laminate including a light-transmitting layer and a wavelength conversion layer, a plurality of light-emitting elements having an emission surface and an electrode surface located on the opposite side of the emission surface are arranged one-dimensionally or two-dimensionally in such a manner that the emission surface is opposite to the wavelength conversion layer, and the plurality of light-emitting elements are bonded to the wavelength conversion layer; between the plurality of light-emitting elements, a wavelength conversion component and a light-transmitting component are arranged on the plurality of light-emitting elements respectively by forming a first groove that divides the laminate from the wavelength conversion layer side; between the plurality of light-emitting elements, a light-shielding component is arranged, the light-shielding component covers the side surfaces of the plurality of wavelength conversion components, the side surfaces of the plurality of light-transmitting components, and the side surfaces of the plurality of light-emitting elements; on the surface of the light-transmitting component on the opposite side of the wavelength conversion component, at least a part of the light-shielding component located between the plurality of light-transmitting components is removed, and a second groove is formed that exposes a part of the plurality of light-transmitting components from the light-shielding component.

[0007] A method for manufacturing a light source according to another embodiment of the present invention comprises the following steps: on the wavelength conversion layer of a laminate including a light-transmitting layer and a wavelength conversion layer, a plurality of light-emitting elements having an emission surface and an electrode surface located on the opposite side of the emission surface are arranged one-dimensionally or two-dimensionally in a manner in which the emission surface is opposite to the wavelength conversion layer, and the plurality of light-emitting elements are bonded to the wavelength conversion layer; between the plurality of light-emitting elements, wavelength conversion components are respectively arranged on the plurality of light-emitting elements by dividing the wavelength conversion layer from the wavelength conversion layer side to form a first groove reaching the light-transmitting layer; between the plurality of light-emitting elements, a shading component is arranged, the shading component covers the side surfaces of the plurality of wavelength conversion components, the portion of the light-transmitting layer exposed in the first groove, and the side surfaces of the plurality of light-emitting elements; between the plurality of light-emitting elements, a second groove reaching the shading component is formed by removing a portion of the light-transmitting layer from the light-transmitting layer side, thereby forming a plurality of light-transmitting components respectively located on the plurality of wavelength conversion components.

[0008] According to one embodiment of the present invention, a light source, a light source device, and a method for manufacturing a light source having excellent light emission characteristics during partial irradiation are provided. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 It is a schematic perspective view of the light source 101 according to the first embodiment.

[0010] Figure 2A yes Figure 1 Schematic top view of the light source shown.

[0011] Figure 2B yes Figure 2A A schematic cross-sectional view of a light source along line 2B-2B is shown.

[0012] Figure 2C is a schematic cross-sectional view of a light emitting unit.

[0013] Figure 2D is a schematic top view of a light emitting unit.

[0014] Figure 3 1 is a flowchart showing the method for manufacturing the light source according to the first embodiment.

[0015] Figure 4A The diagram is a cross-sectional view showing the steps of the method for manufacturing the light source according to the first embodiment.

[0016] Figure 4B The diagram is a cross-sectional view showing the steps of the method for manufacturing the light source according to the first embodiment.

[0017] Figure 4C The diagram is a cross-sectional view showing the steps of the method for manufacturing the light source according to the first embodiment.

[0018] Figure 4D The diagram is a cross-sectional view showing the steps of the method for manufacturing the light source according to the first embodiment.

[0019] Figure 4E The diagram is a cross-sectional view showing the steps of the method for manufacturing the light source according to the first embodiment.

[0020] Figure 4F The diagram is a cross-sectional view showing the steps of the method for manufacturing the light source according to the first embodiment.

[0021] Figure 4G The diagram is a cross-sectional view showing the steps of the method for manufacturing the light source according to the first embodiment.

[0022] Figure 5A It is a schematic cross-sectional view of the front end portion of a tool for forming the first groove or the second groove.

[0023] Figure 5B It is a schematic cross-sectional view of the front end portion of a tool for forming the first groove or the second groove.

[0024] Figure 5C It is a schematic cross-sectional view of the front end portion of a tool for forming the first groove or the second groove.

[0025] Fig. 6A It is a schematic cross-sectional view showing another form of the light emitting unit.

[0026] Figure 6B It is a schematic cross-sectional view showing another form of the light emitting unit.

[0027] Fig. 7A It is a schematic cross-sectional view showing another form of the light source.

[0028] Figure 7B yes Fig. 7A A schematic cross-sectional view of a light emitting unit in the light source shown.

[0029] Figure 7C It is a schematic cross-sectional view showing another form of the light emitting unit.

[0030] Fig. 8A It is a schematic cross-sectional view showing a light source according to a second embodiment.

[0031] Figure 8B It is a schematic cross-sectional view of a light emitting unit according to a second embodiment.

[0032] Fig.9A It is a cross-sectional view showing the steps of the method for manufacturing the light source according to the second embodiment.

[0033] Fig. 9B It is a cross-sectional view showing the steps of the method for manufacturing the light source according to the second embodiment.

[0034] Fig. 10A It is a schematic cross-sectional view showing another form of the light emitting unit.

[0035] Fig. 10B It is a schematic cross-sectional view showing another form of the light emitting unit.

[0036] Fig. 10C It is a schematic cross-sectional view showing another form of the light emitting unit.

[0037] Fig.11 It is a schematic top view of a light source according to a third embodiment.

[0038] Fig. 12A It is a schematic plan view of a light source device according to a fourth embodiment.

[0039] Fig. 12B yes Fig. 12A A schematic cross-sectional view of the light source device along line 12B-12B is shown.

[0040] Fig.13A It is a simulation result which shows the brightness distribution of the light source of the experimental example.

[0041] Fig. 13B 3 is a simulation result showing the brightness distribution of the light source of the comparative example.

