Circuit board, light emitting device, and manufacturing method thereof

Abstract

To provide a method for manufacturing a circuit board having high dimensional accuracy and a method for manufacturing a light emitting device, and a circuit board and a light emitting device.SOLUTION: A method for manufacturing a circuit board 100 includes the steps of: preparing a first substrate 10 comprising a convex post portion 11 formed on a top surface side of the first substrate, and a second substrate 20a having a first surface and a second surface opposite to the first surface, comprising a first metal layer 22 formed on at least the first surface, and having an opening 25 through which a top surface of the post portion 11 is exposed in a plan view; bonding at least a portion of a top surface of the first substrate 10 excluding the post portion 11 and the second surface of the second substrate 20a such that the top surface of the post portion 11 is exposed through the opening 25; and forming a circuit pattern 222 by removing a portion of the first metal layer 22. In the step of forming the circuit pattern 222, the portion of the first metal layer 22 is removed such that another portion of the first metal layer 22 surrounds a periphery of the post portion 11 in a plan view.SELECTED DRAWING: Figure 1B

Description

[Technical field]

[0001] The present disclosure relates to a circuit board and a light emitting device, and to a method for manufacturing the same. [Background technology]

[0002] For example, Patent Document 1 discloses a method for laminating a wiring board having a copper foil layer formed on the surface of an insulating part onto a copper plate member having a convex metal post part to produce a laminated board. In manufacturing such a laminated board, a method is used in which a copper plate having a post part formed thereon and a wiring board having a copper foil circuit pattern formed thereon are bonded together to produce a circuit board. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2017-73513 A Summary of the Invention [Problem to be solved by the invention]

[0004] An object of the present disclosure is to provide a method for manufacturing a circuit board and a light emitting device with high dimensional accuracy, as well as a circuit board and a light emitting device. [Means for solving the problem]

[0005] A method for manufacturing a circuit board according to an embodiment of the present disclosure includes the steps of: preparing a first substrate having a convex post portion formed on its upper surface; and a second substrate having a first surface and a second surface opposite the first surface, a first metal layer formed on at least the first surface, and an opening exposing an upper surface of the post portion in a planar view; bonding at least a portion of the upper surface of the first substrate excluding the post portion to the second surface of the second substrate so that the upper surface of the post portion is exposed from the opening; and removing a portion of the first metal layer to form a circuit pattern, wherein in the step of forming the circuit pattern, a portion of the first metal layer is removed such that another portion of the first metal layer surrounds the post portion in a planar view.

[0006] A method for manufacturing a light emitting device according to an embodiment of the present disclosure includes a step of manufacturing a circuit board by the circuit board manufacturing method, and a step of placing a light emitting component on the post portion of the circuit board.

[0007] A circuit board according to an embodiment of the present disclosure comprises a first substrate having a convex post portion formed on its upper surface, and a second substrate having a first surface and a second surface opposite the first surface, a first metal layer formed on at least the first surface, and arranged so that at least a portion of the upper surface of the first substrate excluding the post portion faces the second surface, wherein the second substrate has an opening exposing an upper surface of the post portion in a planar view, and the second substrate has the first metal layer in direct contact with the periphery of the post portion or arranged in a ring shape at a predetermined distance from the post portion, and a circuit pattern made of the same material as the first metal layer.

[0008] A light emitting device according to an embodiment of the present disclosure includes the circuit board and a light emitting component mounted on the post portion of the circuit board. Effect of the Invention

[0009] According to the embodiments of the present disclosure, it is possible to provide a method for manufacturing a circuit board with high dimensional accuracy, a method for manufacturing a light emitting device, and a circuit board and a light emitting device. [Brief description of the drawings]

[0010] [Figure 1A] FIG. 2 is a plan view illustrating an example of a circuit board according to an embodiment. [Figure 1B] FIG. 1B is a schematic cross-sectional view taken along line IB-IB in FIG. 1A. [Figure 2A] FIG. 1 is a plan view illustrating an example of a light emitting device according to an embodiment. [Figure 2B] FIG. 2B is a schematic cross-sectional view taken along line IIB-IIB in FIG. 2A. [Diagram 3] 4 is a flowchart showing a method for manufacturing a circuit board according to the embodiment. [Figure 4A] 4 is a plan view showing a schematic diagram of a first substrate on which post portions are formed in the method for manufacturing a circuit board according to the embodiment. FIG. [Figure 4B] 4B is a schematic cross-sectional view taken along line IVB-IVB in FIG. 4A. [Figure 5A] 5 is a plan view showing a schematic diagram of a second substrate in which an opening is formed, in the method for manufacturing a circuit board according to the embodiment. FIG. [Figure 5B] 5B is a schematic cross-sectional view taken along line VB-VB in FIG. 5A. [Figure 6A] 3 is a plan view showing a schematic state in which a first substrate and a second substrate are bonded together in the method for manufacturing a circuit board according to the embodiment. FIG. [Figure 6B] FIG. 6B is a schematic cross-sectional view taken along line VIB-VIB in FIG. 6A. [Figure 7A] 1 is a plan view showing a schematic state in which a dry film is provided in a method for manufacturing a circuit board according to an embodiment of the present invention. FIG. [Figure 7B] FIG. 7B is a schematic cross-sectional view taken along line VIIB-VIIB in FIG. 7A. [Figure 8A] 1 is a plan view showing a schematic state in which a part of a dry film is exposed in a method for manufacturing a circuit board according to an embodiment. FIG. [Figure 8B] 8B is a schematic cross-sectional view taken along line VIIIB-VIIIB in FIG. 8A. [Figure 9A]10 is a plan view showing a state in which the dry film has been removed from areas other than those exposed to light in the method for manufacturing a circuit board according to the embodiment. FIG. [Figure 9B] 9B is a schematic cross-sectional view taken along line IXB-IXB in FIG. 9A. [Figure 10A] 4 is a plan view showing a schematic state in which a part of the first metal layer has been removed in the method for manufacturing a circuit board according to the embodiment. FIG. [Figure 10B] 10B is a schematic cross-sectional view taken along line XB-XB in FIG. 10A. [Figure 11A] 10 is a plan view showing a state in which the dry film has been removed from the exposed portion in the method for manufacturing a circuit board according to the embodiment; FIG. [Figure 11B] 11B is a schematic cross-sectional view taken along line XIB-XIB in FIG. 11A. [Figure 12A] 4 is a cross-sectional view showing a schematic state in which a part of the dry film is exposed to light in the method for manufacturing a circuit board according to the embodiment. FIG. [Figure 12B] 10 is a cross-sectional view showing a schematic state in which the dry film has been removed from the exposed portion in the method for manufacturing a circuit board according to the embodiment. FIG. [Figure 12C] 5 is a cross-sectional view that typically shows a state in which a portion of the first metal layer has been removed in the method for manufacturing a circuit board according to the embodiment. FIG. [Figure 13] 4 is a flowchart showing a method for manufacturing a light emitting device according to an embodiment. [Figure 14A] 4 is a plan view showing a state in which a resist and a plating layer are formed in the manufacturing method of the light emitting device according to the embodiment. FIG. [Figure 14B] 14B is a schematic cross-sectional view taken along line XIVB-XIVB in FIG. 14A. [Figure 15A] 4 is a plan view showing a state in which a light emitting component is placed on a circuit board in a manufacturing method for a light emitting device according to an embodiment; FIG. [Figure 15B] 15B is a schematic cross-sectional view taken along line XVB-XVB in FIG. 15A. [Figure 16A] 1 is a cross-sectional view showing a schematic example of a light emitting device according to Modification 1. FIG. [Figure 16B]11 is a cross-sectional view illustrating an example of a light emitting device according to Modification 2. FIG. [Figure 17A] FIG. 13 is a perspective view showing a schematic example of a light emitting device according to an application example. [Figure 17B] FIG. 11 is a plan view showing a schematic example of a configuration of a wiring substrate of a light emitting device according to an application example. [Figure 17C] 17C is a schematic cross-sectional view taken along line XVIIC-XVIIC in FIG. 17B. [Figure 18A] FIG. 2 is an exploded perspective view showing a schematic example of the configuration of a light emitting component. [Figure 18B] FIG. 2 is a plan view illustrating a schematic configuration inside a package of a light emitting component. [Figure 18C] 18C is a schematic cross-sectional view taken along line XVIIIC-XVIIIC in FIG. 18B. [Figure 18D] 4 is a bottom view showing a schematic configuration of the lower surface of the light emitting component. FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] <<Embodiment>> The embodiments will be described below with reference to the drawings. However, the embodiments shown below are merely examples of a circuit board and a light emitting device for realizing the technical idea of ​​the present embodiment, and a manufacturing method thereof, and are not limited to the following. Furthermore, unless otherwise specified, the dimensions, materials, shapes, and relative positions of the components described in the embodiments are merely examples and are not intended to limit the scope of the present invention. Note that the sizes and positional relationships of the components shown in each drawing may be exaggerated or simplified to clarify the explanation.

