Manufacturing method of translucent member and manufacturing method of light emission device

Abstract

To provide a method of manufacturing a translucent member with high accuracy and a light emission device using the translucent member.SOLUTION: A manufacturing method of a translucent member 10 includes the steps of: removing a part of a tabular member from a first surface side by using a first blade having a first blade thickness to form two first grooves extending along a first direction in top view and being parallel to each other and to form a first portion sandwiched by the two first grooves and having a first width, a second portion sandwiching the first portion, and a third portion connecting the first portion and the second portion and being thinner than the first portion and the second portion; removing a part of the first portion from the first surface side by using a second blade having a second blade thickness larger than the first width to make the first portion thinner; and separating the third portion and the first portion by using a third blade having a third blade thickness smaller than the second blade at a position separated from the second portion.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to a method for manufacturing a light-transmitting member and a method for manufacturing a light-emitting device. [Background technology]

[0002] BACKGROUND ART Light emitting devices (LEDs) in which a light-transmitting member is used on a light emitting element are known (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2019-96675 Summary of the Invention [Problem to be solved by the invention]

[0004] An object of the present disclosure is to provide a manufacturing method for forming a light-transmitting member with high precision, and a manufacturing method for a light-emitting device using the light-transmitting member. [Means for solving the problem]

[0005] The present disclosure includes the following configurations. providing a plate-like member having a first surface and a second surface opposite the first surface; a step of removing a portion of the plate-like member from the first surface side using a first blade having a first blade thickness to form two first grooves extending along a first direction in a top view and parallel to each other, thereby forming a first portion sandwiched between the two first grooves and having a first width, a second portion sandwiching the first portion, and a third portion connecting the first portion and the second portion and having a thickness thinner than the first portion and the second portion; a step of thinning the thickness of the first portion by removing a part of the first portion from the first surface side using a second blade having a second blade thickness greater than the first width; separating the third portion and the first portion using a third blade having a third blade thickness smaller than that of the second blade at a position spaced apart from the second portion; A method for manufacturing a light-transmitting member comprising: [Effects of the Invention]

[0006] As described above, it is possible to provide a method for manufacturing a light-transmitting member with high precision and a light-emitting device using the light-transmitting member. [Brief explanation of the drawings]

[0007] [Figure 1] FIG. 2 is a schematic perspective view showing an example of a light-transmitting member obtained by a method for manufacturing a light-transmitting member according to an embodiment. [Figure 2] 5A to 5C are schematic cross-sectional views illustrating a method for manufacturing a light-transmitting member according to an embodiment. [Figure 3] 5A to 5C are schematic cross-sectional views illustrating a method for manufacturing a light-transmitting member according to an embodiment. [Figure 4A] 5A to 5C are schematic cross-sectional views illustrating a method for manufacturing a light-transmitting member according to an embodiment. [Figure 4B] 5A to 5C are schematic top views illustrating a method for manufacturing a light-transmitting member according to an embodiment. [Figure 5] 5A to 5C are schematic cross-sectional views illustrating a method for manufacturing a light-transmitting member according to an embodiment. [Figure 6] 5A to 5C are schematic cross-sectional views illustrating a method for manufacturing a light-transmitting member according to an embodiment. [Figure 7] 5A to 5C are schematic cross-sectional views illustrating a method for manufacturing a light-transmitting member according to an embodiment. [Figure 8] 5A to 5C are schematic cross-sectional views illustrating a method for manufacturing a light-transmitting member according to an embodiment. [Figure 9] 1 is a schematic perspective view showing an example of a light-emitting device obtained by a method for manufacturing a light-transmitting member according to an embodiment. [Figure 10A] 4 is a schematic cross-sectional view showing a second blade used in the method for manufacturing a light-transmitting member according to the embodiment. FIG. [Figure 10B] 4 is a schematic cross-sectional view showing a second blade used in the method for manufacturing a light-transmitting member according to the embodiment. FIG. [Figure 10C] 4 is a schematic cross-sectional view showing a second blade used in the method for manufacturing a light-transmitting member according to the embodiment. FIG. [Figure 11A] 3 is a schematic cross-sectional view showing a first blade and a second blade used in the method for manufacturing a light-transmitting member according to the embodiment. FIG. [Figure 11B] 3 is a schematic cross-sectional view showing a first blade and a second blade used in the method for manufacturing a light-transmitting member according to the embodiment. FIG. [Figure 11C] 3 is a schematic cross-sectional view showing a first blade and a second blade used in the method for manufacturing a light-transmitting member according to the embodiment. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0008] Hereinafter, embodiments of the present invention will be described with reference to the drawings as appropriate. However, the light-transmitting member and the manufacturing method of the light-emitting device described below are intended to embody the technical concept of the present invention, and unless otherwise specified, the present invention is not limited to the following. Furthermore, the size and positional relationship of the members shown in the drawings may be exaggerated for clarity. Furthermore, the same names may be used for members such as light-transmitting members and covering members before and after curing, or before and after processing.