[0042] Description of Reference Numerals

[0043] 20: Light-emitting element

[0044] 20a: Exit surface

[0045] 20b: Electrode surface

[0046] 20c: Side

[0047] 21: Electrode

[0048] 30: Wavelength conversion components

[0049] 30a: Upper surface

[0050] 30b: Lower surface

[0051] 30c: Side

[0052] 40, 42, 43, 44, 45: Translucent parts

[0053] 40a, 44a, 45a: upper surface

[0054] 40b, 44b, 45b: Lower surface

[0055] 40c, 45c: Side

[0056] 40c1, 41c1, 42c1, 43c1, 44c1: first side

[0057] 40c2, 44c2: Second side

[0058] 40d: middle surface

[0059] 40r: concave part

[0060] 51, 52, 54, 55, 56, 57: Light-emitting units

[0061] 56A: First light emitting unit

[0062] 56B: Second light emitting unit

[0063] 56C: The third light-emitting unit

[0064] 56D: Fourth light-emitting unit

[0065] 60: Light shielding parts

[0066] 101~106: Light source

[0067] 101a: Luminous surface

[0068] 120: Support body

[0069] 130: Wavelength conversion layer

[0070] 140: light-transmitting layer

[0071] 150: Laminated body

[0072] 161, 171: First slot

[0073] 162, 172: Second slot

[0074] 201: Light source device

[0075] 202: Lens

[0076] 203: Light Source

[0077] 203a: Luminous surface

[0078] 204: Support body

[0079] 205: Substrate DETAILED DESCRIPTION

[0080] The embodiments of the present invention are described in detail with reference to the accompanying drawings. The following embodiments are exemplary, and the light source and the method for manufacturing the light source of the present invention are not limited to the following embodiments. For example, the numerical values, shapes, materials, processes, the order of the processes, etc. shown in the following embodiments are only examples, and various changes can be made as long as there is no technical contradiction. The various embodiments described below are only examples, and various combinations can be made as long as there is no technical contradiction.

[0081] The dimensions and shapes of the components shown in the drawings are sometimes exaggerated for ease of understanding, and sometimes do not reflect the dimensions, shapes, and size relationships between the components in the actual light source. In addition, in order to avoid making the drawings too complicated, some elements are sometimes omitted from the drawings, or an end view showing only the cut surface is used as a sectional view.

[0082] In the following description, constituent elements having substantially the same function are indicated by common reference marks, and description is omitted. In addition, terms indicating a specific direction or position may be used (for example, other terms including "upper", "lower", "right", "left" and their terms). However, these terms are used only for ease of understanding of the relative direction or position in the reference figure. If the relative direction or positional relationship of the terms "upper", "lower" and the like in the referenced drawings is the same, then in the drawings, actual products, manufacturing devices, etc. outside the present invention, it is also possible not to have the same configuration as the referenced drawings. In the present invention, "parallel" includes the situation where two straight lines, edges, faces, etc. are within the range of 0° to ±5° as long as it is not specifically mentioned. In addition, in this description, "vertical" or "orthogonal" includes the situation where two straight lines, edges, faces, etc. are within the range of 90° to ±5° as long as it is not specifically mentioned. In addition, the positional relationship represented as "upper" also includes the situation where they are connected and the situation where they are not connected but are located above.

[0083] In the accompanying drawings shown below, arrow marks representing mutually orthogonal x-axis, y-axis and z-axis are shown. The x-direction along the x-axis represents a specified direction in the configuration plane of the light-emitting unit equipped with the light source of the embodiment (in other words, in the arrangement plane where the light-emitting units are arranged), the y-direction along the y-axis represents a direction orthogonal to the x-direction in the configuration plane of the light-emitting unit, and the z-direction along the z-axis represents a direction orthogonal to the configuration plane. In addition, the direction in which the arrow mark on the x-direction points is set to the +x direction, and the opposite direction of the +x direction is set to the -x direction, the direction in which the arrow mark on the y-direction points is set to the +y direction, and the opposite direction of the +y direction is set to the -y direction, the direction in which the arrow mark on the z-direction points is set to the +z direction, and the opposite direction of the +z direction is set to the -z direction. In the embodiment, the light source irradiates light in the +z direction as an example. However, this does not limit the direction of the light source and the light source device when in use, and the direction of the light source and the light source device is arbitrary.

[0084] <First Embodiment>

[0085] (Structure of Light Source 101)

[0086] Figure 1 is a schematic perspective view of the light source 101 of the first embodiment, Figure 2A is a schematic top view of the light source 101, Figure 2B yes Figure 2A The schematic cross-sectional view of the light source 101 taken along the line 2B-2B is shown. The light source 101 includes a plurality of light emitting units 51 and a light shielding member 60 .

[0087] The plurality of light emitting units 51 are arranged one-dimensionally or two-dimensionally. Figure 2A As shown, the light source 101 is arranged two-dimensionally in the x-direction and the y-direction. In the present embodiment, the light source 101 includes 63 light-emitting units 51, which are arranged in 7 rows and 9 columns in the x-direction and the y-direction. However, the number of light-emitting units 51 included in the light source 101 is arbitrary and may be another number. The number of light-emitting units 51 is, for example, about 9 to 400, and the plurality of light-emitting units 51 are, for example, arranged in 3 rows and 3 columns to 20 rows and 20 columns.

[0088] For example, one light emitting unit 51 has a square or rectangular shape with a side of 100 μm to 500 μm, preferably a side of 200 μm to 400 μm, when viewed from above, i.e., in the xy plane. For example, the light source 101 has a square or rectangular shape with a side of 1 mm to 5 mm, preferably a side of 2 mm to 3 mm, in the xy plane. The thickness of the light source 101 is, for example, about 100 μm to 1 mm. The size and number of the light emitting units 51 and the size of the light source 101 are determined according to the application. For example, the light source 101 can be used as a flash for photography or lighting for video recording of portable devices such as smartphones.