[0012] [Circuit board] Fig. 1A is a plan view showing an example of a circuit board according to an embodiment, and Fig. 1B is a schematic cross-sectional view taken along line IB-IB in Fig. 1A.

[0013] The circuit board 100 includes a first substrate 10 having a convex post portion 11 formed on its upper surface, and a second substrate 20 having a first surface and a second surface opposite to the first surface, a first metal layer 221 formed on at least the first surface, and arranged so that at least a portion of the upper surface of the first substrate 10 excluding the post portion 11 faces the second surface. The second substrate 20 has an opening 25 that exposes the upper surface of the post portion 11 in a plan view. The second substrate 20 also has a first metal layer 221 that is in direct contact with the periphery of the post portion 11 or that is arranged in a ring shape at a predetermined distance from the post portion 11, and a circuit pattern 222 made of the same material as the first metal layer 221.

[0014] The first substrate 10 has a flat plate portion 12 and a convex post portion 11 protruding from the flat plate portion 12. The flat plate portion 12 and the post portion 11 are integrally formed. The side surfaces of the post portion 11 are curved inwardly convex on the side surfaces facing each other in a cross-sectional view. However, the side surfaces of the post portion 11 may be curved inwardly convex on the side surfaces facing each other, or may be linear. The post portion 11 is formed by etching or pressing the substrate. The thickness T of the flat plate portion 12 is preferably 1 mm or more and 2 mm or less. If the thickness T of the flat plate portion 12 is 1 mm or more, the strength of the first substrate 10 can be improved. On the other hand, if the thickness T is 2 mm or less, the first substrate 10 can be made thinner. If a slight difference in thickness occurs depending on the part of the flat plate portion 12 when the post portion 11 is formed, the thickness T here can be the average thickness of the flat plate portion 12. The post portion 11 is formed in a rectangular shape in a plan view, but may be a polygonal shape such as a square or a trapezoid, a circle, an ellipse, or another shape. In addition, the corners of the post portion 11 are formed at right angles, but may be rounded.

[0015] It is preferable that the height from the upper surface of the first substrate 10 excluding the post portion 11, that is, the upper surface of the flat portion 12, to the upper surface of the post portion 11 is 50 μm or more and 150 μm or less. That is, it is preferable that the height H of the post portion 11 is 50 μm or more and 150 μm or less. If the height H of the post portion 11 is 50 μm or more, it becomes easy to adjust the thickness of the second substrate 20 arranged on the first substrate 10. On the other hand, if the height H is 150 μm or less, the first substrate 10 can be made thinner. Note that, if there is a slight difference in thickness depending on the part of the flat portion 12 when the post portion 11 is formed, the height H here can be the average height from the upper surface of the flat portion 12 to the upper surface of the post portion 11.

[0016] The first substrate 10 is preferably a metal plate using a metal material. By making the first substrate 10 a metal plate, it has an excellent heat dissipation function for dissipating heat generated from the light emitting components 50 and the like. As the metal material of the first substrate 10, for example, a single metal such as Cu, Ag, Al, Ni, Rh, Au, Ti, Pt, Pd, Mo, Cr, W, or an alloy containing these metals can be used. In particular, the first substrate 10 is preferably a copper plate using Cu from the viewpoint of heat dissipation and economic efficiency. For example, the first substrate 10 is preferably a material containing 90% by mass or more of copper. More preferably, the material contains 95% by mass or more of copper, and even more preferably, the material contains 99% by mass or more of copper.

[0017] The second substrate 20 has a base material 21, and a first metal layer 221 and a circuit pattern 222 disposed on the base material 21. Here, the second substrate 20 further has a bonding sheet 23 on the lower surface of the base material 21.

[0018] The base material 21 is insulating, and may be, for example, a film-like polyimide. The thickness of the base material 21 is preferably 12 μm or more and 50 μm or less. If the thickness of the base material 21 is 12 μm or more, the strength of the base material 21 can be improved. On the other hand, if the thickness is 50 μm or less, the second substrate 20 can be made thin. Note that the base material 21 may be made of glass epoxy, which is obtained by impregnating one or more sheets of glass cloth with a thermosetting insulating resin such as epoxy resin and curing the thermosetting insulating resin, or liquid crystal polymer. When the base material 21 is glass epoxy, the thickness may be, for example, 50 μm or more and 150 μm or less, preferably 20 μm or more and 130 μm or less, depending on the height of the post portion 11.

[0019] The first metal layer 221 and the circuit pattern 222 can be made of a metal material, and for example, a simple metal such as Cu, Ag, Al, Ni, Rh, Au, Ti, Pt, Pd, Mo, Cr, or W, or an alloy containing these metals, can be suitably used. In particular, the first metal layer 221 and the circuit pattern 222 are preferably made of copper foil using Cu from the viewpoints of electrical conductivity and cost efficiency. For example, the first metal layer 221 and the circuit pattern 222 are preferably made of a material containing 90% or more by mass of copper. More preferably, the material contains 95% or more by mass of copper, and even more preferably, the material contains 99% or more by mass of copper. The bonding sheet 23 is a member that bonds the first substrate 10 and the second substrate 20. Examples of the bonding sheet 23 include a heat-resistant resin sheet, a UV-curable sheet, and other sheets known in the art.

