Cap

Abstract

To provide a small light emitting device.SOLUTION: A light-emitting device includes a light-emitting element having a light emission surface from which light is emitted, a substrate having a mounting surface on which the light-emitting element is arranged, and a cap having a plurality of side portions including a first side portion having a first inner surface through which light traveling along an optical axis emitted from the light emission surface passes, and a second side portion having a second inner surface different from the first inner surface, and surrounding the light-emitting element arranged on the substrate, and the first inner surface is inclined toward the side on which the light-emitting element is arranged from a plane perpendicular to the mounting surface, and the second inner surface is inclined toward the side on which the light-emitting element is arranged from a plane perpendicular to the mounting surface by a greater inclination than the first inner surface.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a light-emitting device, a method for manufacturing a cap, or a method for manufacturing a light-emitting device.

Background Art

[0002] Patent Document 1 discloses a laser light source including a semiconductor laser element, a substrate having a mounting surface on which the semiconductor laser element is disposed, and a housing surrounding the semiconductor laser element disposed on the mounting surface. Further, in the laser light source, the inner surface on which the laser light is incident is inclined. Patent Document 1 describes that reducing the size of the housing contributes to downsizing the laser light source.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] To provide a small light-emitting device.

Means for Solving the Problems

[0005] The light-emitting device disclosed in the embodiment includes a light-emitting element having a light-emitting surface that emits light, a substrate having a mounting surface on which the light-emitting element is disposed, a first side portion having a first inner surface through which light traveling along the optical axis emitted from the light-emitting surface passes, and a second side portion having a second inner surface different from the first inner surface, the plurality of side portions including the first side portion and the second side portion, and a cap surrounding the light-emitting element disposed on the substrate. The first inner surface is inclined toward the side on which the light-emitting element is disposed with respect to a plane perpendicular to the mounting surface, and the second inner surface is inclined toward the side on which the light-emitting element is disposed with respect to a plane perpendicular to the mounting surface, and the inclination of the second inner surface is larger than the inclination of the first inner surface.

[0006] The manufacturing method of the cap disclosed in the embodiment is a manufacturing method of a cap, which forms a lower part and one or a plurality of convex parts protruding upward from the lower part in a translucent base material, and provides a plurality of depressions defined by the lower part and the one or a plurality of convex parts; a step of dividing the base material and fragmenting it into a plurality of caps each provided with the depression, in the step of providing the depression, the lower part formed has a first upper surface, and the convex part formed in the step of providing the depression has a plurality of side surfaces and a second upper surface sharing a part of the outer edge of the plurality of side surfaces, and the plurality of surfaces defining the depression provided in the step of providing the depression include the first upper surface and the plurality of side surfaces, and the plurality of side surfaces defining the depression include a first side surface whose angle with the second upper surface exceeds 90 degrees and is less than 100 degrees, and a second side surface whose angle with the second upper surface is larger than the angle formed by the second upper surface and the first side surface. Further, the first upper surface becomes the lower surface of the upper part in the fragmented cap, and the plurality of side surfaces including the first side surface and the second side surface become a plurality of inner side surfaces including the first inner side surface and the second inner side surface in the fragmented cap.

[0007] The manufacturing method of the light-emitting device disclosed in the embodiment includes a step of arranging one or a plurality of light-emitting elements on the mounting surface of a substrate, and a step of bonding the cap manufactured by the above manufacturing method to the substrate so as to surround the one or a plurality of light-emitting elements arranged on the mounting surface and allow the light traveling along the optical axis emitted from the one or a plurality of light-emitting elements to pass through the first inner side surface.

[0008] In at least one of the one or a plurality of inventions disclosed by the embodiment, an effect of contributing to miniaturization of the light-emitting device is expected.

Brief Description of Drawings

[0009]

Figure 1

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Figure 17

Embodiments for Carrying Out the Invention

[0010] In this specification or the claims, with respect to polygons such as triangles and quadrilaterals, those with rounded corners, chamfers, fillets, or other processed shapes at the corners of the polygon are also referred to as polygons. Also, not limited to the corners (ends of the sides), shapes with processing on the middle part of the sides are likewise referred to as polygons. That is, shapes with partial processing while leaving the polygon as a basis are included in the interpretation of "polygon" described in this specification and the claims.

[0011] Also, not limited to polygons, the same applies to terms representing specific shapes such as trapezoids, circles, and unevenness. The same also applies when dealing with each side forming the shape. That is, even if a side has processing at the corner or the middle part, the processed part is included in the interpretation of "side". When distinguishing "polygon" or "side" without partial processing from the processed shape, "strict" is added, for example, described as "strict quadrilateral", etc.

[0012] Also, in this specification or the claims, descriptions such as up and down, left and right, front and back, front and rear, near and far, etc. only describe relative relationships of position, orientation, direction, etc., and do not have to match the relationships during use.

[0013] Also, in the drawings, directions such as the X direction, Y direction, and Z direction may be indicated using arrows. The directions of these arrows are consistent among multiple drawings related to the same embodiment.

[0014] Also, in this specification, when explaining components, etc., it may be described as "member" or "part". "Member" refers to an object physically handled as a single entity. An object physically handled as a single entity can also be said to be an object handled as one part in the manufacturing process. On the other hand, "part" refers to an object that does not have to be physically handled as a single entity. For example, "part" is used when partially grasping a part of one member.

[0015] Note that the distinction between "member" and "part" described above does not indicate an intention to consciously limit the scope of rights in the interpretation of the doctrine of equivalents. That is, even if there is a component described as "member" in the claims, the applicant does not recognize that it is essential for the application of the present invention to handle this component physically as a single entity solely based on this fact.

[0016] In addition, in this specification or the claims, when there are a plurality of certain components and they are to be expressed separately for distinction, "first", "second" may be appended to the heads of these components for distinction. Also, there may be cases where the objects to be distinguished are different between this specification and the claims. Therefore, even if a component with the same appendage as in this specification is described in the claims, the object specified by this component may not match between this specification and the claims.