[0089] Figure 2C is a schematic cross-sectional view of the light emitting unit 51 . Figure 2D : is a schematic top view of the light-emitting unit 51. Each light-emitting unit 51 includes a light-emitting element 20 having an exit surface 20a, a wavelength conversion component 30 arranged on the exit surface 20a, and a translucent component 40 arranged on the upper surface 30a of the wavelength conversion component 30. In the present embodiment, the sizes of the exit surfaces 20a of the plurality of light-emitting elements 20 are equal to each other. The shading component 60 covers the side surfaces 20c of the light-emitting element 20 and the side surfaces 30c of the wavelength conversion component 30, and is continuously arranged between the plurality of light-emitting units 51. In addition, at least a portion of the side surface of the translucent component of each light-emitting unit is exposed from the shading component 60. Below, the structure of the light-emitting unit 51 is described in more detail by dividing into each component.

[0090] [Light emitting element 20]

[0091] The light emitting element 20 comprises an emission surface 20a, an electrode surface 20b and a side surface 20c. The positive and negative electrodes 21 are located on the electrode surface 20b.

[0092] The light emitting element 20 is a semiconductor light emitting element such as a laser diode (LD) or a light emitting diode (LED). The light emitting element 20 is typically an LED. The light emitting element 20 includes, for example, a supporting substrate such as sapphire or gallium nitride and a semiconductor laminate on the supporting substrate. The semiconductor laminate includes an n-type semiconductor layer and a p-type semiconductor layer, an active layer sandwiched therebetween, and a p-side electrode and an n-side electrode electrically connected to the n-type semiconductor layer and the p-type semiconductor layer. The semiconductor laminate may include a nitride semiconductor (Indium nitride) that can emit light in the ultraviolet to visible region. x Al y Ga 1-x-y N, 0≤x, 0≤y, x+y≤1). The positive and negative electrodes 21 are electrically connected to the p-side electrode and the n-side electrode.

[0093] The light emitting element 20 may be a light emitting element that emits blue light or a light emitting element that emits a color other than blue light, such as red light, green light, or ultraviolet light. In this embodiment, as the light emitting element 20 of each light emitting unit 51, an LED that emits blue light is exemplified.

[0094] The light emitting surface 20a, which is the shape of the light emitting element 20 in plan view, is typically rectangular. The length of one side of the rectangular shape of the light emitting surface 20a is preferably smaller than the length of one side of the light emitting unit 51 in plan view. For example, the length of one side of the rectangular shape of the light emitting element 20 is 50 μm to 300 μm.

[0095] [Wavelength conversion member 30]

[0096] The wavelength conversion member 30 is disposed on the emission surface 20a of the light emitting element 20. The wavelength conversion member 30 absorbs a part of the light emitted from the emission surface 20a of the light emitting element 20, and emits light having a longer wavelength than the absorbed light.

[0097] In a plan view, the wavelength conversion member 30 is preferably larger than the emission surface 20a of the light emitting element 20. Thus, wavelength-converted light (e.g., white light) can be emitted from an area larger than the emission surface 20a of the light emitting element 20. Therefore, even if the arrangement interval of the light emitting element 20 in the light source 101 cannot be sufficiently reduced, when a plurality of light emitting units 51 are lit, it is possible to suppress the generation of low-brightness areas between the light emitting units 51.

[0098] The wavelength conversion member 30 includes, for example, a light-transmitting resin and a phosphor. As the phosphor, a yttrium aluminum garnet type phosphor (for example, Y3(Al, Ga)5O 12 : Ce), aluminum garnet phosphors (such as Lu3(Al, Ga)5O 12 : Ce), aluminum garnet phosphors (e.g., Tb3(Al, Ga)5O 12 :Ce), β phosphor (e.g. (Si,Al)3(O,N)4:Eu), α phosphor (e.g. M z (Si, Al) 12 (O, N) 16 (wherein, 0<z≤2, M is a lanthanide element other than Li, Mg, Ca, Y, La and Ce, a nitride phosphor such as a CASN phosphor (e.g., CaAlSiN3:Eu) or a SCASN phosphor (e.g., (Sr, Ca)AlSiN3:Eu), a fluoride phosphor such as a KSF phosphor (e.g., K2SiF6:Mn) or a MGF phosphor (e.g., 3.5MgO·0.5MgF2·GeO2:Mn), a perovskite, a chalcogenide or a quantum dot phosphor, etc.

[0099] As the light-transmitting resin, silicone resin, modified silicone resin, epoxy resin, modified epoxy resin, acrylic resin, fluororesin, etc. A mixture of these resins may also be used.

[0100] The wavelength conversion member 30 may include a plurality of phosphors, for example, a phosphor that absorbs blue light and emits yellow light and a phosphor that absorbs blue light and emits red light. Thus, the light emitting unit 51 can emit desired white light.

[0101] The wavelength conversion member 30 may also include a light diffusion material without blocking light. The content of the light diffusion material included in the wavelength conversion member 30 can be adjusted so that the transmittance of the wavelength conversion member 30 to the light emitted from the light emitting element 20 and / or the wavelength-converted light can be adjusted to be 50% or more and 99% or less, preferably 70% or more and 90% or less. As the light diffusion material, for example, titanium oxide, silicon oxide, aluminum oxide, zinc oxide, or glass can be used.

[0102] Glass containing a fluorescent substance may be used for the wavelength conversion member 30. In addition, the wavelength conversion member may be a sintered body containing only a fluorescent substance, or a sintered body containing a fluorescent substance and the above-mentioned light diffusion material.

[0103] [Light-transmitting member 40]

[0104] The light-transmitting member 40 is disposed on the upper surface 30a of the wavelength conversion member 30 to cover the upper surface 30a. The light-transmitting member 40 constitutes the light-emitting surface of the light-emitting unit 51. The light-transmitting member 40 can suppress uneven brightness of light emitted from the wavelength conversion member 30.