[0009] FIG. 1 is a schematic perspective view showing an example of a light-transmitting member 10 obtained using the light-transmitting member manufacturing method according to the embodiment. The light-transmitting member 10 has a rectangular parallelepiped base 11 and flanges 12 extending laterally from the side surfaces of the base 11. An upper surface 10A of the light-transmitting member 10 is a member that can form a light extraction surface of a light-emitting device 100, as shown in FIG. 9, for example. Specifically, the upper surface of the base 11 of the light-transmitting member 10 is a surface that serves as a light extraction surface. The lower surface of the light-transmitting member 10 is an incident surface onto which light from the light-emitting element 30 is incident. In the example shown in FIG. 1, the shape of the base 11 of the light-transmitting member 10 when viewed from above is a rectangle with long and short sides. The flanges 12 are located on the two long sides of the base 11, respectively. The lower surfaces of the base 11 and the flanges 12 are flush with each other. The flange 12 may be disposed on the short side of the base 11, or on both the long and short sides of the base 11.

[0010] When the light-transmitting member 10 is used in the light-emitting device 100, its side surfaces are covered with a light-shielding covering member 70. Providing the flange 12 on the light-transmitting member 10 makes it difficult for the light-transmitting member 10 to fall off the covering member 70. The flange 12 is entirely covered by the covering member 70 and is not exposed to the outside. However, because the flange 12 is translucent like the base 11, light from the light-emitting element 30 is guided into the flange 12. When optically designing the light-emitting device 100, such light guidance to the flange 12 is also taken into consideration. Therefore, in order to stabilize the optical characteristics of the light-emitting device 100, it is preferable that not only the base 11 of the light-transmitting member 10 but also the thickness and width of the flange 12 be formed to the desired size with high precision.

[0011] The method for manufacturing a light-transmitting member according to the embodiment includes the following main steps: (1) preparing a plate-like member, (2) using a first blade to form a first portion, a second portion, and a third portion that connects the first and second portions and is thinner than the first and second portions, (3) using the second blade to reduce the thickness of the first portion, and (4) using a third blade to separate the first portion from a portion that includes the second and third portions. The portion that includes the second and third portions obtained in this manner is light-transmitting member 10 shown in FIG. 1.

[0012] A blade is a disk-shaped rotary blade that cuts a workpiece by rotating at high speed around the center of its circular main surface as the rotation axis. The shape of the workpiece depends on the shape of the part that the blade's tip surface (the surface located on the outer periphery of the main surface) contacts. For accurate processing, the blade's tip surface is preferably flat when viewed in a cross section parallel to the rotation axis. However, as the blade is used for a long time, the tip surface wears and becomes curved. Here, Figures 10A to 10C and 11A to 11C illustrate how the shape of the blade tip changes with use. Figures 10A and 11A show the state before use, Figures 10B and 11B show the state after the same amount of use, and Figures 10C and 11C show the state after use for an even longer period of time than Figures 10B and 11B. As shown in FIGS. 10A and 11A, the leading edge surfaces of the first blade B1, second blade B2, and third blade B3 are flat before use. For the second blade B2 shown in FIG. 10B, the distance T21 between the leading edge of the second blade B2 and the main surface is greater than the distances T11 and T31 between the leading edge of the first blade B1 or third blade B3 shown in FIG. 11B. Furthermore, for the second blade B2 shown in FIG. 10CB, the distance T22 between the leading edge of the second blade B2 and the main surface is greater than the distances T12 and T32 between the leading edge of the first blade B1 or third blade B3 shown in FIG. 11C. Ultimately, the leading edge surfaces of each blade become curved, with a radius of curvature equal to half the blade thickness. Thus, blades with larger blade thicknesses tend to exhibit greater changes in the curved surface than blades with smaller blade thicknesses. This means that the shape of the workpiece is less stable. Therefore, a blade with a smaller blade thickness can process with greater precision than a blade with a larger blade thickness. However, a blade with a smaller blade thickness takes longer to process. Therefore, it is preferable to use a blade with a larger blade thickness for a portion where you simply want to reduce the thickness and where the portion does not need to be processed with high precision and will not affect the shape of the light-transmitting member.