[0017] For example, in this specification, there are components distinguished by appending "first", "second", "third", and when the components with "first" and "third" appended in this specification are described in the claims, for the sake of clarity, in the claims, "first", "second" may be appended to distinguish the components. In this case, the components with "first", "second" appended in the claims respectively refer to the components with "first", "third" appended in this specification. Note that the application object of this rule is not limited to components, and it is also applied reasonably and flexibly to other objects.

[0018] Hereinafter, embodiments for implementing the present invention will be described. Further, specific embodiments for implementing the present invention will be described with reference to the drawings. Note that the embodiments for implementing the present invention are not limited to this specific embodiment. That is, the illustrated embodiment is not the only form in which the present invention is realized. Note that the sizes, positional relationships, etc. of the members shown in each drawing may be exaggerated for the convenience of understanding.

[0019] <First Embodiment> The cap 50 in the first embodiment will be described. FIGS. 1 to 11 are drawings for explaining an exemplary form of the physical structure of the cap 50 and a method of manufacturing the cap 50. FIG. 1 is a perspective view of the cap 50. FIG. 2 is a transparent view of the cap 50. Each reference numeral attached to the drawing of the cap 50 in FIG. 2 indicates a transmitted portion. FIG. 3 is a cross-sectional view taken along the III-III cross-sectional line of FIG. 1. FIG. 4 is a perspective view of the base material 60 related to the manufacture of the cap 50. FIG. 5 is a top view of the base material 60. FIGS. 6 to 10 are schematic diagrams of each step for explaining the manufacturing method of the cap 50. The schematic diagrams of FIGS. 6 to 10 correspond to a cross-sectional view taken along the VI-VI cross-sectional line of FIG. 4. Note that hatching is not applied to the cross-section for the sake of visibility. FIG. 11 is a schematic diagram for explaining the correspondence between the base material 60 and the cap 50 manufactured from the base material 60.

[0020] The illustrated cap 50 is manufactured through a plurality of steps including a step of providing a plurality of depressions in the base material 60, a step of forming an antireflection film 70 on the surface defining the depressions, a step of polishing the upper surface 64 of the convex portion 63, a step of providing a metal film 80 on the upper surface 64 of the convex portion 63, and a step of dividing the base material 60 into a plurality of individual caps 50.

[0021] Note that the manufacturing method of the cap 50 may include other steps. Also, the manufacturing method of the cap 50 can be carried out even if some of these plurality of steps are excluded. Each step will be described below.

[0022] (Step of providing a plurality of depressions in the base material) FIGS. 4 to 6 show the state after this step. The base material 60 has translucency. Here, "having translucency" means that the transmittance with respect to light is 80% or more. Note that it is not necessary to have a transmittance of 80% or more for light of all wavelengths. The illustrated base material 60 has a transmittance of 80% or more with respect to light in the wavelength range of 420 nm to 1100 nm.

[0023] For example, the base material 60 can be formed using glass as the main material. Also, the base material 60 may be formed using plastic as the main material. Further, the base material 60 may be formed using a mixed material in which glass and plastic are mixed as the main material.

[0024] Here, the main material refers to the material that occupies the largest proportion of the mass or volume in the object to be formed. When the object to be formed is formed from one material, that material is the main material. That is, for a material to be the main material includes the fact that the proportion occupied by that material can be 100%.

[0025] In this step, in the base material 60, a lower part 61 and one or a plurality of convex parts 63 protruding upward from the lower part 61 are formed. The lower part 61 and the one or a plurality of convex parts 63 can be formed, for example, by molding a plate-shaped base material 60. Methods for molding the base material 60 include a method of filling a mold with a material and curing it, a method of forming by pressing, and the like. Note that it is not limited to molding, and for example, it may be formed by cutting.

[0026] A plurality of depressions are defined by the lower part 61 and the one or a plurality of convex parts 63 formed in the base material 60. By this step, the base material 60 has a plurality of surfaces that define each depression. The lower part 61 has an upper surface 62, and this upper surface 62 is included in the plurality of surfaces that define the depression. The convex part 63 has a plurality of side surfaces 65, and these plurality of side surfaces 65 are included in the plurality of surfaces that define the depression.

[0027] The convex part 63 has an upper surface 64 that shares a part of the outer edge of the plurality of side surfaces 65. Here, the upper surface 62 of the lower part 61 is called the first upper surface 62, and the upper surface 64 of the convex part 63 is called the second upper surface 64 for distinction. The second upper surface 64 intersects the plurality of side surfaces 65. The intersection line between the second upper surface 64 and the plurality of side surfaces 65 defines the outer edge (boundary) of the depression. The second upper surface 64 intersects the plurality of side surfaces 65 that define one or a plurality of depressions.

[0028] In the illustrated base material 60, in addition to the lower part 61 and the convex part 63, a groove 68 is further formed. Also, a plurality of convex parts 63 partitioned by this groove 68 are formed. Depressions are provided corresponding to each of the plurality of convex parts 63. Each convex part 63 has a second upper surface 64 that intersects a plurality of side surfaces 65 that define one depression. For example, when the groove 68 is not formed, a plurality of depressions can be defined by one convex part 63.

[0029] The lower part 61 has a first upper surface 62 corresponding to each of the plurality of depressions. The first upper surfaces 62 corresponding to the plurality of depressions are provided on the same plane. Here, "the same" includes a difference of 0 μm or more and 50 μm or less. In the illustrated base material 60, one depression is defined by one first upper surface 62 and four side surfaces 65.

[0030] The side surface 65 intersects the first upper surface 62. The first upper surface 62 intersects any one of the plurality of side surfaces 65 over the entire outer circumference. In a top view, the first upper surface 62 is surrounded by the plurality of side surfaces 65. In the illustrated base material 60, in a top view, the first upper surface 62 is surrounded by four side surfaces 65.