[0020] The thickness of the first metal layer 221 and the circuit pattern 222 is preferably 12 μm or more and 70 μm or less. If the thickness of the first metal layer 221 and the circuit pattern 222 is 12 μm or more, the first metal layer 221 and the circuit pattern 222 are easily formed. On the other hand, if the thickness is 70 μm or less, the second substrate 20 can be made thin. In addition, the first metal layer 221 and the circuit pattern 222 preferably have the same thickness. With this configuration, the first metal layer 221 and the circuit pattern 222 can be easily formed and can be aligned to the same height.

[0021] It is preferable that the upper surface of the post portion 11, the upper surface of the first metal layer 221, and the upper surface of the circuit pattern 222 are flush with each other. With such a configuration, it becomes easier to form the first metal layer 221 and the circuit pattern 222, and it becomes easier to place the light emitting component 50 on the circuit board 100 when manufacturing the light emitting device 200. In addition, "being on the same plane" means that the upper surfaces of the respective members are located in the same plane, and also includes the upper surfaces of the respective members being spaced apart.

[0022] The second substrate 20 has an opening 25 that exposes the post portion 11. The opening 25 is formed to a size that allows the entire post portion 11 to be housed therein. It is preferable that there is a gap 15 between the side surface of the post portion 11 and the inner side surface of the opening 25. By having the gap 15, it becomes easier to insert the post portion 11 into the opening 25. In addition, it is possible to prevent a drug or the like from penetrating from the outside of the first metal layer 221 to the post portion 11 side and coming into contact with the post portion 11, making it easier to protect the post portion 11. Since the circuit board 100 has such a gap 15, the opening of the opening 25 is formed larger than the post portion 11 in a plan view. The plan view shape of the opening 25 may be appropriately determined according to the shape of the post portion 11. In this embodiment, it is formed to be rectangular according to the shape of the post portion 11. It is preferable that the plan view shape of the opening 25 is similar to the shape of the post portion 11. The area of ​​the opening 25 is preferably 1.05 times or more and 2 times or less than the area of ​​the post portion 11, and more preferably 1.1 times or more and 1.8 times or less.

[0023] The first metal layer 221 is disposed in an annular shape so as to surround the periphery of the post portion 11. Here, annular means a shape formed in a frame shape, such as a rectangular annular shape, a square annular shape, or a circular annular shape. The first metal layer 221 is formed in a rectangular annular shape in plan view to match the shape of the post portion 11. The first metal layer 221 only needs to be provided so as to surround the periphery of the post portion 11, and may be in a square annular shape, a circular annular shape, or another annular shape, to match the shape of the post portion 11 or regardless of the shape of the post portion 11.

[0024] By having the first metal layer 221, the circuit board 100 is prevented from infiltrating a drug or the like from the outside of the first metal layer 221 to the post portion 11 side or from infiltrating a foreign object from the outside of the first metal layer 221 to the post portion 11 side when, for example, the light emitting component 50 is placed on the circuit board 100 to manufacture the light emitting device 200. Thus, by having the first metal layer 221, the post portion 11 is protected. Also, as described later, when manufacturing the circuit board 100, the circuit pattern 222 is formed after the first substrate 10 and the second substrate 20a are bonded together, so that the accuracy of the circuit pattern 222 is not deteriorated. Also, when forming the circuit pattern 222, the post portion 11 is protected from a drug or the like by the first metal layer 221. These provide high dimensional accuracy for the circuit board 100. Here, "high dimensional accuracy" means, for example, that the post portions 11 are not damaged, and the accuracy of the circuit pattern 222 is not deteriorated due to misalignment or change in shape of the circuit pattern 222, and that the designed dimensions and processing accuracy are achieved as desired.

[0025] The first metal layer 221 is disposed at a predetermined distance from the post portion 11. The distance D between the upper surface of the post portion 11 and the first metal layer 221 is preferably, for example, 100 μm or more and 300 μm or less. If the distance D is 100 μm or more, the post portion 11 can be easily inserted into the opening 25. In addition, when a drug or the like penetrates from the outside of the first metal layer 221 to the post portion 11 side, the post portion 11 can be more easily protected. On the other hand, if the distance D is 300 μm or less, the gap 15 can be made smaller, so that it is possible to more effectively prevent foreign matter from entering the gap 15. This makes it easier to protect the post portion 11. Note that since the side surface of the post portion 11 is curved, the distance D here is set to the shortest distance between the outer end of the post portion 11 at the portion of the upper surface of the post portion 11 and the inner end of the first metal layer 221 at the portion of the upper surface of the first metal layer 221.

[0026] It is preferable that the first metal layer 221 and the circuit pattern 222 are separated from each other in a plan view. With this configuration, it becomes easier to form the desired circuit pattern 222. It is preferable that the width W of the first metal layer 221 arranged in a ring shape around the post portion 11 is 50 μm or more and 100 μm or less. If the width W of the first metal layer 221 is 50 μm or more, it is possible to better prevent medicines and the like from penetrating from the outside of the first metal layer 221 to the post portion 11 side, and it becomes easier to protect the post portion 11. On the other hand, if the width W is 100 μm or less, it is possible to increase the area in which the circuit pattern 222 is formed, and it becomes easier to form the desired circuit pattern 222.

[0027] The circuit board 100 is arranged so that the entire upper surface of the first board 10 except for the post portions 11, i.e., the entire upper surface of the flat plate portion 12, faces the second surface of the second board 20. However, a portion of the upper surface of the flat plate portion 12 may be arranged to face the second surface of the second board 20. In other words, there may be a portion of the upper surface of the flat plate portion 12 where the second board 20 is not arranged.

[0028] [Light emitting device] Next, the light emitting device will be described. Fig. 2A is a plan view showing an example of a light emitting device according to an embodiment, and Fig. 2B is a schematic cross-sectional view taken along line IIB-IIB in Fig. 2A.

[0029] The light emitting device 200 includes the circuit board 100 and a light emitting component 50 mounted on a post portion 11 of the circuit board 100 . The light emitting device 200 preferably includes at least a circuit board 100 , a resist 30 , a plating layer 40 , and a light emitting component 50 . The circuit board 100 is as described above. The resist 30 is insulating, and is, for example, a solder resist. The resist 30 is provided, for example, on the circuit board 100 in a portion other than the portion where the plating layer 40 is to be formed. As the resist 30, for example, a general resist in which a solvent, a defoaming agent, etc. are mixed with a copolymer resin such as epoxy, or a resist whitened by adding a filler such as titanium oxide can be used.

[0030] The plating layer 40 is provided, for example, on the post portion 11 and on a part of the circuit pattern 222. For example, Au, Ag, Cu, Pt, Ni, Pd, or an alloy containing one of these can be used as the plating layer 40. If the plating layer 40 is made of these materials, the reflectance of the light emitted from the light emitting component 50 to the circuit board 100 can be further increased.

