Light-emitting module and planar light source

Abstract

To provide a light-emitting module and a planar light source, in which the bonding strength between a light source and a conductive member can be increased.SOLUTION: A light-emitting module includes a supporting member including a light-reflective sheet and a hole part, a light source disposed on a first surface of the light-reflective sheet and having an electrode on a lower surface facing the first surface, and a conductive member disposed in the hole part of the light-reflective sheet and connected to the electrode of the light source. The hole part includes a first part penetrating from the first surface to a second surface of the light-reflective sheet, existing on the inner side relative to an outer edge of the lower surface of the light source in a plan view, and overlapping with the electrode, and a second part continuing from the first part and including an inner opening part that opens in the first surface on the inner side relative to the outer edge of the lower surface of the light source and an outer opening part that opens in the first surface on the outer side relative to the outer edge of the lower surface of the light source in the plan view. The conductive member is in contact with the lower surface of the light source in the inner opening part.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present invention relates to a light-emitting module and a planar light source. [Background technology]

[0002] Light-emitting modules, which combine light-emitting elements such as light-emitting diodes with light guide plates, are widely used as planar light sources, such as backlights for liquid crystal displays. In such planar light sources, for example, Patent Document 1 discloses a configuration in which a conductive member is placed in a hole formed in a support substrate that supports the light source and connected to the light source. [Prior art documents] [Patent Documents]

[0003] [Patent Document 1] Japanese Patent Publication No. 2022-72423 [Overview of the project] [Problems that the invention aims to solve]

[0004] The present invention aims to provide a light-emitting module and a planar light source that can increase the bonding strength between the light source and the conductive member. [Means for solving the problem]

[0005] According to one aspect of the present invention, a light-emitting module comprises a light-reflective sheet having a first surface and a second surface located opposite to the first surface, a support member having a hole, a light source disposed on the first surface of the light-reflective sheet and having an electrode on its lower surface facing the first surface, and a conductive member disposed in the hole of the light-reflective sheet and connected to the electrode of the light source. The hole penetrates from the first surface to the second surface of the light-reflective sheet and, in a plan view, is located inside the outer edge of the lower surface of the light source and overlaps with the electrode, and a second portion continuous with the first portion has, in a plan view, an inner opening that opens to the first surface inside the outer edge of the lower surface of the light source and an outer opening that opens to the first surface outside the outer edge of the lower surface of the light source. The conductive member is in contact with the lower surface of the light source at the inner opening. [Effects of the Invention]

[0006] According to the present invention, it is possible to provide a light-emitting module and a planar light source that can increase the bonding strength between the light source and the conductive member. [Brief explanation of the drawing]

[0007] [Figure 1] This is a schematic plan view of a planar light source according to an embodiment. [Figure 2] This is a schematic cross-sectional view along line II-II in Figure 1. [Figure 3] This is an enlarged cross-sectional view of a portion of Figure 2. [Figure 4A] This is a schematic plan view illustrating the arrangement of the light source, the hole, and the conductive member according to the embodiment. [Figure 4B] This is a schematic plan view illustrating the arrangement of the light source, the hole, and the conductive member according to the embodiment. [Figure 4C] This is a schematic plan view illustrating the arrangement of the light source, the hole, and the conductive member according to the embodiment. [Figure 4D] This is a schematic plan view illustrating the arrangement of the light source, the hole, and the conductive member according to the embodiment. [Figure 4E] It is a schematic plan view for explaining the positional relationship among a light source, a hole portion, and a conductive member according to an embodiment. [Figure 4F] It is a schematic plan view for explaining the positional relationship among a light source, a hole portion, and a conductive member according to an embodiment. [Figure 5] It is a schematic cross-sectional view for explaining one step of a method for manufacturing a planar light source according to an embodiment. [Figure 6] It is a schematic cross-sectional view for explaining one step of a method for manufacturing a planar light source according to an embodiment. [Figure 7] It is a schematic cross-sectional view for explaining one step of a method for manufacturing a planar light source according to an embodiment. [Figure 8] It is a schematic cross-sectional view for explaining one step of a method for manufacturing a planar light source according to an embodiment. [Figure 9] It is a schematic cross-sectional view for explaining one step of a method for manufacturing a planar light source according to an embodiment. [Figure 10] It is a schematic cross-sectional view for explaining one step of a method for manufacturing a planar light source according to an embodiment. [Figure 11] It is a schematic cross-sectional view showing another example of a planar light source according to an embodiment.