[0105] The light-transmitting component 40 has an upper surface 40a and a lower surface 40b on the opposite side of the upper surface 40a. In addition, the light-transmitting component 40 includes a first region R1 located above the light-emitting element 20 in a plan view from the upper surface 40a side and a second region R2 located outside the first region R1. In the present embodiment, the area of ​​the first region R1 is larger than the area of ​​the emission surface 20a of the light-emitting element 20, but the area of ​​the first region R1 may be the same as the area of ​​the emission surface 20a. Figure 2D In the figure, for ease of understanding, the first region R1 is not shaded, and the second region R2 and the light shielding member 60 are shaded in the same manner as the cross section shown in FIG. 2c. Figure 2D As shown, the second region R2 surrounds the first region R1.

[0106] In the light-transmitting member 40, the thickness of the first region R1 is greater than the thickness of the second region. In other words, the thickness t2 of the second region R2 is less than the thickness t1 of the first region R1. In this embodiment, a recess 40r (a second groove 162 described later) is provided around the light-transmitting member 40 on the upper surface of the light source 101, thereby forming the second region R on the light-transmitting member 40. By providing the recess 40r, the area of ​​the upper surface 40a is smaller than the area of ​​the lower surface 40b.

[0107] The light-transmitting component 40 has a side surface located between the upper surface 40a and the lower surface 40b. The side surface includes a first side surface 40c1 and a second side surface 40c2 arranged along the height direction of the light-transmitting component 40. The first side surface 40c1 and the second side surface 40c2 are respectively defined by a recess 40r. In addition, the light-transmitting component 40 may also have an intermediate surface 40d located between the first side surface 40c1 and the second side surface 40c2 and substantially parallel to the upper surface 40a and the lower surface 40b.

[0108] The first side surface 40c1 is a side surface of the recessed portion 40r and is adjacent to the upper surface 40a. The second side surface 40c2 is adjacent to the lower surface 40b. The intermediate surface 40d is the bottom surface of the recessed portion 40r. As described later, the first side surface 40c1 is exposed from the light shielding member 60, and the second side surface 40c2 is covered by the light shielding member 60. That is, by providing the recessed portion 40r, at least a portion of the side surface of the light-transmitting member 40 is exposed from the light shielding member 60.

[0109] The light-transmitting member 40 can be formed of the same resin as the light-transmitting resin used in the wavelength conversion member 30. Alternatively, the light-transmitting member 40 can be formed of glass, light-transmitting ceramics, or the like.

[0110] The light-transmitting member 40 preferably includes a light diffusing material. As the light diffusing material, the same material as the light diffusing material that can be added to the wavelength conversion member 30 can be used.

[0111] [Light shielding member 60]

[0112] The light shielding member 60 covers the side surface 20c of the light emitting element 20 of each light emitting unit 51 and the side surface 30c of the wavelength conversion member 30 and is continuously arranged between the plurality of light emitting units 51. The light shielding member 60 has a light shielding property or a light reflecting property. The light shielding member 60 suppresses light emitted from the side surface 20c of the light emitting element 20 of each light emitting unit 51 and the side surface 30c of the wavelength conversion member 30 from entering the adjacent light emitting unit 51 by covering at least these side surfaces.

[0113] In this embodiment, the light shielding member 60 extends from the side surface of the light emitting element 20 and also covers the electrode surface 20b of the light emitting element 20. In addition, at this time, the surface of the electrode 21 of the electrode surface 20b is exposed from the light shielding member 60. In addition, since the wavelength conversion member 30 is larger than the emission surface 20a of the light emitting element 20, the region of the lower surface 30b of the wavelength conversion member 30 that is not in contact with the emission surface 20a is covered by the light shielding member 60. The light shielding member 60 also covers the second side surface 40c2 of the light-transmitting member 40.

[0114] The reflectivity of the light shielding member 60 is preferably, for example, 20% to 95%, and more preferably 50% to 95%. The light shielding member 60 includes, for example, a light diffusing material and a resin material. The resin material and the light diffusing material can use the same materials as the light-transmitting resin and the light diffusing material used for the wavelength conversion member 30. In addition, the light shielding member may include a light absorbing material such as carbon black in addition to the light diffusing material.

[0115] [Operation of Light Source 101]

[0116] In the light source 101, the light emitted from the emission surface 20a of the light emitting element 20 is radiated to the outside through the wavelength conversion member 30 and the light-transmitting member 40. At this time, the wavelength of at least a part of the light from the light emitting element 20 is converted by the wavelength conversion member 30. The light emitted to the outside includes the light emitted from the light emitting element 20 and the light after the wavelength conversion. For example, when blue light is emitted from the light emitting element 20 and the wavelength conversion member 30 contains at least a yellow phosphor, the light source 101 emits white light by mixing the blue light and the yellow light.

[0117] The light source 101 has the above-mentioned structure, and has excellent luminous characteristics during partial illumination. Specifically, first, in a plan view, the wavelength conversion component 30 is larger than the emission surface 20a of the light emitting element 20, so that white light can be emitted from an area larger than the emission surface 20a of the light emitting element 20. Therefore, even if the arrangement interval of the light emitting element 20 cannot be sufficiently small, when a plurality of light emitting units 51 are lit, it is possible to suppress the generation of low brightness areas between the light emitting units 51.

[0118] In addition, in adjacent light emitting units 51, the distance between the wavelength conversion members 30 is smaller than the distance between the light emitting elements 20. In contrast, in the light source 101, the light shielding member 60 is disposed between the side surfaces of the light emitting elements 20 facing each other in the adjacent light emitting units 51 and between the side surfaces 30c of the wavelength conversion members 30. Therefore, it is possible to suppress the light incident from the light emitting elements 20 of each light emitting unit 51 from entering the wavelength conversion member 30 of the adjacent light emitting unit 51 and the light from propagating between the adjacent wavelength conversion members 30. Therefore, it is possible to suppress the light leakage at the boundary between the light emitting unit 51 that is lit and the light emitting unit 51 that is not lit.