[0031] The light emitting component 50 is placed on and around the post portion 11 of the circuit board 100 via the plating layer 40. The light emitting component 50 is adhered to the circuit board 100 by an adhesive such as solder paste. The light emitting component 50 may be, for example, a light emitting component having a known light emitting element mounted on a substrate, a package, or the like. Examples of the light emitting element include a semiconductor laser element, an LED (Light Emitting Diode), and an organic electroluminescence element. The light emitting component 50 may also be a known light emitting element itself. That is, the light emitting device 200 may be a light emitting device having at least a light emitting component including a light emitting element mounted on the circuit board 100, or a light emitting element directly mounted on the circuit board 100.

[0032] [Circuit board manufacturing method] Next, an example of a method for manufacturing a circuit board according to the embodiment will be described. Fig. 3 is a flowchart showing a method for manufacturing a circuit board according to an embodiment. Fig. 4A to Fig. 12C are drawings showing a method for manufacturing a circuit board according to an embodiment. Fig. 4A is a plan view showing a first substrate on which post portions are formed. Fig. 4B is a schematic cross-sectional view taken along line IVB-IVB in Fig. 4A. Fig. 5A is a plan view showing a second substrate on which openings are formed. Fig. 5B is a schematic cross-sectional view taken along line VB-VB in Fig. 5A. Fig. 6A is a plan view showing a state in which the first substrate and the second substrate are bonded together. Fig. 6B is a schematic cross-sectional view taken along line VIB-VIB in Fig. 6A.

[0033] FIG. 7A is a plan view showing a state where a dry film is provided. FIG. 7B is a schematic cross-sectional view taken along line VIIB-VIIB in FIG. 7A. FIG. 8A is a plan view showing a state where a part of the dry film is exposed to light. FIG. 8B is a schematic cross-sectional view taken along line VIIIB-VIIIB in FIG. 8A. FIG. 9A is a plan view showing a state where the dry film is removed from the portion other than the exposed portion. FIG. 9B is a schematic cross-sectional view taken along line IXB-IXB in FIG. 9A. FIG. 10A is a plan view showing a state where a part of the first metal layer is removed. FIG. 10B is a schematic cross-sectional view taken along line XB-XB in FIG. 10A. FIG. 11A is a plan view showing a state where the dry film is removed from the exposed portion. FIG. 11B is a schematic cross-sectional view taken along line XIB-XIB in FIG. 11A.

[0034] Fig. 12A is a cross-sectional view showing a state where a part of the dry film is exposed to light, Fig. 12B is a cross-sectional view showing a state where the dry film at the exposed portion is removed, and Fig. 12C is a cross-sectional view showing a state where a part of the first metal layer is removed. In the method for manufacturing a circuit board according to the embodiment, a plurality of circuit boards are manufactured at the same time.

[0035] The manufacturing method of the circuit board 100 includes the steps of preparing a first board 10 having a convex post portion 11 formed on its upper surface side, and a second board 20a having a first surface and a second surface opposite to the first surface, a first metal layer 22 formed on at least the first surface, and an opening 25 exposing the upper surface of the post portion 11 in a plan view, a step of bonding at least a part of the upper surface of the first board 10 excluding the post portion 11 to the second surface of the second board 20a so that the upper surface of the post portion 11 is exposed from the opening 25, and a step of removing a part of the first metal layer 22 to form a circuit pattern 222. Then, in the step of forming the circuit pattern 222, a part of the first metal layer 22 is removed so that another part of the first metal layer 22 surrounds the periphery of the post portion 11 in a plan view.

[0036] Specifically, the method for manufacturing the circuit board 100 includes a substrate preparation step S101, a bonding step S102, and a circuit pattern formation step S103. The materials and arrangement of each component are the same as those described above in connection with the circuit board 100, and therefore will not be described here as appropriate.

[0037] The first metal layer 221 surrounding the post portion 11 and the circuit pattern 222 are made of the same material and are formed, for example, by etching one first metal layer 22 provided on the base material 21. The first metal layer 221 surrounding the post portion 11 after etching will hereinafter be referred to as the annular first metal layer 221 as appropriate.

[0038] (Substrate preparation process) The substrate preparation step S101 is a step of preparing a first substrate 10 and a second substrate 20a.

[0039] In this step S101, in preparation of the first substrate 10, for example, first, a copper plate is etched or pressed to form the post portions 11 to manufacture the first substrate 10. In addition, in this step S101, for example, a commercially available single-sided copper-clad laminate having a copper foil as the first metal layer 22 attached to one side of the base material 21 is prepared as the preparation of the second substrate 20a. Next, a bonding sheet 23 is provided on the surface of the base material 21 opposite to the surface on which the first metal layer 22 is provided. Alternatively, for example, a commercially available double-sided copper-clad laminate having copper foil attached to both sides is prepared as the preparation of the second substrate 20a. Next, the copper foil on one side is removed by etching or the like to provide the bonding sheet 23. Note that the first metal layer 22 such as copper foil may be bonded to one side of the base material 21 without using a commercially available single-sided copper-clad laminate or double-sided copper-clad laminate. Next, a hole is drilled at a desired position to form an opening 25. Alternatively, the second substrate 20a may be used in which the base material 21 with the opening 25 and the first metal layer 22 are bonded together.

[0040] (Laminating process) The bonding step S102 is a step of bonding the first substrate 10 and the second substrate 20a together. In this step S102, the bonding sheet 23 of the second substrate 20a is adhered to the first substrate 10 so that the upper surfaces of the post portions 11 of the first substrate 10 are exposed from the openings 25, thereby bonding the first substrate 10 and the second substrate 20a together.

[0041] In the process of bonding the first substrate 10 and the second substrate 20a, it is preferable to bond the first substrate 10 and the second substrate 20a so that the upper surface of the post portion 11 and the upper surface of the first metal layer 22 are flush with each other. To achieve the flush surface, for example, the thickness of the flat plate portion 12 and the height of the post portion 11 of the first substrate 10, the thickness of the base material 21 and the thickness of the first metal layer 22 of the second substrate 20a, and the thickness of the bonding sheet 23 may be adjusted.

[0042] (Circuit pattern formation process) The circuit pattern forming step S103 is a step of forming a ring-shaped first metal layer 221 and a circuit pattern 222 by removing a part of the first metal layer 22 of the second substrate 20a.

[0043] In the process of forming the circuit pattern 222, a negative method preferably includes the steps of providing a dry film 60 on the post portion 11 and the first metal layer 22, exposing the dry film 60 in a planar view from the position of the post portion 11 to the position where it contacts the first metal layer 22 around the post portion 11, and exposing the dry film 60 at the location where the circuit pattern 222 is to be formed, developing the dry film 60 and removing the dry film 62 other than the exposed locations, and etching the locations where part of the dry film 60 has been removed and the first metal layer 22 is exposed, thereby removing part of the first metal layer 22.