[0013] In this embodiment, blades with small blade thicknesses (first blade, third blade) and a blade with a larger blade thickness (second blade) are used. Specifically, the first blade with small blade thickness is used as the blade used to define the thickness of the flange.

[0014] After the first blade forms the flange, a second blade, which is thicker than the first blade, is used to thin the thicker part between the flanges, thereby reducing the reduction in processing speed and enabling the translucent member to be formed efficiently.

[0015] Furthermore, a third blade having a small blade thickness is used to define the width of the flange (extension length from the base to the side).

[0016] As described above, by using blades with different blade thicknesses, it is possible to form a light-transmitting member having a flange with high precision.

[0017] F The method for manufacturing the light-transmitting member will be described with reference to FIGS. 2A to 8. FIG.

[0018] (1) A step of preparing a plate-shaped member First, a plate-shaped member is prepared. As shown in FIG. 2, the plate-shaped member 20 has a first surface 20A and a second surface 20B opposite the first surface 20A. As shown in FIG. 2, directions parallel to the first surface 20A of the plate-shaped member 20 and perpendicular to each other are defined as the X direction and the Y direction. A direction perpendicular to the X direction and the Y direction is defined as the Z direction. In this specification, a plane parallel to the X direction and the Y direction may be referred to as the XY plane. Furthermore, a direction inclined from the X direction in the XY plane at an angle of 0° or more and less than 360° may be referred to as the lateral direction, and the Z direction may be referred to as the vertical direction.

[0019] The first surface 20A and the second surface 20B are each a substantially flat surface and are parallel to each other. The plate-shaped member 20 may have a thickness of, for example, 0.1 mm to 0.5 mm. The light-transmitting member 10 obtained by processing the plate-shaped member 20 is a portion that becomes the light extraction portion of the light-emitting device 100 as shown in FIG. 9, and therefore may be any member that is translucent to the light emitted from the light-emitting element 30. The light transmittance of the plate-shaped member 20 at the emission peak wavelength of the light-emitting element 30 is preferably 60% or more, more preferably 70% or more, and even more preferably 80% or more. The plate-shaped member 20 may be made of glass, ceramic, resin, or the like.

[0020] The plate-shaped member 20 may contain a wavelength conversion substance such as a phosphor in the above-mentioned light-transmitting material. The wavelength conversion substance is a material that can absorb at least a part of the light emitted by the light-emitting element and convert it into light of a different wavelength. Examples of phosphors that can be used include yttrium-aluminum-garnet phosphors, lutetium-aluminum-garnet phosphors, terbium-aluminum-garnet phosphors, CCA phosphors, SAE phosphors, chlorosilicate phosphors, silicate phosphors, oxynitride phosphors such as β-sialon phosphors and α-sialon phosphors, nitride phosphors such as LSN phosphors, BSESN phosphors, SLA phosphors, CASN phosphors and SCASN phosphors, fluoride phosphors such as KSF phosphors, KSAF phosphors and MGF phosphors, quantum dots having a perovskite structure, II-VI group quantum dots, III-V group quantum dots, and quantum dots having a chalcopyrite structure. The plate-shaped member 20 may further contain silicon oxide, aluminum oxide, zirconium oxide, zinc oxide, or the like as an additive.