[0119] The light-transmitting component 40 includes a first region R1 located on the light-emitting element 20 and a second region located outside the first region R1. In the light-transmitting component 40, the thickness of the second region R2 located around the first region r1 and having lower brightness is reduced relative to the first region R1 directly above the light-emitting element 20 having higher brightness. Therefore, by including a light-diffusing material in the light-transmitting component 40, absorption and diffusion in the light-transmitting component 40 can be suppressed, and the uniformity of the brightness of the light emitted from the light-transmitting component 40 can be improved.

[0120] In addition, the light-transmitting member 40 has a first side surface 40c1 that is not covered by the light-shielding member 60. That is, between the light-emitting units 51 adjacent to the light source 101, the first side surface 40c1 of the light-transmitting member 40 is disposed opposite to each other without sandwiching the light-shielding member 60. Therefore, in the light-transmitting member 40, light is emitted laterally from the first side surface 40c1, and a decrease in brightness between adjacent light-emitting units 51 can be suppressed. Thus, when the adjacent light-emitting units 51 are lit, generation of dark lines between the light-emitting units 51 can be suppressed.

[0121] (Method of Manufacturing Light Source 101)

[0122] An embodiment of a method for manufacturing the light source 101 will be described. Figure 3 is a flowchart showing an example of a method for manufacturing the light source 101. Figure 4A to Figure 4G yes Figure 3 The manufacturing method of the light source 101 of the present embodiment at least includes a step of bonding a light emitting element (S1), a step of forming a first groove (S2), a step of arranging a light shielding member (S3), and a step of forming a second groove (S4).

[0123] [Step of bonding a light emitting element (S1)]

[0124] like Figure 4A As shown, a light-transmitting layer 140 as a collection of light-transmitting components and a wavelength conversion layer 130 as a collection of wavelength conversion components are bonded together using an adhesive or an adhesive sheet to obtain a laminate 150. The light-transmitting layer 140 and the wavelength conversion layer 130 may have a size corresponding to one light source 101 or a size capable of forming a plurality of light sources 101. The light-transmitting layer 140 of the laminate 150 is temporarily fixed to the support 120.

[0125] like Figure 4B As shown, a plurality of light emitting elements 20 are bonded to the laminate 150. The light emitting elements 20 are arranged so that the emission surface 20a of the light emitting element 20 faces the wavelength conversion layer 130, and the plurality of light emitting elements 20 are bonded to the wavelength conversion layer 130. The bonding can be performed by pre-arranging a light-transmitting bonding member such as an adhesive or an adhesive sheet on the surface of the wavelength conversion layer 130 or the emission surface 20a of the light emitting element 20. The plurality of light emitting elements 20 are arranged one-dimensionally or two-dimensionally at the pitch of the light emitting unit 51 in the light source 101.

[0126] Alternatively, the light-transmitting layer 140 and the wavelength conversion layer 130 , and the wavelength conversion layer 130 and the light-emitting element 20 may be directly bonded using the adhesiveness of the light-transmitting layer 140 and the wavelength conversion layer 130 without using a bonding member.

[0127] [Step of forming the first groove (S2)]

[0128] like Figure 4C As shown in FIG. 1 , first grooves 161 are formed between the plurality of light emitting elements 20 to separate the laminate 150. Figure 4B As shown, a cutter such as a dicing saw is pressed against the position indicated by the arrow mark of the laminate 150, and a first groove 4C having a width w1 is formed on the laminate 150 from the wavelength conversion layer 130 side between each light emitting element 20. Thus, the wavelength conversion member 30 and the light-transmitting member 40 are arranged on each light emitting element 20. In addition, on the side of the first groove 161, the side surface 30c of the wavelength conversion member 30 and the side surface 40c of the light-transmitting member 40 are exposed.

[0129] In this step, the first groove 161 may not completely divide the laminate 150. It is sufficient as long as at least the wavelength conversion layer 130 is completely divided to reach the light-transmitting layer 140. The light-transmitting layer 140 may be partially removed by the first groove 161, or may not be removed at all.

[0130] [Step of arranging light shielding member (S3)]

[0131] like Figure 4D As shown, a light shielding member 60 is arranged between the plurality of light emitting elements 20. Specifically, the light shielding member 60 is arranged to cover the side surfaces 30c of the plurality of wavelength conversion members 30 and the side surfaces 40c of the plurality of light-transmitting members 40 and the side surfaces 20c of the plurality of light emitting elements 20 exposed on the side surfaces of the first groove 161. In the present embodiment, the light shielding member 60 is arranged to cover the electrode surfaces 20b of the plurality of light emitting elements 20 and the electrodes 21 of the electrode surfaces. The light shielding member 60 can be formed, for example, by transfer molding, potting, printing, spraying, or the like.

[0132] like Figure 4E As shown in FIG. 1 , a portion of the light shielding member 60 is ground or polished from the upper surface 60 b to expose the surface of the electrode 21 of each light emitting element 20 .

[0133] [Step of forming the second groove (S4)]

[0134] like Figure 4F As shown in FIG. 1 , the support 120 is removed from the light-transmitting member 40 to expose the upper surface 40a of the light-transmitting member 40 which is the surface on the opposite side of the wavelength conversion member 30. Figure 4G As shown, the outer edge of the light shielding member 60 between the plurality of light-transmitting members 40 is removed from the upper surface 40a side to form a second groove 162 that exposes a portion of the plurality of light-transmitting members from the light shielding member 60. The second groove 162 can be formed using a cutter such as a dicing saw.

[0135] In the present embodiment, the second groove 162 has a width w2 wider than the width w1 of the first groove 161, and therefore, the second groove 162 also removes the outer edge portion of the light-transmitting member 40 that is opposed via the light-shielding member 60. The second groove 162 does not reach the wavelength conversion member 30, and has a depth that is half the thickness of the light-transmitting member 40. In the step of forming the first groove 161, when the first groove 161 does not completely divide the laminate 150, the second groove 162 is formed to a depth that reaches the first groove 161.