[0044] In this case, in this step S103, first, the dry film 60 is provided on the entire upper surface of the laminate obtained by laminating the first substrate 10 and the second substrate 20a. Next, the dry film 60 is exposed using a mask to match the desired shape of the annular first metal layer 221 and the desired shape of the circuit pattern 222. At this time, the dry film 60 is exposed from the position of the post portion 11 to the position where it contacts the first metal layer 22 around the post portion 11 so that when a part of the first metal layer 22 is etched, another part of the first metal layer 22 surrounds the periphery of the post portion 11 in a plan view. Also, the dry film 60 at the portion where the circuit pattern 222 is to be formed is exposed. Here, the "position in contact with the first metal layer 22" refers to the position of the outer end in the width direction of the annular first metal layer 221 when the annular first metal layer 221 surrounding the periphery of the post portion 11 is formed on the upper surface of the first metal layer 22. In other words, the dry film 60 is exposed to a position where the annular first metal layer 221 has a desired width.

[0045] Next, the dry film 60 is developed, and the dry film 62 is removed from areas other than the exposed areas. Next, the first metal layer 22 exposed from the dry film 61 in the exposed areas is removed by etching. Then, the dry film 61 in the exposed areas is removed. In this way, the circuit board 100 is manufactured, on which the desired annular first metal layer 221 and the desired circuit pattern 222 are formed.

[0046] In addition, in the process of forming the circuit pattern 222, a positive type method preferably includes the steps of providing a dry film 60 on the post portion 11 and the first metal layer 22, exposing the dry film 60 in a ring shape surrounding the post portion 11 at a predetermined distance from the post portion 11 in a planar view, and exposing the dry film 60 in the areas where the circuit pattern 222 is not to be formed, developing the dry film 60 and removing the dry film 61 in the exposed areas, and etching the areas where part of the dry film 60 has been removed and the first metal layer 22 is exposed, thereby removing part of the first metal layer 22.

[0047] In this case, in this step S103, first, the dry film 60 is provided on the entire upper surface of the laminate obtained by laminating the first substrate 10 and the second substrate 20a. Next, the dry film 60 is exposed using a mask to match the desired annular shape of the first metal layer 221 and the desired shape of the circuit pattern 222. At this time, the dry film 60 is exposed in an annular shape surrounding the periphery of the post portion 11 at a predetermined distance from the post portion 11 so that when a part of the first metal layer 22 is etched, another part of the first metal layer 22 surrounds the periphery of the post portion 11 in a plan view. In addition, the dry film 60 in a portion where the circuit pattern 222 is not formed is exposed.

[0048] Next, the dry film 60 is developed, and the dry film 61 in the exposed areas is removed. Next, the first metal layer 22 exposed from the dry film 62 in areas other than the exposed areas is removed by etching. Then, the dry film 62 in areas other than the exposed areas is removed. In this way, the circuit board 100 is manufactured, on which the desired annular first metal layer 221 and the desired circuit pattern 222 are formed.

[0049] In the step of removing a portion of the first metal layer 22, it is preferable to remove the portion of the first metal layer 22 so that the width of the first metal layer 221 surrounding the periphery of the post portion 11 is 50 μm or more and 100 μm or less. The width of the first metal layer 221 can be controlled by adjusting the range of the dry film 60 to be exposed. In the method for manufacturing a circuit board according to the embodiment, multiple circuit boards 100 are manufactured simultaneously, but the circuit boards 100 may be separated into individual pieces, or the assembly of circuit boards 100 may be moved to the method for manufacturing a light emitting device 200 described below.

[0050] For example, if a circuit pattern is formed on a substrate before bonding a copper plate and a wiring substrate as in the conventional technology, the substrate is easily deformed during processing, and the accuracy of the circuit pattern may deteriorate due to misalignment or change in shape of the circuit pattern. As a result, the desired dimensions and processing accuracy may not be obtained. In contrast, in the method for manufacturing a circuit substrate according to the embodiment, the circuit pattern 222 is formed after bonding the first substrate 10 and the second substrate 20a. Therefore, since the second substrate 20a is fixed to the first substrate 10, the accuracy of the circuit pattern 222 is not deteriorated when the circuit pattern 222 is formed.

[0051] Furthermore, in the method for manufacturing a circuit board according to the embodiment, a part of the first metal layer 22 is removed such that another part of the first metal layer 22 surrounds the periphery of the post portion 11 in plan view. This forms a ring-shaped first metal layer 221. Therefore, when the circuit pattern 222 is formed, the post portion 11 is protected by the ring-shaped first metal layer 221, and therefore, it is possible to prevent the post portion 11 from being eroded more than necessary by etching or the like. Therefore, the method for manufacturing a circuit board according to the embodiment can manufacture a circuit board 100 with high dimensional accuracy.

[0052] [Manufacturing method of light emitting device] Next, an example of a method for manufacturing the light emitting device according to the embodiment will be described. Fig. 13 is a flow chart showing a method for manufacturing a light emitting device according to an embodiment. Fig. 14A is a plan view showing a state in which a resist and a plating layer are formed in the method for manufacturing a light emitting device according to an embodiment. Fig. 14B is a schematic cross-sectional view taken along line XIVB-XIVB in Fig. 14A. Fig. 15A is a plan view showing a state in which a light emitting component is placed on a circuit board in the method for manufacturing a light emitting device according to an embodiment. Fig. 15B is a schematic cross-sectional view taken along line XVB-XVB in Fig. 15A. In the method for manufacturing the light emitting device according to the embodiment, a plurality of light emitting devices are manufactured at the same time.

[0053] The method for manufacturing a light emitting device includes the steps of manufacturing a circuit board 100 by the above-described method for manufacturing a circuit board, and placing a light emitting component 50 on a post portion 11 of the circuit board 100.

[0054] Specifically, the method for manufacturing a light emitting device includes a circuit board manufacturing process S11, a resist forming process S12, a plating layer forming process S13, and a light emitting component mounting process S14. The materials and arrangement of each member are the same as those described above in connection with the light emitting device 200, and therefore will not be described here as appropriate.

[0055] (Circuit board manufacturing process) The circuit board manufacturing process S11 is a process for manufacturing the circuit board 100 by the above-mentioned circuit board manufacturing method. In this process, the circuit board 100 is manufactured by carrying out the above-mentioned steps S101 to S103.

[0056] (Resist formation process) The resist formation step S12 is a step of forming a resist 30 on the upper surface of the circuit board 100. The resist 30 can be formed by, for example, a screen printing method using a screen mask.

[0057] (Plating layer formation process) The plating layer forming step S13 is a step of forming a plating layer 40 on the upper surface of the circuit board 100. The plating layer 40 can be formed by electroless plating or electrolytic plating.

[0058] (Light emitting component placement process) The light emitting component mounting step S14 is a step of mounting the light emitting component 50 on the circuit board 100. In this step S14, the light emitting component 50 is placed on the post portion 11 of the circuit board 100 and on the surrounding plating layer 40 and resist 30 using an adhesive such as solder paste.