[0021] Next, as shown in FIG. 3, the first blade B1 is moved along the first direction (X direction) to remove a portion of the plate-like member 20 from the first surface 20A side. The diameter of the first blade B1 can be, for example, 50 cm to 60 cm. The thickness of the first blade B1 (first blade thickness BW1) can be, for example, 0.1 mm to 0.2 mm. That is, the first blade B1 can be used until the radius of curvature of the tip surface finally becomes 0.05 mm to 0.1 mm. The first blade B1 can be moved along the first direction (X direction) at a moving speed of 3 mm / s to 20 mm / s while rotating at a rotation speed of, for example, 10,000 rpm to 30,000 rpm. Furthermore, when the first blade B1 is used to process a portion requiring high processing accuracy, it needs to be replaced before the degree of wear on the tip surface becomes too great. In contrast, when the first blade B1 is used to process a portion requiring less processing accuracy, as in the present embodiment, it can be used for a long time until the entire tip surface becomes curved, as described above. This reduces the time required to replace the blades and the number of blades used.

[0022] By removing a portion of the plate-shaped member 20, a first groove G1 is formed as shown in Figures 4A and 4B. The width (first width GW1) of the first groove G1 is approximately the same as the first blade thickness BW1 of the first blade B1, and may be, for example, 0.1 mm to 0.2 mm. The depth of the first groove G1 may be 30% to 70% of the thickness of the plate-shaped member 20. The depth of the first groove G1 may be, for example, 0.03 mm to 0.35 mm.

[0023] At least two first grooves G1 are formed, each extending along the first direction (X direction). That is, the multiple first grooves G1 are parallel to one another. After the multiple first grooves G1 are formed, the plate-like member 20 has a first portion 21, a second portion 22, and a third portion 23 connecting these.

[0024] The first portion 21 is a portion sandwiched between two first grooves G1 in the second direction (Y direction) and will be removed later. In other words, the first portion 21 is not a component that constitutes the light emitting device 100. The width of the first portion 21 in the Y direction (first width 21W) can be set to, for example, 0.5 mm to 1.5 mm.

[0025] The second portion 22 is a portion that will later become a part of the light-transmitting member 10. More specifically, the second portion 22 is a portion that will become the base 11 of the light-transmitting member 10. The second portion 22 is spaced apart from the first portion 21. When a plurality of first grooves G1 are formed, the second portion 22 will also be sandwiched between the first grooves G1, and it is the second portion 22 that will later become a light-transmitting member that will form a part of the light-emitting device.

[0026] The third portion 23 is located between the first portion 21 and the second portion 22. The third portion 23 includes a portion that will later become a part of the light-transmitting member 10. More specifically, the third portion 23 includes a portion that will become the flange portion 12 of the light-transmitting member 10. The third portion 23 is thinner than the first portion 21 and the second portion 22. The thickness of the third portion 23 can be, for example, 30% to 70% of the thickness of the first portion 21 or the second portion 22. For example, the thickness of the third portion 23 can be 0.03 mm to 0.35 mm.

[0027] The portion where the side surface of the second portion 22 meets the upper surface of the third portion 23 forms a curved surface in a cross-sectional view. The radius of curvature of the curved surface between the side surface of the second portion 22 and the upper surface of the third portion 23 may be 0.05 mm to 0.1 mm. This curved surface is due to the shape of the tip portion of the first blade B1, and is formed with relatively high precision.

[0028] 5, a second blade B2 having a second blade thickness BW2 larger than the width (first width 21W) of the first portion 21 is moved along the first direction (X direction) to remove a part of the first portion 21 from the first surface 20A side. Specifically, the first portion 21 is removed until the thickness of the first portion 21 becomes approximately the same as the thickness of the third portion 23.