[0136] The cross-sectional shape of the second groove 162 reflects the cross-sectional shape of the front end portion of the tool used to form the second groove 162. Figure 5A As shown, since the cross section of the front end of the tool has a rectangular shape, a first side surface 40c1 perpendicular to the upper surface 40a is formed. By forming the second groove 162, the first side surface 40c1 exposed from the light shielding component 60 and the second side surface 40c2 covered by the light shielding component 60 are formed on the light-transmitting component 40.

[0137] Thus, the light source 101 is completed. When the light-transmitting layer 140 and the wavelength conversion layer 130 have sizes corresponding to the plurality of light sources 101, the plurality of light sources 101 are connected via the light-shielding member 60. Therefore, at the junction between the light sources 101, the light-shielding member 60 is cut off, and the plurality of light sources 101 are separated, and the light source 101 is completed.

[0138] [Other methods]

[0139] The light source of the present invention can be modified in various ways. As described above, the shape of the tip of the cutter for forming the second groove 162 can make the shape of the first side surface of the light-transmitting member 40 of each light-emitting unit 51 different.

[0140] like Figure 5B As shown, when a tool having a U-shaped or curved front end in cross section is used to form the second groove 162, as shown in FIG. Fig. 6A As shown, the light-transmitting member 40 includes a first side surface 40c1 having a curved surface portion. Since the second side surface 40c2 is formed by the first groove 161, the second side surface 40c2 is Figure 3 It is also a plane.

[0141] like Figure 5C As shown, when the second groove 162 is formed using a tool having a trapezoidal front end in cross section, as shown in FIG. Figure 6B As shown, the light-transmitting member 40 has a first side surface 40c1 inclined from the vertical direction.

[0142] By making the first side surface 40c1 different in shape and inclination, the direction of light emitted from the first side surface 40c1 can be made different. Therefore, the light distribution of light emitted laterally from the light emitting unit 51 can be adjusted.

[0143] Fig. 7A and 7B 2 shows an example in which the light-transmitting member has other forms of light source 102. Fig. 7A and Figure 7B As shown, each light emitting unit 52 of the light source 102 is Figure 2A and Figure 2B The light source 101 shown is different in that the translucent component does not have a second side surface. In the light emitting unit 52 of the light source 102, the translucent component 42 does not have a second side surface, and the first side surface 41c1 is adjacent to the upper surface 40a and the lower surface 40b. That is, the entire side surface of the translucent component 42 of each light emitting unit 52 of the light source 102 is exposed from the light shielding component 60. The first side surface 42c1 has a curved surface portion. The light source 102 having the translucent component 42 of this shape can be formed by using the second groove 162 in the process of forming the second groove 162. Figure 5B The cutter with the cross-sectional shape shown in FIG. 1 forms the second groove 162 until it reaches the wavelength conversion member 30. Similarly, by using Figure 5C The cutter with the cross-sectional shape shown in FIG. 1 forms the second groove 162 until reaching the wavelength conversion component 30, and can also manufacture a wavelength conversion component having a wavelength conversion component 30. Figure 7C The light source 103 of the light-transmitting member 43 is shaped as shown. The light-transmitting member 43 has a planar first side surface 43c1 inclined from the vertical direction.

[0144] <Second Embodiment>

[0145] Fig. 8A is a schematic cross-sectional view of a light source 104 according to the second embodiment, Figure 8B : is a schematic cross-sectional view of the light emitting unit 54. The light source 104 is different from the light source 101 of the first embodiment in that, in each light emitting unit 54, the area of ​​the upper surface 44a of the light-transmitting member 44 is larger than the area of ​​the lower surface 44b. The light-transmitting member 44 is similar to the first embodiment, and the thickness of the second region R2 is smaller than the thickness of the first region R12. In addition, the first side surface 44c1 is exposed from the light-shielding member 60, and the second side surface 44c2 is covered by the light-shielding member 60. The light source 104 also has the same effect as the first embodiment.

[0146] The light source 104 can be manufactured by changing the process of forming the first groove 161 and the second groove 162 in the light source manufacturing method of the first embodiment. Fig.9AAs shown, between the plurality of light emitting elements 20, the wavelength conversion layer 130 is divided from the wavelength conversion layer 130 side, and a first groove 171 reaching the light-transmitting layer 140 is formed. The width w1 of the first groove 171 is greater than the width w1 of the first groove 161 of the first embodiment. In addition, the first groove 171 is formed so as not to reach the support 120. In other words, the light-transmitting layer 140 is not divided by the first groove 171. By forming the first groove 171, the wavelength conversion layer 130 is divided, and the wavelength conversion member 30 corresponding to each light emitting unit 54 is formed. The light shielding member 60 is arranged in the first groove 171.

[0147] Furthermore, between the plurality of light emitting elements, a portion of the light transmissive layer 140 is removed from the light transmissive layer 140 side to form a second groove reaching the light shielding member 60. Thus, a plurality of light transmissive members 40 are formed, which are respectively located on the plurality of wavelength conversion members 30. Fig. 9B As shown, when forming the second groove 172, it is preferred that the width w2 of the second groove 172 is smaller than the width w1 of the first groove 171. In this embodiment, the second groove 172 cuts through the translucent layer 140 and is set to reach the depth of the first groove 171. The translucent layer 140 is divided by forming the second groove 172, and the translucent member 44 corresponding to each light emitting unit 54 is formed.

[0148] [Other forms]

[0149] As in the first embodiment, by making the shape of the cutter used to form the first groove 171 different, the shape of the second side surface of the light-transmitting member 44 of each light-emitting unit 54 can be made different.