[0031] The plurality of side surfaces 65 that define the depression include at least two side surfaces 65 that are inclined with respect to the first upper surface 62. This side surface 65 is inclined in a direction toward the outside of the first upper surface 62 in a top view as it goes upward. In other words, this side surface 65 is inclined in a direction to expand the depression. In the illustrated base material 60, all of the plurality of side surfaces 65 that define the depression are inclined with respect to the first upper surface 62.

[0032] For example, when the lower part 61 and the convex part 63 are formed on the base material 60 by mold forming, an operation of separating the mold from the formed and cured base material 60 occurs. At this time, due to the provision of the inclined side surface 65, the mold fitted in the depression can be easily pulled out, and the cap 50 can be stably manufactured.

[0033] The plurality of side surfaces 65 that define the depression include the first upper surface 62 in a top view and define an outer edge larger than the first upper surface 62. In the illustrated base material 60, four side surfaces 65 define a rectangular outer edge that surrounds the depression in a top view. This rectangle has a long side and a short side. The direction of the long side of this rectangle is the same as the X direction, and the direction of the short side is the same as the Y direction. The length of the long side of this rectangle is 1.2 times or more and 3 times or less the length of the short side.

[0034] At least the first side surface 651 and the second side surface 652 are included in the two or more inclined side surfaces 65. The second side surface 652 is a side surface whose angle with the second upper surface 64 is larger than the angle formed by the second upper surface 64 and the first side surface 651. Note that the angle formed by the second upper surface 64 and the side surface 65 is an angle less than 180 degrees. Here, let the angle formed by the first side surface 651 and the second upper surface 64 be the first angle, and the angle formed by the second side surface 652 and the second upper surface 64 be the second angle.

[0035] The first angle is greater than 90 degrees and less than 105 degrees. Also, the first angle is preferably 92 degrees or more and 100 degrees or less. Also, the first angle is preferably 93 degrees or more and 97 degrees or less. As the side surface of the manufactured cap 50, it is preferable to be closer to perpendicular to the second upper surface 64, but considering the stable manufacture of the cap 50, it is better to have an inclination. From this balance, it is desirable for the first angle to satisfy any of the numerical ranges listed here.

[0036] The second angle is greater than 95 degrees and less than or equal to 120 degrees. Also, the second angle is preferably greater than 95 degrees and less than or equal to 115 degrees. Also, the second angle is preferably greater than 95 degrees and less than or equal to 110 degrees. Also, the second angle is preferably 100 degrees or more and 110 degrees or less. When the second angle is large, the cap 50 becomes larger. On the other hand, the closer the first angle is to 90 degrees, the larger the second angle leads to stable manufacture. Therefore, it is preferable for the second angle to satisfy any of the numerical ranges listed here under the condition that the second angle is larger than the first angle. In the illustrated base material 60, the first angle is 95 degrees and the second angle is 100 degrees.

[0037] Among the two or more inclined side surfaces 65, a second side surface 652 facing the first side surface 651 is included. It is preferable that all of the plurality of side surfaces 65 defining the recess are inclined side surfaces 65. This makes it easier to stably manufacture the cap 50. In the illustrated base material 60, among the plurality of side surfaces 65 defining the recess, there are included a first side surface 651 whose surface direction is parallel to the X direction, a second side surface 652 facing the first side surface 651 and whose surface direction is parallel to the X direction, and two second side surfaces 652 whose surface direction is parallel to the Y direction.

[0038] The plurality of side surfaces 65 defining the recess are preferably composed of a first side surface 651 and a plurality of second side surfaces 652. By taking the first side surface 651 as one and the remaining side surfaces 65 as the second side surfaces 652 among the plurality of side surfaces 65, it becomes easier to manufacture the cap 50.

[0039] The inclination of the first side surface 651 with respect to the first upper surface 62 is smaller than the inclination of the second side surface 652 with respect to the first upper surface 62. In other words, the first side surface 651 has an inclination closer to being perpendicular to the upper surface 62 than the second side surface 652. In a top view, the outer edge of the second side surface 652 is at a greater distance from the upper surface 62 than the outer edge of the first side surface 651.

[0040] The first upper surface 62 is parallel to the second upper surface 64. The angle formed by the first side surface 651 and the first upper surface 62 is equal to the angle formed by the first side surface 651 and the second upper surface 64. Here, "equal" includes a difference within ±5 degrees. Also, the angle formed by the side surface 65 and the first upper surface 62 is an angle less than 180 degrees.

[0041] A groove 68 is provided in the base material 60. In the base material 60, the grooves 68 are provided in a grid pattern. In the inside of each frame separated by the grid-like grooves 68 in a top view, a convex portion 63 is formed and a recess is provided. It can be said that the groove 68 is provided between adjacent convex portions 63. The groove 68 extends below the first upper surface 62. The groove 68 extends 50 μm or more below the first upper surface 62.

[0042] The depth of the groove 68 from the plane including the second upper surface 64 is greater than the distance from the plane including the second upper surface 64 to the plane including the first upper surface 62. The length in the Z direction from the plane including the second upper surface 64 to the tip of the groove 68 is greater than the length in the Z direction from the plane including the second upper surface 64 to the plane including the first upper surface 62.

[0043] The convex portion 63 has a side surface 66. Through the groove 68, the side surfaces 66 of adjacent convex portions 63 face each other. The convex portion 63 has a side surface 66 on the opposite side of the first side surface 651. In the illustrated base material 60, side surfaces 66 are provided on the opposite sides of a plurality of side surfaces 65 that define depressions.

[0044] The plurality of side surfaces 66 include at least a third side surface 663 and a fourth side surface 664. The fourth side surface 664 is a side surface 66 whose angle formed with the second upper surface 64 is larger than the angle formed by the second upper surface 64 and the third side surface 663. Note that the angle formed by the second upper surface 64 and the side surface 66 is an angle less than 180 degrees. Here, the angle formed by the third side surface 663 and the second upper surface 64 is called the third angle, and the angle formed by the fourth side surface 664 and the second upper surface 64 is called the fourth angle.