[0029] The second blade B2 has a second blade thickness BW2 that is greater than the distance between the two first grooves G1. The second blade B2 has a second blade thickness BW2 that is smaller than the distance between the second portions 22. The diameter of the second blade B2 can be, for example, 60 cm to 70 cm. The thickness of the second blade B2 (second blade thickness BW2) can be, for example, 0.5 mm to 1.5 mm. That is, the second blade B2 can be used until the radius of curvature of the tip surface finally reaches 0.25 mm to 0.75 mm. The second blade B2 can be moved along the first direction (X direction) at a moving speed of 3 mm / s to 10 mm / s while being rotated at a rotation speed of 10,000 rpm to 30,000 rpm.

[0030] The second blade B2 removes the first portions 21 sandwiched between the first grooves G1, that is, removes the first portions 21 to a depth similar to that of the first grooves G1, thereby forming a single second groove G2 that includes the portion that was originally the first groove G1, as shown in FIG. 6. The second width GW2 of the second groove G2 is the distance between adjacent second portions 22. The second groove G2 is defined by the side surfaces of the second portions 22, the top surfaces of the third portions 23, and the top surface of the thinned first portions 21. The top surfaces of the thinned first portions 21 and the top surfaces of the third portions 23 are collectively referred to as the bottom surface that defines the second groove G2.

[0031] The bottom surface defining the second groove G2 is made up of a portion formed by the first blade B1 and a portion formed by the second blade B2. That is, the central portion of the bottom surface is the portion formed by the second blade B2 (first portion 21), which is a gently curved surface as shown in Fig. 6. On both sides of the curved surface are portions formed by the first blade B1 (third portions 23), which are approximately flat surfaces as shown in Fig. 6.

[0032] 7, a third blade B3 having a third blade thickness BW3 smaller than that of the second blade B2 is moved in the first direction (X direction) at a position away from the second portion 22 to remove the portion extending from the bottom surface defining the second groove G2 to the second surface 20B. This separates the thinned first portion 21 from a portion including the second portion 22 and the third portion 23. The portion including the second portion 22 and the third portion 23 is the light-transmitting member 10.

[0033] The diameter of the third blade B3 can be, for example, 50 cm to 60 cm. The thickness of the third blade B3 (third blade thickness BW3) can be, for example, 0.1 mm to 0.2 mm. That is, the third blade B3 can be used until the radius of curvature of the tip surface finally becomes 0.05 mm to 0.1 mm. The third blade B3 can be moved along the first direction (X direction) at a moving speed of 3 mm / s to 20 mm / s while being rotated at a rotation speed of 10,000 rpm to 30,000 rpm, for example.

[0034] The portion removed by the third blade B3 is either the first portion 21 alone, a portion including the first portion 21 and the third portion 23, or the third portion 23 alone. In either case, the portion where the second portion 22 and the third portion 23 are continuous and formed with relatively high precision is left. Furthermore, by using the third blade B3 with a relatively small blade thickness BW3 to remove the first portion 21 and the third portion 23 whose thickness has been reduced, misalignment of the removed portion can be reduced. Therefore, variation in the width of the third portion 23 can be reduced. Furthermore, the portion removed by the third blade B3 is the first portion 21 and the third portion 23 after their thickness has been reduced. Therefore, even a third blade B3 with a small blade thickness can be removed in a short time.

[0035] Using the light-transmitting member 10 obtained as described above, a light-emitting device 100 as shown in Fig. 9 can be obtained. The method for manufacturing a light-emitting device mainly comprises the following steps: (1) preparing a substrate; (2) arranging light-emitting elements on the substrate; (3) arranging a light-transmitting member on the light-emitting elements; and (4) arranging a covering member on the substrate so as to cover the side surfaces of the light-emitting elements and the side surfaces of the light-transmitting member. When multiple light-emitting elements 30 are arranged on one substrate, the method can further comprise the step of cutting the substrate 50 and the covering member 70 so as to include the required light-emitting elements 30.

[0036] The substrate 50 may be made of a ceramic base material such as aluminum nitride or silicon nitride, with copper or other metal wiring. The light-emitting element 30 may be made of a gallium nitride-based semiconductor or other light-emitting element. The light-emitting element 30 may emit light ranging from ultraviolet to blue light. The light-emitting element and wiring are joined together with a conductive material such as solder. The light-transmitting member 10 and the light-emitting element 30 are joined together with a light-transmitting adhesive such as silicone resin. The covering member 70 may be formed by, for example, potting, printing, or other methods of disposing a resin material containing a white pigment such as titanium oxide in silicone resin, and then heating and curing the material. Alternatively, the covering member 70 may be formed by, for example, potting, printing, or other methods of disposing an inorganic material containing boron nitride or alkali metal silicate, and then heating and curing the material.