[0150] like Figure 5B As shown, in the case where the first groove 171 is formed using a tool having a curved front end in cross section, as shown in FIG. Fig. 10A As shown, the light-transmitting member 44 includes a second side surface 40c2 having a curved surface portion.

[0151] like Figure 5C As shown, in the case where the first groove 171 is formed using a tool having a trapezoidal front end in cross section, as shown in FIG. Fig. 10B As shown, the light-transmitting member 44 has a second side surface 40c2 inclined from the vertical direction.

[0152] In addition, in forming the first groove 171, a tool having the same shape as that used to form the second groove 172 is used, and by making the width w1 of the first groove 171 and the width of the second groove 172 the same, the light source 105 having the light emitting unit 55 can be manufactured. Fig. 10C A light-transmitting component 45 of the form shown.

[0153] The light source 105 is different from the light source 101 of the first embodiment in that, in each light-emitting unit 55, the area of the upper surface 45a of the light-transmissive member 45 is equal to the area of the lower surface 45b. The light-transmissive member 45 has side surfaces 45c adjacent to the upper surface 45a and the lower surface 45b. A part of the side surface 45c on the upper surface 45a side is exposed from the light-shielding member 60, and a part of the side surface 45c on the lower surface 45b side is covered by the light-shielding member 60.

[0154] <Third Embodiment>

[0155] Fig.11 It is a schematic top view of the light source 106 of the third embodiment. The light source 106 is different from the light source 101 of the first embodiment in that the sizes of the emission surfaces of the light-emitting elements of the plurality of light-emitting units are different.

[0156] The light source 106 includes a plurality of two-dimensionally arranged light-emitting units 56. The plurality of light-emitting units 56 includes a plurality of first light-emitting units 56A, a plurality of second light-emitting units 56B, a plurality of third light-emitting units 56C, and a plurality of fourth light-emitting units 56D.

[0157] In Fig.11 as shown by the shading, among the first light-emitting units 56A, the plurality of second light-emitting units 56B, the plurality of third light-emitting units 56C, and the plurality of fourth light-emitting units 56D, the sizes of the emission surfaces 20a of the light-emitting elements are different. If the areas of the emission surfaces 20a of the first light-emitting units 56A, the plurality of second light-emitting units 56B, the plurality of third light-emitting units 56C, and the plurality of fourth light-emitting units 56D are respectively set as Aa, Ab, Ac, and Ad, the relationship Aa < Ab < Ac < Ad is satisfied.

[0158] In the light source 106, the distances from the center C of the light-emitting surface (i.e., the upper surface of the light source 106) where the plurality of light-emitting units 56 are arranged to the centers of the first light-emitting units 56A, the second light-emitting units 56B, the third light-emitting units 56C, and the fourth light-emitting units 56D in a top view are respectively set as ra, rb, rc, and rd. When any two light-emitting units 56 with different areas of the emission surface 20a are selected, the relationship ra < rb < rc < rd is satisfied. That is, the larger the emission surface 20a of the light-emitting element 20 of the light-emitting unit, the farther it is arranged from the center C.

[0159] Therefore, the second light emitting unit 56B is farther from the center C than the first light emitting unit 56A (ra<rb), and the area of ​​the exit surface 20a of the light emitting element 20 of the second light emitting unit 56B is larger than the area of ​​the exit surface 20a of the light emitting element 20 of the first light emitting unit 56A. The first light emitting unit 56A, the third light emitting unit 56C, and the fourth light emitting unit 56D also satisfy the same relationship. In addition, the second light emitting unit 56B, the third light emitting unit 56C, and the fourth light emitting unit 56D also satisfy the same relationship as the third light emitting unit 56C and the fourth light emitting unit 56D.

[0160] The light source 106 has the above-mentioned structure, so when all the light-emitting units 56 are lit, the brightness in the light-emitting surface 101a is higher in the peripheral area than in the vicinity of the center. Such a light-emitting characteristic can realize more appropriate illumination light when used in a lighting device in combination with a lens for projection. This is described in detail in the fourth embodiment.

[0161] <Fourth Embodiment>

[0162] Embodiments of the light source device will be described. Fig. 12A is a schematic front view of the light source device 201, Fig. 12B yes Fig. 12A Schematic cross-sectional view of the light source device 201 taken along line 12B-12B.

[0163] The light source device 201 includes a lens 202 and a light source 203. In the present embodiment, the light source device 201 further includes a substrate 205 and a support body 204. The light source 203 may be the light source described in any of the above embodiments. For example, the light source 203 is the light source 106 of the third embodiment. The light source 203 is disposed on the substrate 205. A circuit of the light emitting unit 56 capable of independently driving the light source 203 is formed on the substrate 205, and is electrically connected to each light emitting element 20 of the plurality of light emitting units 57.

[0164] The support body 204 holds the lens 202 at a predetermined distance from the light emitting surface 203a of the light source 203. The lens 202 is, for example, a convex lens, and the optical axis of the lens 202 is located at the center of the light emitting surface 203a.

[0165] The lens 202 is a projection optical system that amplifies the light emitted from the light source 203 and projects it to the outside. Therefore, when the plurality of light emitting units 57 are partially driven, light of intensity and illumination area corresponding to the light intensity or flicker of the partial drive is projected from the lens 202.

[0166] As described in the first embodiment, the projected light has excellent luminous properties when partially illuminated. In addition, the light emitted from the light source 203 is magnified and projected by the lens 202, so that, like the imaging optical system, the amount of light in the periphery is reduced. However, as described in the third embodiment, since the brightness in the light-emitting surface 203a is higher in the peripheral area than in the vicinity of the center, the reduction in the amount of light is suppressed. Therefore, it is possible to irradiate the object with light of uniform illumination.