[0045] In the convex portion 63, the side surface 66 on the opposite side of the first side surface 651 is the third side surface 663. In the convex portion 63, the side surface 66 on the opposite side of the second side surface 652 is the fourth side surface 664. The distance between the first side surface 651 and the third side surface 663 is the width of the convex portion 63. The distance between the second side surface 652 and the fourth side surface 664 is the width of the convex portion 63.

[0046] The third angle is greater than 90 degrees and less than 105 degrees. Also, the third angle is preferably 92 degrees or more and 100 degrees or less. Also, the first angle is preferably 93 degrees or more and 97 degrees or less. Also, the third angle may be the same angle as the first angle. Similar to the first side surface 651, the third side surface 663 is preferably close to being perpendicular to the second upper surface 64 as the side surface of the cap 50 to be manufactured.

[0047] The fourth angle exceeds 95 degrees and is equal to or less than 120 degrees. Preferably, the fourth angle exceeds 95 degrees and is equal to or less than 115 degrees. Preferably, the fourth angle exceeds 95 degrees and is equal to or less than 110 degrees. Preferably, the fourth angle is equal to or more than 100 degrees and equal to or less than 110 degrees. Also, the fourth angle may be the same as the second angle. In the illustrated base material 60, the direction perpendicular to the first upper surface 62 is equal to the Z-axis direction. The direction perpendicular to the second upper surface 64 is equal to the Z-axis direction.

[0048] In the illustrated base material 60, the height from the first upper surface 62 to the second upper surface 64 in the Z-axis direction is 200 μm or more and 1500 μm or less. Among the plurality of side surfaces 65 that define the depression, the length between the side surfaces 65 facing each other in the X-axis direction is 400 μm or more and 5000 μm or less. Among the plurality of side surfaces 65 that define the depression, the length between the side surfaces 65 facing each other in the Y-axis direction is 400 μm or more and 5000 μm or less.

[0049] (Step of forming an antireflection film on the surface that defines the depression) FIG. 7 shows the state after this step. In this step, an antireflection film 70 is formed on the base material 60 in which the depression is formed. The antireflection film 70 is formed on the first side surface 651. The antireflection film 70 is provided on the side surface 66 opposite to the first side surface 651.

[0050] The antireflection film 70 can be formed, for example, by vapor deposition or sputtering. The antireflection film 70 is formed on the second upper surface 64 of one or more convex portions 63 and the plurality of side surfaces 65. The antireflection film 70 is also formed on the side surface 66 of one or more convex portions 63.

[0051] (Step of polishing the upper surface of the convex portion) FIG. 8 shows the state after this step. In this step, the second upper surface 64 of one or more convex portions is polished with respect to the base material 60 on which the antireflection film 70 is formed, and the antireflection film 70 formed on the second upper surface 64 is removed. The second upper surface 64 polished by this step is a flatter surface than the second upper surface 64 of the convex portion 63 formed in the step of providing a plurality of depressions in the base material.

[0052] When performing the polishing process in this project, the conditions regarding the angular ranges of the first angle and the second angle described in the step of providing a plurality of depressions in the base material are preferably satisfied with respect to the second upper surface 64 after polishing.

[0053] (Step of providing a metal film on the upper surface of the convex portion) FIG. 9 shows the state after this step. In this step, a metal film 80 is provided on the second upper surface 64 of the convex portion 63. The metal film 80 is provided in an annular shape so as to surround the first upper surface 62 in a top view. The metal film 80 can be provided, for example, by vapor deposition or sputtering.

[0054] (Step of dividing the base material and fragmenting it into a plurality of caps) FIG. 10 shows the portion to be removed for dividing the base material in this step with a dotted line. FIG. 11 shows the fragmented caps 50 after this step. In this step, the base material 60 is divided. The base material 60 is divided while leaving a plurality of depressions provided in the base material 60. The base material 60 is divided and fragmented into a plurality of caps 50 each provided with a depression.

[0055] The base material 60 directly below the groove 68 is cut to divide the base material 60 for each depression. For example, the base material 60 is diced using a blade capable of cutting the base material 60, and thus the base material 60 is divided. By cutting the base material 60 from the surface on the opposite side of the first upper surface 62 of the lower portion 61 toward the first upper surface 62 up to a position before reaching the plane including the first upper surface 62, the base material 60 is divided.

[0056] The tip of the groove 68 formed in the base material 60 may be smaller than the width of the blade used for dicing the base material 60. In this case, if dicing is performed from the side of the first upper surface 62 toward the surface on the opposite side of the first upper surface 62 of the lower portion 61, the convex portion 63 may be cut above the first upper surface 62, which may not be preferable. By performing dicing from the surface on the opposite side of the first upper surface 62 of the lower portion 61, it is possible to avoid excessive cutting of the convex portion 63.

[0057] By such a manufacturing method, the cap 50 can be stably manufactured while reducing the inclination on at least one side surface 65. Further, by suppressing the inclination on at least one side surface 66 to a small value, it is possible to contribute to miniaturization of the outer shape of the cap 50. Thereby, it becomes possible to provide a small light-emitting device using the small cap 50.

[0058] The cap 50 has a first upper surface 62, a second upper surface 64, a plurality of side surfaces 65, and a plurality of side surfaces 66. The cap 50 has a lower portion 61 and a convex portion 63. The cap 50 may have a side surface 67 formed by dicing. The side surface 67 intersects the side surface 66 (third side surface 663) opposite to the first side surface 651. The cap 50 has a side surface 67 intersecting the side surface 66 for each of the plurality of side surfaces 66. The side surface 66 is a flatter surface than the side surface 67. Each side surface 67 may be a curved surface.

[0059] The cap 50 can create a closed space, for example, by joining the second upper surface 64 to the plane of the substrate. When the cap 50 is thus disposed on the substrate to create a closed space, the convex portion 63 will be located below the lower portion 61.

[0060] As shown in FIG. 3, the cap 50 has an upper portion 51 and a plurality of side portions 54. The upper portion 51 has an upper surface 52 and a lower surface 53. The plurality of side portions 54 have a plurality of inner side surfaces 55, a plurality of outer side surfaces 56, and a lower surface 58. Further, the plurality of side portions 54 have one or a plurality of outer side surfaces 57. Here, the outer side surface 56 shall be referred to as the first outer side surface 56, and the outer side surface 57 shall be referred to as the second outer side surface 57.

[0061] As shown in FIG. 11, the lower part 61 of the base material 60 corresponds to the upper part 51 of the cap 50. The convex parts 63 of the base material 60 correspond to the plurality of side parts 54 of the cap 50. The first upper surface 62 of the base material 60 becomes the lower surface 58 of the cap 50. The plurality of side surfaces 65 that define the recess of the base material 60 become the plurality of inner surfaces 55 of the cap 50. The side surface 66 of the base material 60 becomes the first outer surface 56 of the cap 50. The second upper surface 64 of the base material 60 becomes the lower surface 58 of the cap 50. The side surface 67 of the base material 60 becomes the second outer surface 57 of the cap 50. The plurality of inner surfaces 55 of the cap 50 include a first inner surface 551 corresponding to the first side surface 651 and a second inner surface 552 corresponding to the second side surface 652.

[0062] Hereinafter, in the description of the cap 50, it will be described based on the above-described constituent elements of the cap 50, namely, the upper part 51, the side parts 54, the upper surface 52, the lower surface 53, the inner surfaces 55, the first outer surface 56, the lower surface 58, and the second outer surface 57. For each constituent element of the cap 50, the description made for the constituent elements of the base material 60 will be appropriately followed based on the correspondence with the above-described base material 60.

[0063] Each of the plurality of side parts 54 has inner surfaces 55 that are different from each other. The cap 50 has side parts 54 corresponding to the respective inner surfaces 55. Each of the plurality of side parts 54 has first outer surfaces 56 that are different from each other. The cap 50 has side parts 54 corresponding to the respective first outer surfaces 56. Here, the side part 54 having the first inner surface 551 is referred to as the first side part 54, and the side part 54 having the second inner surface 55 is referred to as the second side part 54.

[0064] The first outer surface 56 of the first side part 54 constitutes a part of the outer edge of the cap 50 in a top view. In other words, there is no surface that constitutes the cap 50 outside this first outer surface 56. In a top view, the outer edge of the cap 50 is determined by the outer edges of the first outer surfaces 56 of the plurality of side parts 54. In other words, for any of the plurality of first outer surfaces 56, there is no surface that constitutes the cap 50 outside the first outer surface 56.

[0065] The upper ends of the first outer surfaces 56 of the plurality of side portions 54 constitute the outer edge of the cap 50 in a top view. The upper ends of the first outer surfaces 56 are located above the lower surface 58 (in the direction where the upper portion 51 is located). The outer edge of the first outer surface 56 in a top view is the upper end of the first outer surface 56. The upper end of the first inner surface 551 is at a position lower than the upper end of the first outer surface 56. The upper end of the first inner surface 551 is at a position lower than the lower end of the second outer surface 57.

[0066] (Modification of the step of dividing the base material into a plurality of caps) The step of dividing the base material into a plurality of caps can be executed not only by the method illustrated in FIG. 10 but also by the method illustrated in FIG. 12. FIG. 12 shows the portion of the base material that is cut away in this step with hatching surrounded by a dotted line. FIG. 13 shows the caps 50 that have been individualized through this step.

[0067] In the example shown in FIG. 12, the base material 60 is divided by polishing and scraping the base material 60 from the surface opposite to the first upper surface 62 of the lower portion 61 toward the first upper surface 62 up to a position before reaching the tip of the groove 68 and before reaching the plane including the first upper surface 62.

[0068] The caps 50 individualized by this method do not have the second outer surface 57, which is different from the caps 50 shown in FIG. 11. The upper surface 52 of the cap 50 intersects with the first outer surface 56. The upper surface 52 shares a part of the outer edge with the first outer surface 56 of the first side portion 54. The caps 50 shown in FIG. 13 can have a smaller height in the vertical direction than the caps 50 shown in FIG. 11.

[0069] <Second Embodiment> The light-emitting device 1 having the cap 50 will be described. FIGS. 14 to 16 are drawings for explaining an exemplary form of the light-emitting device 1. FIG. 14 is a perspective view of the light-emitting device 1. FIG. 15 is a perspective view of the state where the cap 50 is removed from the light-emitting device 1. The arrow indicates the direction in which light is emitted from the light-emitting surface of the light-emitting element 20. FIG. 16 is a cross-sectional view taken along the XVI-XVI cross-sectional line of FIG. 14.

[0070] The light-emitting device 1 includes a plurality of components. The plurality of components include a substrate 10, one or more light-emitting elements 20, one or more submounts 30, one or more protective elements 40, and a cap 50. Note that the light-emitting device 1 may further include other components. Also, the light-emitting device 1 may not include some of the plurality of components listed here. First, each component will be described.

[0071] (Substrate 10) The substrate 10 has an upper surface 11, a lower surface 12, and one or more outer surfaces. The shape of the substrate 10 is a rectangular parallelepiped. Note that it does not have to be a rectangular parallelepiped. In a top view, the outer edge shape of the substrate 10 is rectangular. This rectangle can be a rectangle having a long side and a short side. In the illustrated substrate 10, the long side direction of this rectangle is the same direction as the X direction, and the short side direction is the same direction as the Y direction. Note that in a top view, the outer edge shape of the substrate 10 does not have to be rectangular.

[0072] On the upper surface 11 side of the substrate 10, there are a first mounting region 13 and a second mounting region 15. In a top view, the first mounting region 13 is surrounded by the second mounting region 15. In the illustrated substrate 10, the first mounting region 13 is provided on the upper surface 11. The second mounting region 15 is provided on the substrate 10. Note that the first mounting region 13 may be provided on a surface different from the surface on which the second mounting region 15 is provided.