[0059] In this manner, an assembly of the light emitting devices 200 is manufactured. Then, this assembly is separated into individual light emitting devices 200, thereby obtaining a plurality of light emitting devices 200.

[0060] Although the embodiments of the invention have been described above in detail, the gist of the present invention is not limited to these descriptions and should be broadly interpreted based on the claims. In addition, various changes and modifications based on these descriptions are also included in the gist of the present invention. The following describes modified examples and application examples. Note that the materials and arrangements of the components are the same as those described in the embodiment, and therefore will not be described here as appropriate.

[0061] <<Variation>> [Variation 1] FIG. 16A is a cross-sectional view illustrating an example of a light emitting device according to Modification 1. FIG. In the circuit board 100A and the light emitting device 200A, the second substrate 20A has a second metal layer . In the second substrate 20A, a first metal layer 221 and a circuit pattern 222 are provided on a base material 21, and a second metal layer 24 is provided on the opposite side of the first metal layer 221 and the circuit pattern 222 provided on the base material 21. The circuit substrate 100A and the light emitting device 200A can improve heat dissipation by having the second substrate 20A have the second metal layer 24. As the material of the second metal layer 24, for example, those exemplified for the first metal layer 221 and the circuit pattern 222 can be used.

[0062] Furthermore, in the manufacturing method of variant example 1, in the process of preparing the above-mentioned substrate, a first metal layer 22 is provided on a base material 21 of the second substrate 20A, and a second metal layer 24 is provided on the opposite side to the first metal layer 22 provided on the base material 21. The second substrate 20A can be prepared, for example, by using a commercially available double-sided copper-clad laminate. Alternatively, the second metal layer 24 may be bonded to one surface of a commercially available single-sided copper-clad laminate having the first metal layer 22 provided on the other surface. Alternatively, the first metal layer 22 may be provided on one surface of a base material 21, and the second metal layer 24 may be bonded to the other surface of the base material 21, without using a commercially available single-sided copper-clad laminate or double-sided copper-clad laminate.

[0063] [Variation 2] FIG. 16B is a cross-sectional view illustrating an example of a light emitting device according to Modification 2. As shown in FIG. In the circuit board 100B and the light emitting device 200B, the first metal layer 221 is in direct contact with the periphery of the post portion. In the first substrate 10A, the side surface of the post portion 11A is linear, and the post portion 11A is rectangular in cross section. In the first substrate 10A, the base material 21, the first metal layer 221, and the bonding sheet 23 are in direct contact with the side surface of the post portion 11A. With this configuration, the adhesion between the first substrate 10A and the second substrate 20 can be improved.

[0064] In addition, for example, the plating layer may be provided only in a part, or may not be provided at all. The part where the plating layer is not provided may be a part where the first substrate, the annular first metal layer, and the circuit pattern are exposed. Also, as described later, the post part may have a long resist on the upper surface thereof.

[0065] Furthermore, the method for manufacturing a circuit board may include other steps between, before, or after each of the steps, as long as they do not adversely affect the steps. For example, a foreign matter removal step for removing foreign matter that has been mixed in during the manufacturing process may be included. Furthermore, the method for manufacturing a light emitting device may include other steps between, before, or after each of the steps, as long as they do not adversely affect the other steps. For example, the method may include a foreign matter removal step for removing foreign matter that has been mixed in during the manufacturing process.

[0066] <Application Example> Next, an example of an application of the circuit board and the light emitting device using a semiconductor laser element will be described. Note that, as an example of the application, the form of the circuit board and the light emitting device is slightly different from that of the above-mentioned embodiment. In this way, the circuit board and the light emitting device of the embodiment can be applied to various forms.

[0067] FIG. 17A is a perspective view showing an example of a light emitting device according to an application example. FIG. 17B is a plan view showing an example of a configuration of a wiring board of a light emitting device according to an application example. FIG. 17C is a schematic cross-sectional view taken along line XVIIC-XVIIC in FIG. 17B. FIG. 18A is an exploded perspective view showing an example of a configuration of a light emitting component. FIG. 18B is a plan view showing an internal configuration of a package of a light emitting component. FIG. 18C is a schematic cross-sectional view taken along line XVIIIC-XVIIIC in FIG. 18B. FIG. 18D is a bottom view showing an example of a configuration of a lower surface of a light emitting component.

[0068] The light emitting device 200C includes at least a wiring board 110, a light emitting component 50A, and a thermistor 150. The wiring board 110 has at least a resist 30 and a plating layer 40 on the upper surface. The plating layer 40 includes a plating layer 41, plating layers 42a, 42b, plating layers 43a, 43b, plating layers 44a, 44b, and plating layers 45a, 45b. The wiring board 110 also has a first metal layer 221 and a circuit pattern 222 below the resist 30 and the plating layer 40.

[0069] The plating layer 41 is a plating layer in the central region where the light emitting component 50A is placed. The plating layer 42a is a plating layer in the front region where the light emitting component 50A is placed. The plating layer 42b is a plating layer in the rear region where the light emitting component 50A is placed. The plating layers 43a and 43b are plating layers in the region where the thermistor 150 is placed. The plating layers 44a and 44b are plating layers in predetermined regions for thermistor inspection terminals. The plating layers 45a and 45b are plating layers in predetermined regions for laser element inspection terminals.

[0070] The plating layer 41 and the plating layers 42a and 42b are the portions on which the light emitting component 50A is placed. The plating layers 43a and 43b are the portions on which the thermistor 150 is placed. In the plating layer 41, a plurality of elongated resists 30 are arranged extending from the periphery of the rectangle toward the center in a region formed in a rectangular shape in accordance with the outer edge of the first metal layer 221 in a plan view. The plating layer 41 is a portion of the rectangular region where the resists 30 are not arranged. When the light emitting component is placed on the post portion, air bubbles may remain between the post portion and the light emitting component. In the light emitting device 200C, the wiring board 110 has a plurality of elongated resists 30 on the upper surface of the post portion 11, which makes it easier to disperse air bubbles through the elongated resists 30. This further improves the heat dissipation of the wiring board 110.

[0071] The resist 30 is provided on the upper surface of the wiring board 110 excluding the plating layer 40. In a plan view, three plating layers 42a are provided on the front side of the plating layer 41. In a plan view, three plating layers 42b are provided on the rear side of the plating layer 41. The plating layers 42a, 42b, which are provided in pairs on the front and rear sides of the plating layer 41, are electrically connected from one to the other by bonding to a metal film 87 provided on the bottom surface of the light emitting component 50A.

[0072] The plating layer 42a and the plating layer 45a are electrically connected via a circuit pattern 222. The plating layer 42b and the plating layer 45b are electrically connected via a circuit pattern 222. The plating layers 45a, 45b function as a laser element inspection terminal. The plating layer 43a and the plating layer 44a are electrically connected via a circuit pattern 222. The plating layer 43b and the plating layer 44b are electrically connected via a circuit pattern 222. The plating layers 44a, 44b function as a thermistor inspection terminal. The thermistor 150 is an example of a temperature detection element used to measure the temperature when the light emitting device 200C is operating. The thermistor 150 is placed in a state of being connected to the plating layers 43a and 43b, thereby allowing electrical continuity from the plating layer 43a through the thermistor 150 to the plating layer 43b.

[0073] The light emitting component 50A includes a package 71, a semiconductor laser element 72, a submount 73, a light reflecting member 74, a protective element 75, a wire 76, a cover member 77, an adhesive portion 78, and a lens member 79.

[0074] The package 71 has a rectangular recess 80 in a plan view. The term "rectangle" as used herein includes shapes that are generally rectangular, such as a shape with corners or a part of the side cut out like the package 71, or a shape with curved corners like the recess 80. In addition, the package 71 has step portions 83 formed on two of the four inner surfaces 82 of the recess 80 in the short direction that face each other. The package 71 can be formed mainly from ceramic. The package 71 can be formed not only from ceramic but also from metal. For example, ceramics such as aluminum nitride, silicon nitride, aluminum oxide, and silicon carbide can be used as the main material of the package 71. Metals such as copper, aluminum, iron, and composites such as copper molybdenum, copper-diamond composite material, and copper tungsten can be used as the main material of the package 71.

[0075] A metal film is provided on each of the lower surface 84 of the package 71 and the upper surface of the step portion 83. The metal film on the lower surface 84 of the package 71 includes metal films 87 provided in pairs on both ends of the package 71, and a metal film 88 provided in the center of the lower surface 84 of the package 71 between the metal films 87 at both ends. Each of the metal films 87 is provided at three locations along each of the two sides facing each other and spaced apart from each other. The metal films 87 are formed facing each other so as to be connected to the plating layers 42a and 42b of the wiring board 110. The metal film 88 is formed so as to be connected to the plating layer 41 of the wiring board 110. In the package 71, the metal film on the upper surface of the step portion 83 and the metal film 87 on the lower surface 84 are electrically connected by metal wiring passing through the inside.

[0076] The semiconductor laser element 72 and the protective element 75 are electrically connected to the connection wiring, which is a metal film provided on the upper surface of the step portion 83. A wire 76 is bonded for this conduction. As a result, the semiconductor laser element 72 and the protective element 75 are electrically connected via the metal film 87 provided on the lower surface 84 of the package 71.

[0077] In such a light emitting component 50A, a pair of metal films 87 provided on a lower surface 84 of the package 71 are joined to the plating layers 42a, 42b of the wiring board 110. In addition, a metal film 88 provided in the center of the lower surface 84 of the package 71 is joined to the plating layer 41 of the wiring board 110. The light emitting component 50A and the wiring board 110 can be joined by soldering.

[0078] The semiconductor laser element 72 is mounted on a bottom surface 81 (upper surface of a bottom portion 86) of a recess 80 of the package 71 via a submount 73. The multiple semiconductor laser elements 72 mounted on the light emitting component 50A are arranged side by side in one direction, specifically, in the longitudinal direction of the package 71. The orientation of the emission end surface of each mounted semiconductor laser element 72 is aligned so that the mounted semiconductor laser elements 72 emit laser light in the same direction. The multiple semiconductor laser elements 72 arranged side by side in one direction are electrically connected in series using wires 76.

[0079] The lower surface of the submount 73 is bonded to the bottom surface 81 of the recess 80 of the package 71 with an adhesive such as Au paste, and the upper surface of the submount 73 is bonded to the semiconductor laser element 72. The submount 73 can be made of, for example, silicon nitride, aluminum nitride, or silicon carbide. In addition, a metal film such as Cu plating is provided on the upper surface of the submount 73.

[0080] The light reflecting member 74 is a member that reflects light from the semiconductor laser element 72. The light reflecting member 74 has its lower surface bonded to the bottom surface 81 of the recess 80 of the package 71 by an adhesive member. The adhesive member is formed by applying a mixture of particles of Ag, Au, Cu, etc. and an organic solvent, and then heating to remove the organic solvent and fuse the particles of Ag, Au, Cu, etc. The light reflecting members 74 are independently disposed corresponding to the respective semiconductor laser elements 72. The light reflecting member 74 has a lower surface, an upper surface, a side surface, and an inclined surface, and the inclined surface serves as the light reflecting surface. The light reflecting surface is flat and inclined from the upper surface to the lower surface.

[0081] The light reflecting member 74 can be formed by forming its outer shape using a main material, and forming a light reflecting film on the surface of the formed outer shape on which the light reflecting surface is to be provided. The main material is preferably a heat-resistant material, and for example, quartz or glass such as BK7 (borosilicate glass), metal such as aluminum, or Si can be used. The light reflecting film is preferably a material with high light reflectance, and metals such as Ag and Al, and dielectric multilayer films such as Ta2O5 / SiO2, TiO2 / SiO2, and Nb2O5 / SiO2 can be used. Note that when the outer shape of the light reflecting member 74 is formed using a material with high light reflectance such as a metal as the main material, the formation of the light reflecting film may be omitted.

[0082] A major portion of the light emitted from the semiconductor laser element 72 is irradiated onto the corresponding light reflecting surface of the light reflecting member 74. Note that the light emitting component may not include the light reflecting member 74, and the light emitting end surface of the semiconductor laser element 72 may face upward.

[0083] The protective element 75 is placed on the upper surface of the submount 73. The protective element 75 is, for example, a Zener diode. The wire 76 is a metal wiring. Examples of the material of the wire 76 include metals such as Au, Ag, Cu, Pt, and Al, and alloys thereof. Note that the light emitting component may not have the protective element 75.

[0084] The lid member 77 is a member that covers the semiconductor laser element 72 and the light reflecting member 74. The lid member 77 is translucent as a whole, but may have a non-translucent region in part. The lid member 77 may be formed using sapphire as a main material. A metal film is provided in a part of the lid member 77. Note that, other than sapphire, for example, glass may also be used as the main material. The lower surface of the lid member 77 is joined to the upper surface of the package 71 (the upper surface of the frame portion 85). A metal film is provided in the joined area of ​​the lid member 77 and the package 71, and they are fixed via Au-Sn or the like. In the light emitting component 50A, a closed space is formed by joining the package 71 and the lid member 77. This closed space is a hermetically sealed space. By hermetically sealing the light emitting component 50A in this manner, it is possible to suppress the collection of organic matter and the like on the light emitting end face of the semiconductor laser element 72.

[0085] The adhesive portion 78 is formed on the upper surface of the lid member 77 in a region that bonds the lid member 77 to the lens member 79. The adhesive portion 78 may be made of, for example, an ultraviolet-curing resin.

[0086] The lens member 79 is provided facing the upper surface of the cover member 77. The lens member 79 is formed integrally with a lens portion 791 having a lens shape and a rectangular support plate portion 792 supporting the lens portion 791. In the lens member 79, each of the lens portions 791 is provided at a position facing the optical axis of the semiconductor laser element 72. The arrangement and shape of each lens portion 791 are designed so that the reflected light emitted from the corresponding semiconductor laser element 72 and reflected by the light reflecting member 74 passes through the lens portion 791 and is collimated. For example, glass such as BK7 or B270 can be used for the lens member 79. [Industrial Applicability]

[0087] The circuit board and the light emitting device according to the embodiments of the present disclosure can be used in various electronic devices. [Explanation of symbols]

[0088] 10, 10A 1st board 11, 11A Post section 12 Flat plate part 15. Gap 20, 20a, 20A Second board 21 Base material 22 1st metal layer 221 First metal layer (Annular first metal layer) 222 Circuit Pattern 23 Bonding sheet 24 Second metal layer 25 Opening 30 Resist 40 Plating layer 41 Plating layer 42a, 42b plating layer 43a, 43b plating layer 44a, 44b plating layer 45a, 45b plating layer 50, 50A Light Emitting Components 60 Dry Film 61 Dry film of exposed area 62 Dry film other than the exposed area 71 Packages 72 Semiconductor laser element 73 Submount 74 Light reflecting material 75 Protection elements 76 Wire 77 Lid member 78 Adhesive part 79 Lens parts 791 Lens section 792 Support plate part 80 Recess 81 Bottom of the recess 82 Inner surface of recess 83 Step 84 Bottom surface 85 Frame 86 Bottom 87 Metal Film 88 Metal Film 100, 100A, 100B Circuit Board 110 Wiring board 150 Thermistor 200, 200A, 200B, 200C Light-emitting device D Gap distance H Post height T Thickness of the flat part W is the width of the first metal layer

Claims

1. A step of preparing a first substrate having a convex post portion formed on an upper surface side thereof, and a second substrate having a first surface and a second surface opposite to the first surface, a first metal layer formed on at least the first surface, and an opening exposing an upper surface of the post portion in a plan view; a step of bonding at least a portion of an upper surface of the first substrate excluding the post portion to the second surface of the second substrate such that an upper surface of the post portion is exposed from the opening; removing a portion of the first metal layer to form a circuit pattern; In the bonding step, the first substrate and the second substrate are bonded together such that a distance between an upper surface of the post portion and the first metal layer is 100 μm or more and 300 μm or less; A method for manufacturing a circuit board in which, in the process of forming the circuit pattern, a portion of the first metal layer is removed so that, in a planar view, another portion of the first metal layer surrounds the post portion and so that the first metal layer is separated from the circuit pattern, thereby forming the first metal layer in a ring shape with a predetermined width to match the shape of the post portion.

2. The method for manufacturing a circuit board according to claim 1 , wherein in the preparing step, the side surfaces of the post portions facing each other are curved and convex inwardly in a cross-sectional view.

3. 2. The method for manufacturing a circuit board according to claim 1, wherein in the preparing step, the side surfaces of the post portions facing each other have a curved shape that is convex outward or a straight shape in a cross-sectional view.

4. In the preparing step, a thickness of a flat portion on an upper surface of the first substrate excluding the post portion is 1 mm or more and 2 mm or less; 4. The method for manufacturing a circuit board according to claim 1, wherein a height from an upper surface of the flat plate portion to an upper surface of the post portion is 50 [mu]m or more and 150 [mu]m or less.

5. 5. The method for manufacturing a circuit board according to claim 1, wherein in the preparing step, the post portion is formed by etching or pressing the board.

6. In the preparing step, the second substrate has the first metal layer provided on a base material, and a bonding sheet provided on a lower surface of the base material, 6. The method for manufacturing a circuit board according to claim 1, wherein in the bonding step, the first substrate and the second substrate are bonded together by adhering the bonding sheet to the first substrate.

7. In the preparing step, the second substrate has the first metal layer provided on a base material, a second metal layer provided on a lower surface of the base material, and a bonding sheet provided on a side of the second metal layer opposite to the base material, 6. The method for manufacturing a circuit board according to claim 1, wherein in the bonding step, the first substrate and the second substrate are bonded together by adhering the bonding sheet to the first substrate.

8. 8. The method for manufacturing a circuit board according to claim 1, wherein in the preparing step, a shape of the opening in a plan view is similar to a shape of the post portion.

9. 9. The method for manufacturing a circuit board according to claim 1, wherein in the preparing step, an area of ​​the opening is 1.05 to 2 times an area of ​​the post portion.

10. A step of manufacturing a circuit board by the method for manufacturing a circuit board according to any one of claims 1 to 9; and placing a light emitting component on the post portion of the circuit board.

11. The method for manufacturing a light emitting device according to claim 10 , further comprising the step of forming a resist on an upper surface of the first metal layer of the circuit board after the step of manufacturing the circuit board.

12. The method for manufacturing a light emitting device according to claim 11 , further comprising the step of forming a plating layer on an upper surface of the post portion and an upper surface of the circuit pattern in the circuit board after the step of forming the resist.

13. A first substrate having a convex post portion formed on an upper surface side thereof; a second substrate having a first surface and a second surface opposite to the first surface, a first metal layer formed on at least the first surface, and disposed such that at least a portion of an upper surface of the first substrate excluding the post portion faces the second surface; the second substrate has an opening that exposes an upper surface of the post portion in a plan view, The second substrate is a circuit board having a circuit pattern in which the first metal layer is arranged in a ring shape with a predetermined width to surround the post portion and match the shape of the post portion, and the distance between the top surface of the post portion and the first metal layer is 100 μm or more and 300 μm or less.

14. The circuit board according to claim 13 , wherein the side surfaces of the post portions facing each other are curved and convex inward in a cross-sectional view.

15. The circuit board according to claim 13 , wherein the side surfaces of the post portions facing each other are curved and convex outward in a cross-sectional view, or are linear.

16. a thickness of the flat portion on the upper surface of the first substrate excluding the post portion is 1 mm or more and 2 mm or less; 16. The circuit board according to claim 13, wherein a height from an upper surface of the flat plate portion to an upper surface of the post portion is 50 μm or more and 150 μm or less.

17. The second substrate has the first metal layer provided on a base material, and a bonding sheet provided on a lower surface of the base material, 17. The circuit board according to claim 13, wherein the bonding sheet is between the first substrate and the second substrate.

18. The second substrate has the first metal layer provided on a base material, a second metal layer provided on a lower surface of the base material, and a bonding sheet provided on the second metal layer on a side opposite to the base material, 17. The circuit board according to claim 13, wherein the bonding sheet is between the first substrate and the second substrate.

19. 19. The circuit board according to claim 13, wherein a shape of the opening in a plan view is similar to a shape of the post portion.

20. 20. The circuit board according to claim 13, wherein an area of ​​the opening is 1.05 to 2 times an area of ​​the post portion.

21. A light emitting device comprising: a circuit board described in any one of claims 13 to 20; and a light emitting component mounted on the post portion of the circuit board.

22. The light emitting device according to claim 21 , wherein a resist is formed on an upper surface of the first metal layer of the circuit board.

23. The light emitting device according to claim 22 , wherein a plating layer is provided on an upper surface of the post portion and an upper surface of the circuit pattern in the circuit board.

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