[0167] <Experimental example>

[0168] The brightness distribution of light emitted from the light source of this embodiment was measured by simulation. Figure 2C The light source shown in the figure has light emitting units 51 arranged in 4 rows and 4 columns, and the brightness is measured in a simulation. Fig.13A The brightness distribution of the light source of the experimental example is shown in FIG. In addition, as a comparative example, the brightness of the light source that is the same as the light source of the experimental example is measured by simulation, except that the light-transmitting component does not have a side surface exposed from the light-shielding component. Fig. 13B The brightness distribution of the light source of the comparative example is shown. In the light emitting unit 51 of the experimental example, the thickness of the first region t1 is 60 μm, and the thickness of the second region t2 is 30 μm. The light emitting unit of the comparative example does not have the first region t1, and the thickness of the light-transmitting component is 30 μm. In both the experimental example and the comparative example, the distance between the side surfaces of the light-transmitting component and the wavelength conversion component that are opposite to each other through the light-shielding component is 25 μm. Fig.13A and Fig. 13B This is the brightness distribution when the 4 central light-emitting units are not lit and the 12 surrounding light-emitting units are lit. Fig.13A and Fig. 13B It is shown in the figure that the whiter the area, the higher the brightness.

[0169] Depend on Fig.13A and Fig. 13B It can be seen that in the experimental example, there is almost no area with reduced brightness between the peripheral light-emitting units that are lit, but in the comparative example, there is an area with low brightness between the light-emitting units. In addition, in the experimental example, the contrast between the lit area and the extinguished area is high, while in the comparative example, the contrast between the lit area and the extinguished area is low. In this way, according to the light source of the embodiment, it can be seen that the luminous characteristics of partial illumination are excellent.

[0170] Industrial Applicability

[0171] The light source and light source device of the present invention can be used as light emitting devices for various purposes. For example, they can be appropriately used as light emitting devices for lamps for various purposes.

Claims

1. A method for manufacturing a light source, wherein: The process includes the following steps: On the wavelength conversion layer of a laminate including a light-transmitting layer and a wavelength conversion layer, a plurality of light-emitting elements having an emission surface and an electrode surface located on the opposite side of the emission surface are arranged one-dimensionally or two-dimensionally in such a manner that the emission surface and the wavelength conversion layer are opposed to each other, and the plurality of light-emitting elements are bonded to the wavelength conversion layer; Between the plurality of light emitting elements, a first groove is formed to divide the laminate from the wavelength conversion layer side, and a wavelength conversion member and a light-transmitting member are respectively arranged on the plurality of light emitting elements; Disposing a light shielding member between the plurality of light emitting elements, the light shielding member covers the side surfaces of the plurality of wavelength conversion members, the side surfaces of the plurality of light-transmitting members, and the side surfaces of the plurality of light emitting elements; On the surface of the translucent member on the opposite side to the wavelength conversion member, at least a portion of the light shielding member located between the plurality of translucent members is removed to form a second groove that exposes a portion of the plurality of translucent members from the light shielding member.

2. The method for manufacturing a light source according to claim 1, wherein: The step of forming the second groove includes the step of exposing a portion of the side surfaces of the plurality of light-transmitting members.

3. The method for manufacturing a light source according to claim 1, wherein: In the step of forming the second groove, the second groove is formed by also removing the outer edge portions of the plurality of light-transmitting members, so that the side surfaces exposed from the light-shielding member are formed at the outer edges of the plurality of light-transmitting members.

4. A method for manufacturing a light source, wherein: The process includes the following steps: On the wavelength conversion layer of a laminate including a light-transmitting layer and a wavelength conversion layer, a plurality of light-emitting elements having an emission surface and an electrode surface located on the opposite side of the emission surface are arranged one-dimensionally or two-dimensionally in such a manner that the emission surface and the wavelength conversion layer are opposed to each other, and the plurality of light-emitting elements are bonded to the wavelength conversion layer; Between the plurality of light emitting elements, the wavelength conversion layer is divided from the wavelength conversion layer side to form a first groove reaching the light-transmitting layer, and wavelength conversion members are respectively arranged on the plurality of light emitting elements; Disposing a light shielding member between the plurality of light emitting elements, the light shielding member covers the side surfaces of the plurality of wavelength conversion members, the portion of the light-transmitting layer exposed in the first groove, and the side surfaces of the plurality of light emitting elements; Between the plurality of light emitting elements, a second groove reaching the light shielding member is formed by removing a portion of the light transmissive layer from the light transmissive layer side, thereby forming a plurality of light transmissive members respectively located on the plurality of wavelength conversion members.

5. The method for manufacturing a light source according to any one of claims 1 to 4, wherein: The width of the second groove is smaller than the width of the first groove.

6. The method for manufacturing a light source according to any one of claims 1 to 4, wherein: The width of the second groove is equal to the width of the first groove.

7. The method for manufacturing a light source according to any one of claims 1 to 4, wherein: The width of the second groove is greater than the width of the first groove.

8. The method for manufacturing a light source according to claim 7, wherein: The cross-sectional shape of the second groove is one selected from the group consisting of a rectangle, a trapezoid and a U shape.

9. The method for manufacturing a light source according to any one of claims 1 to 4, wherein: The wavelength conversion member is larger than the emission surface of the light emitting element in a plan view.

10. The method for manufacturing a light source according to any one of claims 1 to 4, wherein: The light-transmitting layer includes a diffusion material.

11. The method for manufacturing a light source according to any one of claims 1 to 4, wherein: In the step of bonding the plurality of light emitting elements, the plurality of light emitting elements are two-dimensionally arranged in a predetermined area, and the plurality of light emitting elements include at least a first light emitting element and a second light emitting element. The second light emitting element is further away from the center of the predetermined area than the first light emitting element. The emission surface of the second light emitting element is larger than the emission surface of the first light emitting element.

12. A light source, wherein: The light source is manufactured by the method for manufacturing a light source according to any one of claims 1 to 11.

13. A light source device, wherein: It comprises: the light source according to claim 12; and a lens arranged at a predetermined distance from the light source.

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