BEST MODE FOR CARRYING OUT THE INVENTION

[0008] Hereinafter, embodiments will be described with reference to the drawings. Dimensions, materials, shapes, relative arrangements, etc. of the components described in the embodiments are not intended to be limited only to those, but are merely illustrative examples unless specifically described. Note that the sizes, positional relationships, etc. of the members shown in each drawing may be exaggerated for clarity of explanation. Further, in the following description, the same names and reference numerals indicate the same or similar members, and detailed descriptions will be omitted as appropriate. In addition, as a cross-sectional view, there may be a case where an end view showing only the cut surface is shown.

[0009] In the following description, terms indicating specific directions or positions (e.g., "up," "down," and other terms including these) may be used. However, these terms are used merely for clarity to indicate the relative directions or positions in the referenced drawings. If the relative direction or position relationship indicated by terms such as "up" and "down" in the referenced drawings is the same, the arrangement in drawings other than those disclosed, actual products, etc., does not have to be the same as in the referenced drawings. In this specification, the positional relationship expressed as "up (or down)" includes, for example, the case where two members are in contact with each other, and the case where the two members are not in contact but one member is located above (or below) the other member. Furthermore, unless otherwise specified, "a member covers an object" includes the case where the member is in contact with the object and directly covers it, and the case where the member does not contact the object and indirectly covers it.

[0010] In the diagrams shown below, directions may be indicated by the X, Y, and Z axes. The X, Y, and Z axes are orthogonal to each other. The light-emitting surface of the light-emitting module according to the embodiment is parallel to the XY plane, and the Z axis is orthogonal to the XY plane. Furthermore, the direction of the arrow on the Z axis is defined as upward, and the direction opposite to the direction of the arrow on the Z axis is defined as downward. Also, the direction that is tilted from the X direction in the XY plane at an angle of 0° or more and less than 360° is defined as the lateral direction. For example, in this specification, the direction along the X axis is defined as the first direction X, the direction along the Y axis is defined as the second direction Y, and the direction along the Z axis is defined as the third direction Z. The third direction Z is the thickness direction of the light-emitting module and planar light source according to the embodiment. In this specification, unless otherwise specified, the thickness of each member is defined as the value at which the distance from the top surface to the bottom surface of each member in the third direction Z is maximum.

[0011] The light-emitting module 100 and the planar light source 300 according to the embodiment will be described below with reference to Figures 1 to 4A.

[0012] As shown in Figure 2, the light-emitting module 100 according to the embodiment comprises a light source 10, a support member 200, and a conductive member 80. The support member 200 has at least a light-reflective sheet 40 and a perforated portion 70. In addition to the above configuration, the planar light source 300 according to the embodiment further includes a substrate 61 in the support member 200.

[0013] The following provides a detailed explanation of each element constituting the light-emitting module 100 and the planar light source 300.

[0014] [light source] As shown in Figure 2, the light source 10 includes a light-emitting element 11. The light-emitting element 11 includes a semiconductor structure. The semiconductor structure includes, for example, an element substrate such as sapphire or gallium nitride, an n-type semiconductor layer disposed on the element substrate, a p-type semiconductor layer, and a light-emitting layer sandwiched between the n-type and p-type semiconductor layers. The semiconductor structure does not necessarily have an element substrate. In this case, it becomes easier to miniaturize the light source 10 in the third direction Z. The light-emitting element 11 also includes an n-side electrode electrically connected to the n-type semiconductor layer and a p-side electrode electrically connected to the p-type semiconductor layer. The n-side electrode and the p-side electrode constitute a part of the lower surface of the light-emitting element 11.

[0015] The structure of the light-emitting layer may be a double heterostructure, a single quantum well structure (SQW) with a single active layer, or a multiple quantum well structure (MQW) with a group of active layers. The light-emitting layer is capable of emitting visible light or ultraviolet light. The light-emitting layer is capable of emitting visible light from blue to red. An example of a semiconductor structure containing such a light-emitting layer is In x Al y Ga 1-x-yN(0≦x, 0≦y, x+y≦1) can be included. The semiconductor structure may include at least one light-emitting layer capable of the light emission described above. For example, the semiconductor structure may have a structure that includes one or more light-emitting layers between an n-type semiconductor layer and a p-type semiconductor layer, or it may have a structure in which a structure containing an n-type semiconductor layer, a light-emitting layer, and a p-type semiconductor layer in sequence is repeated multiple times. When the semiconductor structure includes multiple light-emitting layers, it may include light-emitting layers with different emission peak wavelengths, or it may include light-emitting layers with the same emission peak wavelength. Note that the emission peak wavelengths may be the same, for example, with variations of a few nanometers. Such combinations of light-emitting layers can be selected as appropriate. For example, when the semiconductor structure includes two light-emitting layers, the light-emitting layers can be selected in combinations such as blue light and blue light, green light and green light, red light and red light, ultraviolet light and ultraviolet light, blue light and green light, blue light and red light, or green light and red light. Furthermore, the light-emitting layer may include multiple active layers with different emission peak wavelengths, or it may include multiple active layers with the same emission peak wavelength.

[0016] A single light source 10 includes one light-emitting element 11. A single light source 10 may include multiple light-emitting elements 11. The emission peak wavelengths of the multiple light-emitting elements 11 included in a single light source 10 may be the same or different. For example, if a single light source 10 includes two light-emitting elements 11, the emission peak wavelengths of the light-emitting elements 11 can be selected from combinations such as blue light and green light, blue light and red light, ultraviolet light and blue light, ultraviolet light and green light, ultraviolet light and red light, or green light and red light. For example, if a single light source 10 includes three light-emitting elements 11, the emission peak wavelengths of the light-emitting elements 11 can be selected from combinations such as blue light and green light and red light, ultraviolet light and green light and red light, ultraviolet light and blue light and green light, ultraviolet light and blue light and red light, or ultraviolet light and green light and red light.

[0017] One light source 10 has a first electrode 12A and a second electrode 12B on the lower surface 10a of the light source 10. As shown in FIG. 4A, in a plan view, the second electrode 12B is located away from the first electrode 12A in the first direction X. One of the first electrode 12A and the second electrode 12B is electrically connected to the p-side electrode of the light emitting element 11, and the other is electrically connected to the n-side electrode of the light emitting element 11. Note that the p-side electrode of the light emitting element 11 may constitute the first electrode of the light source 10, and the n-side electrode of the light emitting element 11 may constitute the second electrode of the light source 10. In this specification, the first electrode 12A and the second electrode 12B may be simply referred to as the electrode 12 without distinguishing them from each other.

[0018] In the example shown in FIG. 2, the light source 10 may further include a translucent member 13 (hereinafter referred to as a light source translucent member). The light source translucent member 13 covers the upper surface and the side surface of the light emitting element 11. The light emitting element 11 can be protected by the light source translucent member 13. The light source translucent member 13 may be arranged so as to expose at least a part of the upper surface of the light emitting element 11. In this case, it becomes easier to miniaturize the light source 10 in the third direction Z.

[0019] The light source translucent member 13 has translucency with respect to the light emitted by the light emitting element 11. For example, the light source translucent member 13 may contain a translucent resin and may further contain a phosphor. As the translucent resin, for example, a silicone resin or an epoxy resin can be used. As the phosphor, yttrium aluminum garnet-based phosphors (for example, (Y,Gd)3(Al,Ga)5O 12 :Ce), lutetium aluminum garnet-based phosphors (for example, Lu3(Al,Ga)5O 12 :Ce), terbium aluminum garnet-based phosphors (for example, Tb3(Al,Ga)5O 12 :Ce), CCA-based phosphors (for example, Ca 10 (PO4)6Cl2:Eu), SAE-based phosphors (for example, Sr4Al 14 O 25 :Eu), chlorosilicate-based phosphors (for example, Ca8MgSi4O 16Cl2:Eu), silicate phosphors (e.g., (Ba,Sr,Ca,Mg)2SiO4:Eu), β-sialon phosphors (e.g., (Si,Al)3(O,N)4:Eu), or α-sialon phosphors (e.g., Ca(Si,Al) 12 (O,N) 16 Oxynitride phosphors such as Eu, LSN phosphors (e.g., (La,Y)3Si6N 11 Nitride phosphors such as (Ba,Sr)2Si5N8:Eu, 1-x Al x )F 6-x :Mn Here, x satisfies 0[x[1]. ) or fluoride-based phosphors such as MGF-based phosphors (e.g., 3.5MgO·0.5MgF2·GeO2:Mn), quantum dots having a perovskite structure (e.g., (Cs,FA,MA)(Pb,Sn)(F,Cl,Br,I)3 Here, FA and MA represent formamidinium and methylammonium, respectively), group II-VI quantum dots (e.g., CdSe), group III-V quantum dots (e.g., InP), or quantum dots having a chalcopyrite structure (e.g., (Ag,Cu)(In,Ga)(S,Se)2), etc., can be used as the phosphor added to the light source transparent member 13.

[0020] The light source 10 may further include a light-reflecting member 15 (hereinafter referred to as the light source light-reflecting member) positioned on the lower surface of the light-emitting element 11. The light source light-reflecting member 15 is positioned such that the lower surface of the electrode 12 of the light source 10 is exposed from the light source light-reflecting member 15. The light source light-reflecting member 15 is also positioned on the lower surface of the light-transmitting member 13 that covers the side surface of the light-emitting element 11.

[0021] The light source light reflecting member 15 has reflectivity to light emitted by the light-emitting element 11. For example, the light source light reflecting member 15 can be made of a resin material containing a gas such as nitrogen or oxygen, or a resin material containing light-scattering particles. As the resin material of the light source light reflecting member 15, for example, thermoplastic resins such as acrylic resin, polycarbonate resin, cyclic polyolefin resin, polyethylene terephthalate resin or polyester resin, or thermosetting resins such as epoxy resin or silicone resin can be used. As the light-scattering particles of the light source light reflecting member 15, for example, particles such as titania, silica, alumina, zinc oxide, magnesium oxide, zirconia, yttria, calcium fluoride, magnesium fluoride, niobium pentoxide, barium titanate, tantalum pentoxide, barium sulfate, or glass can be used. The light source light reflecting member 15 may contain both a gas and light-scattering particles.

[0022] The light source 10 may include a light adjustment member 14 (hereinafter referred to as the light source light adjustment member). The light source light adjustment member 14 constitutes at least a part of the upper surface of the light source 10. The light source light adjustment member 14 is positioned above the light-emitting element 11 and above the light source light-transmitting member 13. The light source light adjustment member 14 adjusts the amount and direction of light emitted above the light-emitting element 11 and the light source light-transmitting member 13. The light source light adjustment member 14 has reflectivity and light transmission properties for light emitted by the light-emitting element 11. The transmittance of the light source light adjustment member 14 with respect to the peak wavelength of the light-emitting element 11 is preferably 1% to 50%, and more preferably 3% to 30%. A portion of the light emitted from the upper surface of the light source light-transmitting member 13 is reflected by the light source light adjustment member 14, and another portion is transmitted through the light source light adjustment member 14. By including the light source light adjustment member 14 in the light source 10, it is possible to reduce the area directly above the light source 10 from becoming too bright. This reduces brightness unevenness in the light-emitting module 100.

[0023] The light source light adjustment member 14 can be made of, for example, a resin member containing a gas such as nitrogen or oxygen, or a resin member containing light scattering particles. The resin member of the light source light adjustment member 14 can be made of the same material as the resin member of the light source light reflecting member 15. The light scattering particles of the light source light adjustment member 14 can be made of the same material as the light scattering particles of the light source light reflecting member 15. Furthermore, the light source light adjustment member 14 may be made of, for example, a metal member such as aluminum or silver, or a dielectric multilayer film.

[0024] The light source 10 is not limited to the form shown in Figure 2. Other forms of the light source 10 are described below.

[0025] The light source 10 does not necessarily have to include the light source light adjustment member 14. This makes it easier to miniaturize the light source 10 in the third direction Z compared to when the light source 10 includes the light source light adjustment member 14 which is positioned above the light-emitting element 11.

[0026] The light source 10 does not necessarily have to include the light source light reflecting member 15. For example, the lower surface of the light source 10 may be formed by the lower surface of the light-emitting element 11, the lower surface of the electrode 12, and the lower surface of the light source light-transmitting member 13.

[0027] The light source 10 may consist of only the light-emitting element 11.

[0028] The light source 10 may not include the light source light reflecting member 15 and the light source light transmitting member 13, and the light source light adjusting member 14 may be arranged on the upper surface of the light-emitting element 11.

[0029] The light source 10 may not include the light source light-transmitting member 13, and may have a configuration in which a light source light adjustment member 14 is placed on the upper surface of the light-emitting element 11, and a light source light reflecting member 15 is placed on the lower surface of the light-emitting element 11.

[0030] The shape of the light source 10 in plan view is not particularly limited. The shape of the light source 10 in plan view can be, for example, a circle, a triangle, a square, a hexagon, or an octagon. If the shape of the light source 10 in plan view is a square, the pair of parallel outer edges of the light source 10 may be parallel to the first direction X, or they may be inclined with respect to the first direction X. In this embodiment, as shown in Figure 1, the pair of parallel outer edges of the light source 10 are inclined at 45° with respect to the first direction X.

[0031] [Support member] The support member 200 supports the light source 10. Furthermore, if the light-emitting module 100 has a first light-transmitting member 21 and a light-guiding member 50, which will be described later, the support member 200 supports the first light-transmitting member 21 and the light-guiding member 50.

[0032] [Light-reflective sheet] The light-reflective sheet 40 is positioned below the light source 10, below the light guide member 50, and below the first light-transmitting member 21. Furthermore, if the light guide member 50 has a partition groove 54, which will be described later, the light-reflective sheet 40 is positioned below the partition groove 54.

[0033] The light-reflective sheet 40 has a first surface 40a and a second surface 40b located opposite the first surface 40a in a third direction Z. The light source 10 is placed on the first surface 40a of the light-reflective sheet 40. The lower surface 10a of the light source 10 faces the first surface 40a.

[0034] The light-reflective sheet 40 has a three-layer structure, for example, comprising a first layer 41, a second layer 42, and a third layer 43. The second layer 42 is placed on the third layer 43, and the first layer 41 is placed on the second layer 42. The first surface 40a of the light-reflective sheet 40 includes the upper surface of the first layer 41. The second surface 40b of the light-reflective sheet 40 includes the lower surface of the third layer 43. The light-reflective sheet 40 may have a single-layer, two-layer, or four-layer or more structure.

[0035] The third layer 43 is positioned between the substrate 61 and the second layer 42, and adheres the substrate 61 and the second layer 42 together. The third layer 43 can be made of, for example, a resin member containing light-scattering particles. As the resin member of the third layer 43, for example, a material similar to that of the resin member of the light source light reflecting member 15 can be used. As the light-scattering particles of the third layer 43, for example, a material similar to that of the light-scattering particles of the light source light reflecting member 15 can be used. A sheet-like optically clear adhesive (OCA) may be used as the third layer 43.

[0036] The refractive index of the resin material of the third layer 43 is preferably lower than that of the resin material of the second layer 42. By making the refractive index of the resin material of the third layer 43 lower than that of the resin material of the second layer 42, some of the light traveling from the second layer 42 to the third layer 43 is more likely to undergo total internal reflection at the interface between the second layer 42 and the third layer 43. This reduces the amount of light that escapes downward from the light-emitting module 100, thus improving the light extraction efficiency of the light-emitting module 100.

[0037] The second layer 42 is reflective to the light emitted by the light source 10. The second layer 42 can be composed of a resin member and a reflector contained within the resin member. For example, the same material as the resin member of the light source light reflector 15 can be used as the resin member of the second layer 42. The same material as the light scattering particles of the light source light reflector 15 can be used as the reflector material of the second layer 42. A gas such as nitrogen or oxygen may be used as the reflector of the second layer 42. Furthermore, the second layer 42 may contain both light scattering particles and a gas as the reflector.

[0038] It is preferable that the refractive index of the reflector in the second layer 42 is lower than the refractive index of the resin component of the second layer 42. By making the refractive index of the reflector in the second layer 42 lower than that of the resin component of the second layer 42, a portion of the light from the light source 10 incident on the second layer 42 is more likely to undergo total internal reflection at the interface between the resin component of the second layer 42 and the reflector in the second layer 42. As a result, the amount of light that escapes downward from the second layer 42 can be reduced, which improves the light extraction efficiency of the light-emitting module 100.

[0039] When the refractive index of the reflector in the second layer 42 is lower than the refractive index of the resin member of the second layer 42, it is preferable that the refractive index of the resin member of the second layer 42 is higher than the refractive index of the light guide member 50. This makes it easier to increase the refractive index difference between the resin member of the second layer 42 and the reflector in the second layer 42, making it easier for a portion of the light from the light source 10 incident on the second layer 42 to undergo total internal reflection at the interface between the resin member of the second layer 42 and the reflector in the second layer 42.

[0040] The first layer 41 is positioned between the second layer 42 and the light guide member 50, and adheres the second layer 42 and the light guide member 50. The first layer 41 can be made of, for example, a resin member containing light scattering particles. As the resin member of the first layer 41, for example, a material similar to the resin member of the light source light reflecting member 15 can be used. As the light scattering particles of the first layer 41, for example, a material similar to the light scattering particles of the light source light reflecting member 15 can be used. A sheet-like optical transparent adhesive may be used as the first layer 41.

[0041] The refractive index of the resin member of the first layer 41 is preferably lower than that of the light guide member 50. By making the refractive index of the resin member of the first layer 41 lower than that of the light guide member 50, some of the light traveling from the light guide member 50 to the first layer 41 is more likely to undergo total internal reflection at the interface between the light guide member 50 and the first layer 41. This reduces the amount of light that escapes downward from the light-emitting module 100, thus improving the light extraction efficiency of the light-emitting module 100.

[0042] The refractive index of the resin member of the first layer 41 is preferably lower than that of the first light-transmitting member 21. By making the refractive index of the resin member of the first layer 41 lower than that of the first light-transmitting member 21, some of the light that travels from the first light-transmitting member 21 to the first layer 41 is more likely to undergo total internal reflection at the interface between the first light-transmitting member 21 and the first layer 41. This reduces the amount of light that escapes downward from the light-emitting module 100, thus improving the light extraction efficiency of the light-emitting module 100.

[0043] [substrate] The substrate 61 is positioned on the second surface 40b side of the light-reflective sheet 40. The substrate 61 has a third surface 61a facing the second surface 40b of the light-reflective sheet 40, and a fourth surface 61b located on the opposite side of the third surface 61a in the third direction Z. The substrate 61 is insulating. For example, a resin such as polyimide can be used as the material for the substrate 61. The substrate 61 may be a rigid substrate or a flexible substrate. To make the planar light source 300 thinner, it is preferable that the substrate 61 be a flexible substrate. The substrate 61 may be composed of a single layer in the third direction Z, or it may be composed of a laminate of multiple layers.

[0044] A wiring layer 62 is arranged on the fourth surface 61b of the substrate 61. The wiring layer 62 is a metal film, for example, a copper film.

[0045] [Hole] As shown in Figure 3, the hole 70 has a first hole 70A and a second hole 70B. Two holes 70 (first hole 70A and second hole 70B) are arranged for one light source 10. In this specification, the first hole 70A and the second hole 70B may not be distinguished from each other and may simply be referred to as the hole 70.

[0046] Each of the first hole 70A and the second hole 70B has a first portion 71 and a second portion 72.

[0047] The first portion 71 penetrates from the first surface 40a of the light-reflective sheet 40 to at least the second surface 40b. In this embodiment, the first portion 71 penetrates from the first surface 40a of the light-reflective sheet 40 to the fourth surface 61b of the substrate 61.

[0048] Furthermore, as shown in Figure 4A, the first portion 71 is located inward from the outer edge of the lower surface 10a of the light source 10 (shown by a solid line in Figure 4A) in a plan view and overlaps with the electrode 12. The first portion 71 of the first hole 70A overlaps with the first electrode 12A in a plan view. The first portion 71 of the second hole 70B is located away from the first portion 71 of the first hole 70A in a first direction X in a plan view and overlaps with the second electrode 12B. For example, the shortest distance between the first portion 71 of the first hole 70A and the first portion 71 of the second hole 70B is preferably 0.1 mm or more and 1 mm or less, and more preferably 0.2 mm or more and 0.5 mm or less. The area of ​​the opening in the first surface 40a of the first portion 71 is larger than the area of ​​the lower surface of the electrode 12. For example, the area of ​​the opening that opens to the first surface 40a in the first portion 71 is preferably 2 to 40 times the area of ​​the lower surface of the electrode 12, and more preferably 5 to 20 times.

[0049] The second part 72 is continuous with the first part 71 and has an opening that opens to the first surface 40a at least outside the outer edge of the lower surface 10a of the light source 10. For example, as shown in Figure 4A, the opening of the second part 72 has an inner opening 72a and an outer opening 72b. The inner opening 72a opens to the first surface 40a at least inside the outer edge of the lower surface 10a of the light source 10. In a plan view, the inner opening 72a overlaps with the lower surface 10a of the light source 10. The outer opening 72b opens to the first surface 40a at least outside the outer edge of the lower surface 10a of the light source 10. In a plan view, the outer opening 72b does not overlap with the lower surface 10a of the light source 10.

[0050] The second portion 72 does not penetrate from the first surface 40a to the second surface 40b of the light-reflective sheet 40. The second portion 72 extends from the first surface 40a to a position between the first surface 40a and the second surface 40b in the third direction Z. The depth of the second portion 72 from the first surface 40a is preferably shallower than the length in the third direction Z of the side surface of the light-reflective sheet 40 and the substrate 61 defining the first portion 71. Specifically, the depth of the second portion 72 from the first surface 40a is preferably, for example, 0.02 mm or more and 0.2 mm or less, and more preferably 0.05 mm or less and 0.1 mm or more.

[0051] As shown in Figure 4A, in a plan view, the outer edge of the lower surface 10a of the light source 10 has, for example, four light source corners 10b. The four light source corners 10b include two light source corners 10b that are separated in a first direction X and two light source corners 10b that are separated in a second direction Y. In a plan view, the second portion 72 of the hole 70 extends from the first portion 71 toward the light source corners 10b. For example, the second portion 72 of the first hole 70A extends toward one of the two light source corners 10b that are separated in the first direction X, and the second portion 72 of the second hole 70B extends toward the other light source corner 10b that is separated in the first direction X.

[0052] In a plan view, in a direction perpendicular to the direction in which the second portion 72 extends, the maximum width of the second portion 72 is preferably smaller than the maximum width of the first portion 71. The maximum width of the second portion 72 in a plan view is preferably, for example, 0.02 mm or more and 0.2 mm or less, and more preferably 0.05 mm or more and 0.1 mm or less.

[0053] In the example shown in Figure 4A, the outer edge of the lower surface of the electrode 12 in plan view is triangular in shape with three corners. In plan view, the outer edge of the first portion 71 of the hole 70 is formed along the outer edge of the lower surface of the electrode 12, and the outer edge of the first portion 71 has three corners. In plan view, the second portion 72 extends outward from one of the three corners 71a of the outer edge of the first portion 71, beyond the outer edge of the lower surface 10a of the light source 10.

[0054] In a plan view, the first electrode 12A and the second electrode 12B are located apart in the first direction X, and the first portion 71 of the first hole 70A overlapping the first electrode 12A and the first portion 71 of the second hole 70B overlapping the second electrode 12B are located apart in the first direction X. In a plan view, the second portion 72 of the first hole 70A and the second portion 72 of the second hole 70B do not extend into the region between the first portion 71 of the first hole 70A and the first portion 71 of the second hole 70B. This makes it difficult for a short circuit to occur between the conductive member 80 located in the second portion 72 of the first hole 70A and the conductive member 80 located in the second portion 72 of the second hole 70B.

[0055] The number of second portions 72 extending from each of the first portion 71 of the first hole 70A and the first portion 71 of the second hole 70B is not limited to one. As shown in Figures 4B and 4C, multiple second portions 72 may extend from each of the first portion 71 of the first hole 70A and the first portion 71 of the second hole 70B to the outside of the outer edge of the lower surface 10a of the light source 10.

[0056] In a plan view, the outer edge of the first portion 71 is not limited to having a corner shape, but may also be circular, as shown in Figures 4D to 4F.

[0057] In a plan view, if the outer edge of the first portion 71 is triangular, as shown in Figures 4A to 4C, one side of the outer edge of the first portion 71 can be positioned between the first electrode 12A and the second electrode 12B, and the other two sides can be positioned along the outer edges of the lower surface 10a of the light source 10. This makes it easier to increase the area over which the conductive member 80 placed in the first portion 71 connects with the lower surface 10a of the light source 10, while ensuring a distance between the first hole 70A and the second hole 70B that makes short circuits less likely.

[0058] [Conductive material] As shown in Figure 3, the conductive member 80 is placed in the hole 70 and connected to the electrode 12 of the light source 10. The conductive member 80 includes, for example, a resin and metal particles contained in the resin. As the resin of the conductive member 80, for example, epoxy resin or phenolic resin can be used. As the metal particles of the conductive member 80, for example, copper or silver particles can be used.

[0059] The conductive member 80 has a first conductive portion 81 positioned in the first portion 71 of the hole 70 and a second conductive portion 82 positioned in the second portion 72 of the hole 70.

[0060] The first conductive portion 81, positioned in the first portion 71, overlaps with the electrode 12 in a plan view and is responsible for the electrical connection with the electrode 12. At the opening that opens in the first surface 40a of the first portion 71, the first conductive portion 81 is in contact with the lower surface of the electrode 12, which is part of the lower surface 10a of the light source 10.

[0061] Furthermore, the first conductive portion 81 is in contact with the lower surface of the light source light reflecting member 15, which is another part of the lower surface 10a of the light source 10. In addition, at the inner opening 72a of the second portion 72, the second conductive portion 82 is in contact with the lower surface of the light source light reflecting member 15. This increases the bonding strength between the light source 10 and the conductive member 80. The outer opening 72b may be completely filled with the conductive member 80, or the entire outer opening 72b may not be filled with the conductive member 80.

[0062] As shown in Figure 2, the conductive member 80 further has a fourth conductive portion 84. The fourth conductive portion 84 is arranged continuously from the first conductive portion 81 on the fourth surface 61b of the substrate 61 and is connected to a wiring layer 62 also arranged on the fourth surface 61b. Power from an external power source is supplied to the light-emitting element 11 via the wiring layer 62, the conductive member 80, and the electrode 12.

[0063] The support member 200 further has an insulating layer 65. The insulating layer 65 is arranged on the fourth surface 61b of the substrate 61 and covers the wiring layer 62 and the conductive member 80. As the material for the insulating layer 65, for example, epoxy resin, urethane resin, or acrylic resin can be used.

[0064] As shown in Figure 2, the light-emitting module 100 according to this embodiment may further include a light guide member 50, a first light-transmitting member 21, a second light-transmitting member 22, and a light-adjusting member 30.

[0065] [Light guide component] The light guide member 50 is a component that propagates light from the light source 10 within itself and emits it from its upper surface. The light guide member 50 is transparent to the light emitted by the light source 10. The transmittance of the light guide member 50 with respect to the emission peak wavelength of the light source 10 is preferably 60% or more, and more preferably 80% or more.

[0066] The material used for the light guide member 50 can be the same material as the resin material used for the light source light reflecting member 15. Alternatively, glass or the like may be used as the material for the light guide member 50. The light guide member 50 may also contain phosphors or light scattering particles.

[0067] The light guide member 50 has a fifth surface 51 which is the upper surface, and a sixth surface 52 which is the lower surface located opposite the fifth surface 51 in the third direction Z. The light guide member 50 is positioned on the light reflective sheet 40 with the sixth surface 52 facing the first surface 40a of the light reflective sheet 40.

[0068] The thickness of the light guide member 50 in the third direction Z is preferably, for example, 150 μm or more and 800 μm or less. The light guide member 50 may be composed of a single layer in the third direction Z, or it may be composed of a laminate of multiple layers. If the light guide member 50 is composed of a laminate, a light-transmitting adhesive may be placed between each layer. However, it is not necessary to place an adhesive between each layer. Each layer of the laminate may use different types of main materials, or it may use the same type of main material.

[0069] The light guide member 50 has a light source placement section 53. The light source placement section 53 is, for example, a through hole that penetrates from the fifth surface 51 to the sixth surface 52 of the light guide member 50, and the light source 10 is placed within the through hole.

[0070] In the plan view shown in Figure 1, the outer edge of the light source placement section 53 is represented, for example, by a circular dashed line. In the plan view, the light source placement section 53 may be, for example, an ellipse, or a polygon such as a triangle, square, hexagon, or octagon. The light source placement section 53 may be a recess that opens only on the sixth surface 52 side of the light guide member 50, or it may be a portion in which the light source 10 is embedded by the light guide member 50. Furthermore, the light guide member 50 may not have a light source placement section 53 and may be positioned above the light source 10.

[0071] The light guide member 50 can be divided into multiple light-emitting regions 50A by partition grooves 54 extending in a first direction X and a second direction Y. One light-emitting region 50A can be used as a drive unit for local dimming. