Manufacturing method for individual pieces of phosphor glass thin plate

Abstract

To provide a manufacturing method of fluorescent glass thin sheet capable of manufacturing fluorescent glass thin sheet more surely.SOLUTION: A manufacturing method of fluorescent glass thin sheet includes steps of: preparing a fluorescent glass base material 21 having a first principal surface 21a and a second principal surface 21b facing mutually; placing the fluorescent glass base material 21 on a stage 22, and fixing the second principal surface 21b on the stage 22, and abrading the first principal surface 21a of the fluorescent glass base material 21 by an abrasive member 23 having an abrasive layer 24.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] The present invention relates to a method for producing a phosphor glass thin plate and pieces thereof, and to a phosphor glass thin plate and pieces thereof. [Background technology]

[0002] In recent years, light-emitting devices using LEDs and laser diodes (LDs) have been attracting increasing attention as next-generation light sources to replace fluorescent lamps and incandescent lamps. One example of such a next-generation light source is a light-emitting device that combines an LED that emits blue light with a wavelength conversion member that includes a phosphor layer that absorbs part of the light from the LED and converts it to yellow light. This light-emitting device emits white light, which is a composite light of the blue light emitted from the LED and the yellow light emitted from the wavelength conversion member. Patent Document 1 proposes a wavelength conversion member that is a phosphor glass plate in which phosphor powder is dispersed in a glass matrix. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2011-122067 Summary of the Invention [Problem to be solved by the invention]

[0004] The thinner the phosphor glass plate, the higher the luminous flux value and the easier it is to reduce the size. However, the thinner the phosphor glass plate, the more likely it is to break during manufacturing, resulting in a problem of reduced yield.

[0005] An object of the present invention is to provide a method for producing a phosphor glass thin plate, which can more reliably produce a phosphor glass thin plate.

[0006] Another object of the present invention is to provide a phosphor glass thin plate more reliably. [Means for solving the problem]

[0007] The method for manufacturing a phosphor glass thin plate of the present invention is characterized by comprising the steps of: preparing a phosphor glass base material having opposing first and second main surfaces; placing the phosphor glass base material on a stage and fixing the second main surface to the stage; and polishing the first main surface of the phosphor glass base material with a polishing member having an abrasive layer.

[0008] It is preferable that the method further comprises the steps of fixing the first main surface of the phosphor glass base material on a stage, and polishing the second main surface of the phosphor glass base material with a polishing member.

[0009] In the step of polishing the phosphor glass base material, the polishing member is preferably rotated around a rotation axis extending in the thickness direction of the phosphor glass base material.

[0010] In the step of polishing the phosphor glass base material, it is preferable that the stage be rotated about a rotation axis extending in the thickness direction of the phosphor glass base material.

[0011] In the step of polishing the phosphor glass base material, it is more preferable that the polishing member and the stage are rotated in opposite directions about a rotation axis extending in the thickness direction of the phosphor glass base material.

[0012] In the step of polishing the phosphor glass base material, it is preferable to polish it so that the thickness becomes 0.15 mm or less.

[0013] In the step of polishing the phosphor glass base material, it is preferable to polish the surface to be polished, either the first or second main surface, so that the arithmetic mean roughness (Ra) is less than 0.1 μm.

[0014] The phosphor glass base material is preferably fixed on the stage by suction.

[0015] After the step of polishing the phosphor glass base material, it is preferable to release the phosphor glass base material from the stage by injecting a liquid onto the phosphor glass base material from the stage side.

[0016] The method for manufacturing individual pieces of a thin phosphor glass plate of the present invention is characterized by comprising the steps of: forming dividing grooves on the main surface of the thin phosphor glass plate manufactured by the above-mentioned manufacturing method; and breaking the thin phosphor glass plate along the dividing grooves.

[0017] The phosphor glass thin plate of the present invention has first and second main surfaces facing each other, the first main surface having an arithmetic mean roughness (Ra) of less than 0.1 μm, and a thickness of 0.15 mm or less.

[0018] The individual pieces of the phosphor glass thin plate of the present invention are individual pieces of the phosphor glass thin plate obtained by dividing the above-mentioned phosphor glass thin plate, and are characterized in that the thickness of the portion located at the outer peripheral edge in plan view is thinner than the thickness of the portion located at the center in plan view. [Effects of the Invention]

[0019] According to the present invention, a method for manufacturing a phosphor glass thin plate can be provided that can more reliably manufacture a phosphor glass thin plate and individual pieces thereof. Also, according to the present invention, a phosphor glass thin plate and individual pieces thereof can be more reliably provided. [Brief explanation of the drawings]

[0020] [Figure 1] 1 is a schematic cross-sectional view showing a phosphor glass thin plate according to one embodiment of the present invention. [Figure 2] 1 is a schematic enlarged cross-sectional view showing a phosphor glass thin plate according to one embodiment of the present invention. [Figure 3] 1 is a schematic cross-sectional view showing an individual piece of a phosphor glass thin plate according to one embodiment of the present invention. [Figure 4] FIG. 2 is a schematic plan view illustrating a method for manufacturing a phosphor glass thin plate according to an embodiment of the present invention. [Figure 5]5(a) and 5(b) are schematic cross-sectional views illustrating a method for producing a phosphor glass thin plate according to one embodiment of the present invention. [Figure 6] 1 is a view showing a polishing member used in a method for producing a phosphor glass thin plate according to an embodiment of the present invention, viewed from the side where the phosphor glass base material is polished. FIG. [Figure 7] FIG. 2 is a schematic perspective view for explaining a method for manufacturing a phosphor glass thin plate according to an embodiment of the present invention. [Figure 8] 8(a) and 8(b) are schematic cross-sectional views illustrating a method for producing a phosphor glass thin plate according to one embodiment of the present invention. [Figure 9] 9(a) and 9(b) are schematic cross-sectional views illustrating a method for producing a phosphor glass thin plate according to one embodiment of the present invention. [Figure 10] 1 is a schematic cross-sectional view showing an example of a light-emitting device using a piece of a phosphor glass thin plate according to an embodiment of the present invention. [Figure 11] 1 is a schematic plan view showing an example of a light-emitting device using a piece of a phosphor glass thin plate according to an embodiment of the present invention. [Figure 12] FIG. 10 is a schematic cross-sectional view of a light-emitting device of a comparative example. [Figure 13] FIG. 10 is a schematic plan view of a light-emitting device of a comparative example. DETAILED DESCRIPTION OF THE INVENTION

[0021] Preferred embodiments will be described below. However, the following embodiments are merely examples, and the present invention is not limited to the following embodiments. In addition, in each drawing, components having substantially the same functions may be referred to by the same reference numerals.

[0022] (Phosphor glass thin plate and its pieces) Fig. 1 is a schematic cross-sectional view showing a phosphor glass thin plate according to one embodiment of the present invention. Fig. 2 is a schematic enlarged cross-sectional view showing a phosphor glass thin plate according to one embodiment of the present invention. The phosphor glass thin plate 1 shown in Fig. 1 is used, for example, as a wavelength conversion member. As shown in Fig. 2, in this embodiment, the phosphor glass thin plate 1 has a phosphor 2 and a glass matrix 3 in which the phosphor 2 is dispersed.

[0023] For example, excitation light is emitted from a light source such as an LED, and the excitation light is incident on the phosphor glass thin plate 1. A part of the excitation light is wavelength-converted by the phosphor 2, and fluorescence is emitted. The combined light of the fluorescence and excitation light is emitted from the phosphor glass thin plate 1.

[0024] The phosphor 2 is not particularly limited as long as it emits fluorescence when excitation light is incident on it. Specific examples of the phosphor 2 include one or more selected from oxide phosphors, nitride phosphors, oxynitride phosphors, chloride phosphors, oxychloride phosphors, sulfide phosphors, oxysulfide phosphors, halide phosphors, chalcogenide phosphors, aluminate phosphors, halophosphate chloride phosphors, and garnet-based compound phosphors. When blue light is used as the excitation light, a phosphor that emits green light, yellow light, or red light as fluorescence can be used.

[0025] The glass matrix 3 is not particularly limited as long as it can be used as a dispersion medium for the phosphor 2. For example, borosilicate glass, phosphate glass, tin phosphate glass, bismuthate glass, etc. can be used. Examples of borosilicate glass include those containing, by mass, 30% to 85% SiO2, 30% to 30% Al2O, 30% to 50% B2O, 0% to 10% Li2O + Na2O + K2O, and 0% to 50% MgO + CaO + SrO + BaO. Examples of tin phosphate glass include those containing, by molar percentage, 30% to 90% SnO and 51% to 70% P2O.

[0026] As shown in FIG. 1, the phosphor glass thin plate 1 has a first principal surface 1a and a second principal surface 1b facing each other. The arithmetic mean roughness (Ra) of the first principal surface 1a and the second principal surface 1b is less than 0.1 μm. This makes it difficult for light to be scattered when excitation light is incident on the phosphor glass thin plate 1. Similarly, when combined light of the excitation light and fluorescence is emitted from the phosphor glass thin plate 1, light scattering is also difficult. This improves the luminous efficiency. Note that it is sufficient that the arithmetic mean roughness (Ra) of at least the first principal surface 1a is less than 0.1 μm. Here, the arithmetic mean roughness (Ra) in this specification is the arithmetic mean roughness (Ra) specified in JIS B 0601:2013.

[0027] The arithmetic mean roughness (Ra) of the first principal surface 1a and the second principal surface 1b is preferably 0.05 μm or less, thereby further increasing the luminous efficiency.

[0028] The thickness of the phosphor glass thin plate 1 is preferably 0.03 mm to less than 0.3 mm, 0.05 mm to 0.15 mm, and particularly preferably 0.08 mm to 0.12 mm. This effectively increases the luminous flux value. In addition, the effect of improving the luminance contrast can be obtained, as will be described later.

[0029] The phosphor glass thin plate 1 of this embodiment has a rectangular shape in plan view. However, the shape of the phosphor glass thin plate 1 in plan view is not limited to the above and may be, for example, a substantially circular shape or a polygonal shape other than a rectangle.

[0030] FIG. 3 is a schematic cross-sectional view showing a phosphor glass thin plate piece according to one embodiment of the present invention. As shown in FIG. 3, the phosphor glass thin plate piece 11 has a first main surface 11a and a second main surface 11b facing each other. The phosphor glass thin plate piece 11 is formed by dividing the phosphor glass thin plate 1. More specifically, the phosphor glass thin plate 1 is cleaved along division grooves formed by scribing the first main surface 1a or the like. Therefore, when the thickness of the portion of the phosphor glass thin plate piece 11 located at the outer peripheral edge 11c in plan view is defined as T1 and the thickness of the portion of the phosphor glass thin plate piece 11 located at the center in plan view is defined as T2, the thickness T1 is thinner than the thickness T2.

[0031] By using the phosphor glass thin plate pieces 11 in a light-emitting device, it is possible to effectively increase the brightness contrast between the light-emitting and non-light-emitting portions. This will be described in detail with reference to an example of the light-emitting device.

[0032] Fig. 10 is a schematic cross-sectional view showing an example of a light-emitting device using a piece of a phosphor glass thin plate according to one embodiment of the present invention. Fig. 11 is a schematic plan view showing an example of a light-emitting device using a piece of a phosphor glass thin plate according to one embodiment of the present invention.

[0033] As shown in Fig. 10, light-emitting device 30 includes phosphor glass thin plate piece 11, light source 34 that irradiates excitation light onto phosphor glass thin plate piece 11, and reflecting member 35 provided to surround phosphor glass thin plate piece 11 and light source 34. As shown in Fig. 11, the light-emitting portion of light-emitting device 30 is the portion where phosphor glass thin plate piece 11 is arranged in plan view. The non-light-emitting portion is the portion where reflecting member 35 is arranged in plan view.

[0034] For example, an LED chip or the like can be used as the light source 34. For example, a resin containing a filler with high reflectivity can be used as the material for the reflective member 35.

[0035] Fig. 12 is a schematic cross-sectional view of a light emitting device of a comparative example, and Fig. 13 is a schematic plan view of the light emitting device of a comparative example.

[0036] The comparative light-emitting device 100 shown in FIG. 12 uses a thick phosphor glass plate piece 101. The reflecting member 35 does not reflect all of the excitation light and fluorescence. The excitation light and fluorescence may pass through the contact area between the phosphor glass plate piece 101 and the reflecting member 35 and leak from the non-emitting area around the emitting area, as indicated by the dashed arrows. This leakage is particularly likely to occur in high-energy areas. In the comparative example, the phosphor glass plate piece 101 is thick, and the contact area is also thick, making it difficult to sufficiently suppress light leakage from the non-emitting area. Therefore, the contrast near the boundary between the emitting and non-emitting areas is low. As shown in FIG. 13, this leakage may widen the area E where the luminance is relatively high in the non-emitting area.

[0037] In contrast, in the light-emitting device 30 shown in Fig. 10, the phosphor glass thin plate pieces 11 are thin, so the contact portions with the reflective member 35 can be effectively thinned. This effectively prevents the excitation light and fluorescence from leaking from the non-light-emitting portions, effectively enhancing the contrast near the boundary between the light-emitting and non-light-emitting portions. As shown in Fig. 11, this leakage can also prevent the area E in the non-light-emitting region where the luminance is relatively high from widening. Therefore, when designing an optical system that combines optical components such as lenses and mirrors, stray light is less likely to occur in the light-emitting device 30, making it easier to obtain light distribution characteristics that match the optical design.

[0038] The light-emitting device 30 equipped with the individual pieces 11 of the phosphor glass thin plate can be suitably used, for example, in ADB (adjustable beam) headlights, which require high directivity and high contrast near the boundary between the illuminated and non-illuminated areas.

[0039] An anti-reflection film may be provided on the first main surface 11a (light exit surface) of the phosphor glass thin plate piece 11. This prevents a decrease in light extraction efficiency due to a difference in refractive index between the phosphor glass thin plate piece 11 and air when fluorescence or excitation light is emitted from the first main surface 11a. Examples of the anti-reflection film include single-layer or multi-layer dielectric films made of SiO2, Al2O3, TiO2, Nb2O5, Ta2O5, etc. An anti-reflection film may be provided on the second main surface 11b (light entrance surface) of the phosphor glass thin plate piece 11. This prevents a decrease in excitation light incidence efficiency due to a difference in refractive index between the phosphor glass thin plate piece 11 and an adhesive layer (not shown) (an adhesive layer provided between the phosphor glass thin plate piece 11 and the light source 34) when excitation light is incident on the phosphor glass thin plate piece 11.

[0040] Typically, the anti-reflection coating is designed taking into account the refractive index of the glass matrix 3 in the phosphor glass sheet piece 11. If the phosphor is exposed on the first main surface 11a of the phosphor glass sheet piece 11, the phosphor has a relatively high refractive index, which may prevent the anti-reflection coating formed on the phosphor portion from being appropriately designed and result in insufficient anti-reflection performance. Therefore, it is preferable to provide a glass layer (a glass layer not containing phosphor) on the first main surface 11a of the phosphor glass sheet piece 11 so as to cover the exposed phosphor. This makes the refractive index of the first main surface 11a of the phosphor glass sheet piece 11 uniform, thereby enhancing the effectiveness of the anti-reflection coating. It is also preferable to provide a glass layer on the second main surface 11b of the phosphor glass sheet piece 11 to enhance the anti-reflection effect, as described above.

[0041] The glass constituting the glass layer is preferably the same as the glass constituting the glass matrix 3 in the phosphor glass thin plate piece 11. This makes the difference in refractive index between the glass matrix 3 in the phosphor glass thin plate piece 11 and the glass layer extremely small, thereby suppressing light reflection loss at both interfaces. The thickness of the glass layer is preferably 0.003 mm to 0.1 mm, 0.005 mm to 0.03 mm, and particularly 0.01 mm to 0.02 mm. If the glass layer is too thin, it may not be possible to sufficiently cover the exposed phosphor. On the other hand, if the glass layer is too thick, excitation light and fluorescence may be absorbed, resulting in a decrease in luminous efficiency.

[0042] Generally, the thinner the phosphor glass sheet to be obtained, the more likely it is to crack during production. In particular, when a phosphor glass sheet with a thickness of less than 0.3 mm is to be obtained, the phosphor glass sheet is more likely to crack during the production process. In contrast, the phosphor glass sheet 1 and individual phosphor glass sheet pieces 11 according to the present invention can be more reliably produced by the production method described below. The production method described below is, however, one example of a method for producing a phosphor glass sheet according to the present invention.

[0043] (Manufacturing method) Fig. 4 is a schematic plan view illustrating a method for producing a phosphor glass thin plate according to one embodiment of the present invention. Figs. 5(a) and 5(b) are schematic cross-sectional views illustrating a method for producing a phosphor glass thin plate according to one embodiment of the present invention. Fig. 6 is a view of a polishing member used in a method for producing a phosphor glass thin plate according to one embodiment of the present invention, viewed from the side where the phosphor glass base material is polished. Fig. 7 is a schematic perspective view illustrating a method for producing a phosphor glass thin plate according to one embodiment of the present invention. Figs. 8(a) and 8(b) are schematic cross-sectional views illustrating a method for producing a phosphor glass thin plate according to one embodiment of the present invention. Figs. 5(a) and 5(b) and 8(a) and 8(b) show cross sections corresponding to the portion along line II in Fig. 7.

[0044] As shown in Fig. 4, a plurality of phosphor glass base materials 21 are prepared. The phosphor glass base material 21 is a base material including the phosphor 2 shown in Fig. 2 and the glass matrix 3 in which the phosphor 2 is dispersed. The phosphor glass base material 21 has a first main surface 21a and a second main surface 21b facing each other. It is only necessary to prepare at least one phosphor glass base material 21.

[0045] Next, the phosphor glass base material 21 is placed on the stage 22, and the second main surface 21b is fixed on the stage 22. Here, as shown in FIG. 5(a), the stage 22 has a plurality of first holes 22a and a plurality of second holes 22b. In this embodiment, the phosphor glass base material 21 is fixed on the stage 22 by sucking it through the plurality of first holes 22a as shown by arrow A. Note that the method for fixing the phosphor glass base material 21 is not limited to the above. Furthermore, the first holes 22a and the second holes 22b may be connected to each other.

[0046] Next, as shown in FIG. 5(b), the first main surface 21a of the phosphor glass base material 21 is polished by a polishing member 23. Here, as shown in FIG. 6, the polishing member 23 has an abrasive layer 24. The abrasive layer 24 has a circular ring shape. The abrasive layer 24 may be composed of a plurality of abrasive layer pieces arranged in a circular ring shape. In this case, it is preferable to provide a gap between adjacent abrasive layer pieces, for example, at an interval of 5° or more and 15° or less in a plan view. This allows polishing sludge generated during the polishing process of the phosphor glass base material 21 to be efficiently discharged to the outside through the gaps between the abrasive layer pieces. In this embodiment, the abrasive layer 24 is a glass sintered body containing diamond particles. The polishing member 23 has a substantially cylindrical shape and an opening 23a. However, the shape and material of the abrasive layer 24 and the shape of the polishing member 23 are not limited to those described above.

[0047] As shown in FIG. 7 , in the process of polishing the phosphor glass base material 21, the polishing member 23 and the stage 22 are positioned so that the center of the polishing member 23 and the center of the stage 22 are different positions in a plan view. In this embodiment, the polishing member 23 is positioned so that the outer edge of the abrasive layer 24 reaches the center of the stage 22 in a plan view. Next, as shown by arrow B in FIG. 7 , the polishing member 23 is rotated counterclockwise around a rotation axis extending in the thickness direction of the phosphor glass base material 21. Furthermore, as shown by arrow C, the stage 22 is rotated clockwise around the rotation axis extending in the thickness direction. In other words, the polishing member 23 and the stage 22 are rotated in opposite directions around the rotation axis extending in the thickness direction. This allows the phosphor glass base material 21 to be polished efficiently. Alternatively, the phosphor glass base material 21 may be rotated clockwise and the stage 22 may be rotated counterclockwise.

[0048] Although the positional relationship between the polishing member 23 and the stage 22 in a plan view is not particularly limited, it is preferable that, as in this embodiment, the outer periphery of the abrasive layer 24 reaches the center of the stage 22. This allows all of the phosphor glass base materials 21 on the stage 22 to be polished reliably and efficiently by rotating the polishing member 23 and the stage 22 in the opposite directions as described above.

[0049] The method for polishing the phosphor glass base material 21 is not limited to the above. For example, the phosphor glass base material 21 may be polished by rotating only one of the polishing member 23 and the stage 22. Alternatively, the phosphor glass base material 21 may be polished by translating at least one of the polishing member 23 and the stage 22.

[0050] Conventionally, when manufacturing a thin phosphor glass plate, the phosphor glass base material is fixed by fitting it into an opening of a plate-shaped jig (carrier) placed on a stage. Therefore, in order to polish the main surface of the phosphor glass base material, the thickness of the jig needed to be thinner than the thickness of the phosphor glass base material. The thinner the phosphor glass plate, the thinner the jig needed to be, which reduces the strength of the jig. Therefore, breakage of the jig during polishing of the phosphor glass base material often leads to breakage of the phosphor glass base material. In particular, when manufacturing a thin phosphor glass plate with a thickness of less than 0.3 mm, the phosphor glass base material is more susceptible to breakage.

[0051] In this embodiment, the second main surface 21b of the phosphor glass base material 21 is fixed directly onto the stage 22. Therefore, the phosphor glass base material 21 can be polished without using the above-mentioned jig. This makes the phosphor glass base material 21 less likely to break, and the phosphor glass thin plate 1 can be manufactured more reliably.

[0052] In the process of polishing the phosphor glass base material 21, it is preferable to spray a liquid such as water onto the phosphor glass base material 21. For example, the liquid may be sprayed onto the phosphor glass base material 21 through the opening 23a of the polishing member 23, or the liquid may be sprayed onto the phosphor glass base material 21 from the outside of the polishing member 23 and the stage 22. This effectively cools the phosphor glass base material 21 during polishing. This prevents the temperature of the phosphor glass base material 21 from unduly increasing and softening and deforming during polishing, which can result in the softened and deformed glass being burned onto the abrasive layer 24, or the polishing rate from changing due to the temperature increase. Furthermore, spraying a liquid such as water onto the phosphor glass base material 21 allows polishing sludge to be efficiently discharged to the outside, thereby preventing unwanted scratches on the surface of the phosphor glass base material 21 caused by excess polishing sludge.

[0053] At least one groove extending from the opening 23a to the outer peripheral edge may be provided on the surface of the abrasive layer 24 that is used to polish the phosphor glass base material 21. In this case, when the phosphor glass base material 21 is polished while a liquid is sprayed from the opening 23a, polishing sludge can be efficiently discharged from the groove. This allows the phosphor glass base material 21 to be polished more efficiently.

[0054] Next, as shown in FIG. 8( a), the suction from the first hole 22a is released, and the phosphor glass base material 21 is peeled off from the stage 22. At this time, as indicated by arrow D, a liquid such as water is sprayed onto the second main surface 21b of the phosphor glass base material 21 from the second hole 22b of the stage 22, thereby peeling the phosphor glass base material 21 off from the stage 22. This allows the phosphor glass base material 21 to be more reliably peeled off from the stage 22. In this embodiment, suction is performed from the first hole 22a and liquid is sprayed from the second hole 22b. However, the stage 22 may have holes for both suction and liquid spray. For example, the stage 22 may be formed of a porous body, and suction and liquid spray may be performed through each pore formed in the porous body. Note that liquid spraying during the peeling process is not necessarily required. Alternatively, gas may be sprayed from the second hole 22b instead of liquid to peel the phosphor glass base material 21 off from the stage 22.

[0055] Next, as shown in FIG. 8(b), the phosphor glass base material 21 is turned over and the polished first main surface 21a is fixed on a stage 22. Next, the second main surface 21b of the phosphor glass base material 21 is polished using a polishing member 23. At this time, fixing and polishing are performed in the same manner as in the steps shown in FIGS. 5(a), 5(b), and 7. This allows the phosphor glass thin plate 1 shown in FIG. 1 to be obtained.

[0056] In the steps of polishing the first principal surface 21a and the second principal surface 21b, it is preferable to polish the surfaces so that the arithmetic mean roughness (Ra) of the polished surfaces is less than 0.1 μm, and particularly 0.05 μm or less. This makes it difficult for light to be scattered when excitation light is incident and when composite light of the excitation light and fluorescence is emitted, thereby improving the luminous efficiency.

[0057] In the steps of polishing the first main surface 21a and the second main surface 21b, it is preferable to polish the plate so that the thickness is 0.03 mm to 0.3 mm (excluding 0.3 mm), 0.05 mm to 0.15 mm, and particularly 0.08 mm to 0.12 mm. This effectively increases the luminous flux value, provides a thin phosphor glass plate without breakage, and makes it easier to mount individual pieces of the thin phosphor glass plate on LEDs, etc.

[0058] 8(a), the phosphor glass thin plate 1 is peeled off from the stage 22. Note that the second main surface 21b of the phosphor glass base material 21 does not necessarily have to be polished, and the phosphor glass thin plate 1 may be obtained by polishing only the first main surface 21a. In this case, it is preferable to polish the first main surface 21a so that the thickness falls within the above-mentioned range in the step of polishing the first main surface 21a.

[0059] An example of a method for manufacturing the phosphor glass thin plate piece 11 shown in FIG. 3 will be described below.

[0060] 9(a) and 9(b) are schematic cross-sectional views illustrating a method for manufacturing individual pieces of a phosphor glass thin plate according to one embodiment of the present invention.

[0061] A thin phosphor glass plate 1 is prepared using the above-described manufacturing method or the like. Next, as shown in FIG. 9(a), the second main surface 1b of the thin phosphor glass plate 1 is attached to a support sheet 25. In this embodiment, the support sheet 25 is a UV-curable resin such as acrylic resin or epoxy resin applied to a sheet made of polyethylene resin, polyolefin resin, or PVC resin, and the UV-curable resin side is attached to the second main surface 1b of the thin phosphor glass plate 1. Note that the material of the support sheet 25 is not limited to the above.

[0062] Next, division grooves 1c are formed on the first main surface 1a of the phosphor glass thin plate 1. In this embodiment, the division grooves 1c are formed in a lattice pattern. The division grooves 1c are not particularly limited, but can be formed, for example, by scribing the first main surface 1a of the phosphor glass thin plate 1. The division grooves 1c may be formed before the phosphor glass thin plate 1 is attached to the support sheet 25. The surface of the phosphor glass thin plate 1 that is attached to the support sheet 25 may be the first main surface 1a. The division grooves 1c may also be formed on the second main surface 1b.

[0063] 9(b), a film 26 is attached to the first main surface 1a on which the dividing grooves 1c are formed. In this embodiment, the film 26 is made of polyethylene resin, polyolefin resin, vinyl chloride resin, or the like. Note that the material of the film 26 is not limited to the above.

[0064] On the other hand, a plurality of receiving blades 27 are prepared for placing the thin phosphor glass plate 1 on. Next, the thin phosphor glass plate 1 is turned over and placed on the plurality of receiving blades 27 so that the film 26 is in contact with the plurality of receiving blades 27. In this embodiment, the thin phosphor glass plate 1 is supported by the receiving blades 27 via the film 26. Therefore, scratches are less likely to occur on the thin phosphor glass plate 1. Note that the film 26 does not necessarily have to be used in the method for manufacturing individual pieces of the thin phosphor glass plate.

[0065] Next, a pressing member 28 is placed in a position facing the dividing groove 1c. The pressing member 28 has a blade 29. The blade 29 presses the area where the dividing groove 1c is formed from the support sheet 25 side. As a result, the phosphor glass thin plate 1 is cleaved in the thickness direction along the dividing groove 1c while remaining attached to the support sheet 25, and is divided into multiple pieces. The other areas where the dividing grooves 1c are formed are similarly cleaved. Next, the film 26 is peeled off from the collection of phosphor glass thin plate pieces 11 into which the phosphor glass thin plate 1 has been divided. Next, UV is irradiated from the support sheet 25 side to harden the UV-curable resin in the support sheet 25. Next, the phosphor glass thin plate pieces 11 are peeled off from the support sheet 25. By dividing the phosphor glass thin plate 1 in this manner, multiple phosphor glass thin plate pieces 11 can be obtained.

[0066] In this embodiment, the thickness of the phosphor glass thin plate 1 before division is reduced by polishing. Therefore, since it can be cleaved with less stress, the phosphor glass thin plate 1 is less likely to break during the cleaving process, and individual phosphor glass thin plate pieces 11 can be more reliably produced. Additionally, since the phosphor glass thin plate 1 is thin and can be easily cleaved even when the pitch of the division grooves 1c is narrow, small phosphor glass thin plate pieces 11 can be more easily and more reliably produced. Therefore, even smaller light-emitting devices can be easily produced.

[0067] The phosphor glass thin plate 1 may be divided by dicing. However, it is preferable to divide the phosphor glass thin plate 1 by the above-mentioned cleaving. This makes it even more difficult for the thin phosphor glass plate 1 to crack during division, as it is thin. [Explanation of symbols]

[0068] 1... Phosphor glass thin plate 1a...first principal surface 1b...Second main surface 1c…Dividing groove 2...Phosphor 3...Glass matrix 11...Individual pieces of phosphor glass thin plate 11a...first principal surface 11b...second principal surface 11c...Outer edge 21...Phosphor glass base material 21a...first principal surface 21b...Second principal surface 22...Stage 22a...First hole 22b...Second hole 23...Abrasive material 23a...Opening 24...abrasive layer 25...Support sheet 26...Film 27...Receiving blade 28...Pressing member 29...Blade 30...Light-emitting device 34…Light source 35...Reflective member 100...Light-emitting device 101...Individual pieces of phosphor glass plate

Claims

1. providing a phosphor glass base material having a first main surface and a second main surface facing each other; placing the phosphor glass base material on a stage and fixing the second main surface on the stage by suction; polishing the first main surface of the phosphor glass base material with a polishing member having an abrasive layer; a step of turning the phosphor glass base material upside down and fixing the polished first main surface on the stage by suction; polishing the second main surface of the phosphor glass base material with the polishing member to obtain a phosphor glass thin plate having a thickness of less than 0.3 mm; forming dividing grooves on a main surface of the phosphor glass thin plate; and splitting the phosphor glass thin plate along the division grooves.

2. 2. The method for manufacturing individual phosphor glass thin plate pieces according to claim 1, wherein in the step of polishing the phosphor glass base material, the polishing member is rotated around a rotation axis extending in a thickness direction of the phosphor glass base material.

3. 3. The method for manufacturing individual pieces of phosphor glass thin plate according to claim 1, wherein in the step of polishing the phosphor glass base material, the stage is rotated around a rotation axis extending in a thickness direction of the phosphor glass base material.

4. 4. The method for manufacturing individual pieces of phosphor glass thin plate according to claim 2, wherein in the step of polishing the phosphor glass base material, the polishing member and the stage are rotated in opposite directions to each other around a rotation axis extending in a thickness direction of the phosphor glass base material.

5. The method for producing individual pieces of a phosphor glass thin plate according to any one of claims 1 to 4, wherein in the step of polishing the phosphor glass base material, the base material is polished to a thickness of 0.15 mm or less.

6. 6. The method for manufacturing an individual piece of a phosphor glass thin plate according to claim 1, wherein in the step of polishing the phosphor glass base material, the first main surface or the second main surface is polished so that the arithmetic mean roughness (Ra) of the first main surface or the second main surface is less than 0.1 μm.

7. 7. The method for manufacturing individual pieces of a phosphor glass thin plate according to claim 1, wherein after the step of polishing the phosphor glass base material, the phosphor glass base material is peeled off from the stage by spraying a liquid onto the phosphor glass base material from the stage side.

8. A method for manufacturing individual pieces of a phosphor glass thin plate described in any one of claims 1 to 7, wherein before the step of breaking the phosphor glass thin plate, a film is attached to the main surface of the phosphor glass thin plate on which the dividing grooves are formed.

9. A method for manufacturing individual pieces of phosphor glass thin plate described in Claim 8, wherein the film is made of polyethylene resin, polyolefin resin or PVC resin.

10. A method for manufacturing individual pieces of a thin phosphor glass plate described in any one of claims 1 to 9, wherein in the process of breaking the thin phosphor glass plate, the thin phosphor glass plate is broken by pressing a position opposite the dividing groove in the thin phosphor glass plate with a pressing member.

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