[0073] One or more wiring patterns 14 are provided in the first mounting region 13. The wiring pattern 14 is electrically connected to a wiring pattern provided on the lower surface of the substrate 10 via a wiring passing through the inside of the substrate 10. A metal film 16 for bonding is provided in the second mounting region 15.

[0074] The substrate 10 can be formed using ceramic as a main material. Examples of the ceramic include aluminum nitride, silicon nitride, aluminum oxide, and silicon carbide. Note that the substrate 10 may be formed from a material other than ceramic.

[0075] (Light-emitting element 20) The light-emitting element 20 has a light-emitting surface that emits light. The light-emitting element 20 has an upper surface, a lower surface, and a plurality of side surfaces. The upper surface or a side surface of the light-emitting element 20 serves as the light-emitting surface. A semiconductor laser element can be adopted for the light-emitting element 20. Note that, the light-emitting element 20 is not limited to a semiconductor laser element, and a light-emitting diode or the like may be adopted.

[0076] For the light-emitting element 20, for example, a light-emitting element that emits blue light, a light-emitting element that emits green light, or a light-emitting element that emits red light can be adopted. Note that, a light-emitting element that emits light of other colors may be adopted for the light-emitting element 20. For example, a light-emitting element that emits infrared light may be adopted for the light-emitting element 20.

[0077] Here, blue light refers to light whose emission peak wavelength is in the range of 420 nm to 494 nm. Green light refers to light whose emission peak wavelength is in the range of 495 nm to 570 nm. Red light refers to light whose emission peak wavelength is in the range of 605 nm to 750 nm.

[0078] Here, a semiconductor laser element, which is an example of the light-emitting element 20, will be described. The semiconductor laser element has a rectangular outer shape with one pair of opposite sides being long sides and the other pair of opposite sides being short sides in a top view. The light (laser light) emitted from the semiconductor laser element has a spread. Also, divergent light is emitted from the emission end face of the semiconductor laser element. The emission end face of the semiconductor laser element can be referred to as the light-emitting surface of the light-emitting element 20.

[0079] The light emitted from the semiconductor laser element forms an elliptical far-field pattern (hereinafter referred to as "FFP") on a plane parallel to the light-emitting end face. The FFP is the shape and light intensity distribution of the emitted light at a position away from the emission end face.

[0080] Here, the light passing through the center of the elliptical shape of the FFP, in other words, the light with the peak intensity in the light intensity distribution of the FFP, is referred to as the light traveling along the optical axis or the light passing through the optical axis. Also, in the light intensity distribution of the FFP, the light having an intensity of 1 / e 2 or more of the peak intensity value is referred to as the light of the main part.

[0081] The shape of the FFP of the light emitted from the semiconductor laser element is an elliptical shape in which the stacking direction is longer than the direction perpendicular to the stacking direction in a plane parallel to the light emitting end face. The stacking direction is the direction in which a plurality of semiconductor layers including the active layer are stacked in the semiconductor laser element. The direction perpendicular to the stacking direction can also be referred to as the plane direction of the semiconductor layer. Also, the major axis direction of the elliptical shape of the FFP can be referred to as the fast axis direction of the semiconductor laser element, and the minor axis direction can be referred to as the slow axis direction of the semiconductor laser element.

[0082] Based on the light intensity distribution of the FFP, the angle at which the light with an intensity of 1 / e 2 of the peak light intensity spreads is defined as the light divergence angle of the semiconductor laser element. The light divergence angle may be obtained, for example, from the light intensity at half the peak light intensity in addition to the light intensity of 1 / e 2 of the peak light intensity. In the description of this specification, when simply referring to the "light divergence angle", it refers to the light divergence angle at the light intensity of 1 / e 2 of the peak light intensity. It should be noted that the divergence angle in the fast axis direction is larger than the divergence angle in the slow axis direction.

[0083] Examples of the semiconductor laser element that emits blue light or the semiconductor laser element that emits green light include a semiconductor laser element including a nitride semiconductor. As the nitride semiconductor, for example, GaN, InGaN, and AlGaN can be used. Examples of the semiconductor laser element that emits red light include those including semiconductors of the InAlGaP system, GaInP system, GaAs system, and AlGaAs system.

[0084] (Submount 30) The submount 30 has two joint surfaces and is configured in the shape of a rectangular parallelepiped. The upper surface of the submount 30 is rectangular in shape. The upper surface of the submount 30 can be rectangular with a short side and a long side.

[0085] On the submount 30, the other joint surface is provided on the opposite side of one joint surface. The distance between the two joint surfaces is smaller than the distance between the other two opposing surfaces. Note that the shape of the submount 30 does not have to be limited to a rectangular parallelepiped. The submount 30 can be formed using, for example, silicon nitride, aluminum nitride, or silicon carbide. Also, a metal film for bonding is provided on the joint surface.

[0086] (Protection element 40) The protection element 40 is for preventing an excessive current from flowing through a specific element (for example, the light-emitting element 20) and causing it to be destroyed. Examples of the protection element 40 include a Zener diode. Also, as the Zener diode, one formed of Si can be adopted.

[0087] (Light-emitting device 1) Next, the light-emitting device 1 including the above-described components will be described. In the light-emitting device 1, one or more light-emitting elements 20 are arranged in the first mounting region 13. Each of the one or more light-emitting elements 20 is arranged such that its light-emitting surface faces sideways. The surface of the substrate 10 on which the light-emitting element 20 is arranged is referred to as the mounting surface. The first mounting region 13 is included in the mounting surface. In the illustrated light-emitting device 1, the upper surface 11 of the substrate 10 is the mounting surface.

[0088] The light-emitting device 1 can include a plurality of light-emitting elements 20. The light-emitting device 1 can include a plurality of light-emitting elements 20 that emit light of different colors. In the illustrated light-emitting device 1, the plurality of light-emitting elements 20 include a light-emitting element 20 that emits first light having a peak wavelength at a first wavelength, a light-emitting element 20 that emits second light having a peak wavelength at a second wavelength different from the first wavelength, and a light-emitting element 20 that emits third light having a peak wavelength at a third wavelength different from the first and second wavelengths. For example, the light-emitting device 1 can include a light-emitting element 20 that emits red light, a light-emitting element 20 that emits green light, and a light-emitting element 20 that emits blue light.

[0089] The plurality of light-emitting elements 20 are arranged side by side such that their respective light-emitting surfaces face the same direction. Here, the same direction includes the case where the rotational displacement of the light-emitting surfaces of adjacent light-emitting elements 20 on a plane parallel to the first mounting region 13 is within the range of ±5 degrees. In the illustrated light-emitting device 1, the plurality of light-emitting elements 20 are arranged side by side in the X direction.

[0090] The light emitted from the light-emitting surface of the light-emitting element 20 includes light traveling in a direction perpendicular to the light-emitting surface. In the light-emitting device 1, the direction perpendicular to the light-emitting surface is parallel to the mounting surface. Here, the light traveling in the direction perpendicular to the light-emitting surface is defined as the light traveling along the optical axis of the light-emitting element 20. In the illustrated light-emitting device 1, the direction perpendicular to the light-emitting surface is the same as the Y direction. From the light-emitting surface of the light-emitting element 20, which is a semiconductor laser element, the light of the FFP with the direction perpendicular to the mounting surface as the fast axis direction is emitted.

[0091] In the light-emitting device 1, one or more light-emitting elements 20 are mounted on one or more submounts 30. The submount 30 joins the light-emitting element 20 at one bonding surface and is joined to the mounting surface at the other bonding surface. The light-emitting element 20 is disposed on the mounting surface via the submount 30. Note that the light-emitting element 20 may be disposed on the mounting surface without passing through the submount 30. In the illustrated light-emitting device 1, a plurality of light-emitting elements 20 are mounted on one submount 30.

[0092] In the light-emitting device 1, one or more protection elements 40 are arranged on the substrate 10. One or more protection elements 40 are arranged on the wiring pattern 14 at a position where a part or all of them overlap the wiring pattern 14 in a top view. Note that they may be arranged at positions other than the wiring pattern 14. For example, the protection element 40 can also be arranged on the submount 30. One or more protection elements 40 are electrically connected to the wiring pattern 14. The protection element 40 is provided one-to-one for an electric circuit that electrically connects one or more light-emitting elements 20.

[0093] In the light-emitting device 1, the cap 50 is arranged on the upper surface of the substrate 10. The lower surface 58 of the cap 50 is joined to the second mounting region 15 of the substrate 10. For example, the metal film 80 provided on the lower surface 58 of the cap 50 and the metal film 16 provided in the second mounting region 15 can be joined by solder such as AuSn to join the cap 50 to the substrate 10.

[0094] By joining the substrate 10 and the cap 50, a closed space surrounded by the substrate 10 and the cap 50 is created. This space is the space where the light-emitting element 20 is arranged. The cap 50 is joined to the substrate 10 so as to surround one or more light-emitting elements. Therefore, the step of joining the cap 50 to the substrate 10 is performed after the step of arranging one or more light-emitting elements 20 in the first mounting region 13 of the substrate 10.

[0095] By joining the cap 50 to the substrate 10 in a predetermined atmosphere, a hermetically sealed closed space is created. When a semiconductor laser element is adopted for the light-emitting element 20, by hermetically sealing the space where the semiconductor laser element is arranged, quality deterioration due to dust collection can be suppressed.

[0096] The cap 50 can improve the mounting accuracy, such as the angle with respect to the mounting surface and the sealing accuracy, by making the lower surface 58 a flatter surface through the step of polishing the upper surface of the convex portion.

[0097] The inner surface 55 of the side portion 54 is inclined toward the side where the light-emitting element 20 is disposed with respect to a plane perpendicular to the mounting surface. The first inner surface 551 of the first side portion 54 is inclined toward the side where the light-emitting element 20 is disposed with respect to a plane perpendicular to the mounting surface. The second inner surface 552 of the second side portion 54 is inclined toward the side where the light-emitting element 20 is disposed with respect to a plane perpendicular to the mounting surface. The second inner surface 552 is inclined more greatly than the first inner surface 551. In the illustrated light-emitting device 1, the plane perpendicular to the mounting surface is parallel to the light-emitting surface of the light-emitting element 20.

[0098] The angle at which the first inner surface 551 is inclined toward the side where the light-emitting element 20 is disposed with respect to a plane perpendicular to the mounting surface can be equal to the angle obtained by subtracting 90 degrees from the first angle in the manufacturing process of the cap 50. Based on the preferable numerical range of the first angle in the manufacturing of the cap 50, the angle at which the first inner surface 551 is inclined toward the side where the light-emitting element 20 is disposed with respect to a plane perpendicular to the mounting surface can, under certain conditions, exceed 0 degrees and be less than 15 degrees, and under certain conditions, be 2 degrees or more and 10 degrees or less, and under certain conditions, be 3 degrees or more and 7 degrees or less.

[0099] The angle at which the second inner surface 552 is inclined toward the side where the light-emitting element 20 is disposed with respect to a plane perpendicular to the mounting surface can be equal to the angle obtained by subtracting 90 degrees from the second angle in the manufacturing process of the cap 50. Based on the preferable numerical range of the second angle in the manufacturing of the cap 50, the angle at which the second inner surface 552 is inclined toward the side where the light-emitting element 20 is disposed with respect to a plane perpendicular to the mounting surface can, under certain conditions, exceed 5 degrees and be less than 30 degrees, and under certain conditions, exceed 5 degrees and be 25 degrees or less, and under certain conditions, exceed 5 degrees and be 20 degrees or less, and under certain conditions, be 10 degrees or more and 20 degrees or less.

[0100] The cap 50 is arranged such that the light emitted from the light-emitting element 20 passes through the first inner surface 551. The cap 50 is arranged such that the first inner surface 551 faces the light-emitting surface of the light-emitting element 20. In the illustrated light-emitting device 1, the light traveling along the optical axis emitted from the light-emitting surface of one or a plurality of light-emitting elements 20 passes through the first inner surface 551. By setting the inner surface 55 where the light emitted from the light-emitting element 20 is incident as the first inner surface 551, light can be made to be incident on the inner surface 55 with a smaller inclination with respect to the mounting surface.

[0101] In the light-emitting device 1, the first inner surface 551 inclines at an angle greater than 0 degrees and less than 15 degrees toward the side where the light-emitting element 20 is arranged with respect to the plane perpendicular to the mounting surface. Further, the first inner surface 551 preferably inclines at an angle greater than 0 degrees and less than or equal to 10 degrees toward the side where the light-emitting element 20 is arranged with respect to the plane perpendicular to the mounting surface. Further, the first inner surface 551 preferably inclines at an angle greater than 0 degrees and less than or equal to 7 degrees toward the side where the light-emitting element 20 is arranged with respect to the plane perpendicular to the mounting surface. The closer the inclination is to being perpendicular, the more the degree to which the light passing through the inner surface 55 advances upward can be suppressed, and the size of the light-emitting device 1 in the vertical direction can be suppressed. Also, an effect of reducing the aberration of the light passing through the inner surface 55 can be expected.

[0102] The light emitted from the light-emitting element 20 and passing through the first inner surface 551 is emitted from the first outer surface 56. The first outer surface 56 is located at the outermost edge of the cap with respect to the traveling direction in which the light traveling along the optical axis emitted from the light-emitting element 20 is emitted from the first outer surface 56.

[0103] In the light-emitting device 1, the second inner surface 552 inclines at an angle greater than 5 degrees and less than or equal to 30 degrees toward the side where the light-emitting element 20 is arranged with respect to the plane perpendicular to the mounting surface. Further, the second inner surface 552 preferably inclines at an angle greater than 5 degrees and less than or equal to 25 degrees toward the side where the light-emitting element 20 is arranged with respect to the plane perpendicular to the mounting surface. Further, the second inner surface X preferably inclines at an angle greater than 5 degrees and less than or equal to 20 degrees toward the side where the light-emitting element 20 is arranged with respect to the plane perpendicular to the mounting surface. The smaller the inclination, the less likely it is to come into contact with other components arranged in the closed space, and the easier it is to manufacture the small light-emitting device 1.

[0104] In the light-emitting device 1, among the inner surfaces 55 each of the plurality of side portions 54 has, the first inner surface 551 has the smallest inclination with respect to a plane perpendicular to the mounting surface. Among the plurality of side portions 54, the inner surfaces 55 of all the side portions 54 except the first side portion 54 are inclined at an angle exceeding 5 degrees and equal to or less than 30 degrees toward the side where the light-emitting element 20 is arranged with respect to the plane perpendicular to the mounting surface.

[0105] (Modification example of the light-emitting device 1) The light-emitting device 1 may also employ the cap 50 of the modification example described in the first embodiment. FIG. 17 is a perspective view of the light-emitting device 1 including the cap 50 of the modification example. The state where the cap 50 of the modification example is removed is the same as that in FIG. 15. As shown in FIG. 17, when the cap 50 of the modification example is employed, the side surface 56 and the upper surface 52 intersect.

[0106] As described above, although each embodiment according to the present invention has been described, the cap and the light-emitting device according to the present invention are not strictly limited to the caps and the light-emitting devices of the respective embodiments. That is, the present invention can be realized without being limited to the outer shapes and structures of the caps and the light-emitting devices disclosed by the respective embodiments. The present invention can be applied without necessarily requiring all the components to be provided in sufficient amounts. For example, when a part of the components of the cap or the light-emitting device disclosed by the embodiment is not described in the claims, regarding that part of the components, the freedom of design by those skilled in the art such as substitution, omission, deformation of the shape, and change of the material is recognized, and it is specified that the invention described in the claims is applied thereon.

Industrial Applicability

[0107] The light-emitting devices described in each embodiment can be used for head-mounted devices, head-mounted displays, projectors, in-vehicle headlights, lighting, displays, and the like.

Explanation of Reference Numerals

[0108] 1 Light-emitting device 10 Substrate 11 Upper surface 12 Lower surface 13 First mounting area 14 Wiring pattern 15 Second mounting area 16 Metal film 20 Light-emitting element 30 Submount 40 Protective element 50 Cap 51 Upper part 52 Upper surface 53 Lower surface 54 Side part 55 Inner surface 551 First inner surface 552 Second inner surface 56 Outer surface (first outer surface) 57 Outer surface (second outer surface) 58 Lower surface 60 Base material 61 Lower part 62 Upper surface 63 Convex part 64 Upper surface 65 Side surface 651 First side surface 652 Second side surface 66 Side surface 663 Third side surface 664 Fourth side surface 67 Side surface 68 Groove 70 Anti-reflection film 80 Metal film

Claims

1. A cap having a recess formed therein, The insulating layer has a plurality of side portions including two opposing inner surfaces, a first inner surface and a second inner surface, and two opposing inner surfaces, a third inner surface and a fourth inner surface; the first inner side surface, the second inner side surface, the third inner side surface, and the fourth inner side surface are each inclined in a direction that widens the recess, The first inner surface, the second inner surface, the third inner surface, and the fourth inner surface define a rectangular outer edge in a top view, Of the outer edges of the rectangle, a side of the outer edge defined by the first inner side surface and the second inner side surface is a long side, and a side of the outer edge defined by the third inner side surface and the fourth inner side surface is a short side, The second inner side surface is inclined at a larger angle than the first inner side surface, and the second inner side surface has a larger recess than the first inner side surface.

2. The cap according to claim 1 , wherein among the first inner side surface, the second inner side surface, the third inner side surface, and the fourth inner side surface, the first inner side surface has the smallest inclination and widens the recess the least.

3. the first inner surface is inclined at an angle greater than 0 degrees and less than 15 degrees; The cap according to claim 1 or 2, wherein the second inner surface is inclined at an angle greater than 5 degrees and less than or equal to 30 degrees.

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