[0037] The light emitting device 100 obtained as described above uses the light-transmitting member 10 formed with high precision, and therefore, variations in light emission characteristics can be reduced.

[0038] For example, aspects of the present invention are as follows.

[0039] (Appendix 1) providing a plate-like member having a first surface and a second surface opposite the first surface; a step of removing a portion of the plate-like member from the first surface side using a first blade having a first blade thickness to form two first grooves extending along a first direction in a top view and parallel to each other, thereby forming a first portion sandwiched between the two first grooves and having a first width, a second portion sandwiching the first portion, and a third portion connecting the first portion and the second portion and having a thickness thinner than the first portion and the second portion; a step of thinning the thickness of the first portion by removing a part of the first portion from the first surface side using a second blade having a second blade thickness greater than the first width; separating the third portion and the first portion using a third blade having a third blade thickness smaller than that of the second blade at a position spaced apart from the second portion; A method for manufacturing a light-transmitting member comprising: (Appendix 2) 2. The method for manufacturing a light-transmitting member according to claim 1, wherein the first blade has a blade thickness of 0.1 mm to 0.2 mm. (Appendix 3) 3. The method for manufacturing a light-transmitting member according to claim 1 or 2, wherein the second blade has a blade thickness of 0.5 mm to 1.5 mm. (Appendix 4) A method for manufacturing a light-emitting device including the light-transmitting member according to any one of Supplementary Note 1 to Supplementary Note 3, providing a substrate; disposing a light-emitting element on the substrate; disposing the light-transmitting member on the light-emitting element; a step of disposing a covering member on the substrate so as to cover a side surface of the light-emitting element and a side surface of the light-transmitting member; A method for manufacturing a light emitting device comprising: [Explanation of symbols]

[0040] 10…Translucent member (10A…top surface, 10B…bottom surface) 11...base, 12...flange 20... Plate-shaped member (20A... First surface, 20B... Second surface) 21...1st part (21W...1st width) 22…Second part 23...Third part 100...Light emitting device 30...Light emitting element 40... Joint member 50...Substrate 70...Covering material B1...First blade (BW1...First blade thickness) B2...2nd blade (BW2...2nd blade thickness) B3...Third blade (BW3...Third blade thickness) G1…1st groove (GW1…1st groove width) G2…Second groove (GW2…Second groove width)

Claims

1. providing a plate-like member having a first surface and a second surface opposite the first surface; a step of removing a portion of the plate-like member from the first surface side using a first blade having a first blade thickness to form two first grooves extending along a first direction in a top view and parallel to each other, thereby forming a first portion sandwiched between the two first grooves and having a first width, a second portion sandwiching the first portion, and a third portion connecting the first portion and the second portion and having a thickness thinner than the first portion and the second portion; a step of thinning the thickness of the first portion by removing a part of the first portion from the first surface side using a second blade having a second blade thickness greater than the first width; separating the third portion and the first portion using a third blade having a third blade thickness smaller than that of the second blade at a position spaced apart from the second portion; A method for manufacturing a light-transmitting member comprising:

2. 2. The method for manufacturing a light-transmitting member according to claim 1, wherein the first blade has a blade thickness of 0.1 mm to 0.2 mm.

3. 2. The method for manufacturing a light-transmitting member according to claim 1, wherein the second blade has a blade thickness of 0.5 mm to 1.5 mm.

4. A method for manufacturing a light-emitting device including a light-transmitting member obtained by the method for manufacturing a light-transmitting member according to any one of claims 1 to 3, comprising: providing a substrate; disposing a light-emitting element on the substrate; disposing the light-transmitting member on the light-emitting element; a step of disposing a covering member on the substrate so as to cover a side surface of the light-emitting element and a side surface of the light-transmitting member; A method for manufacturing a light emitting device comprising:

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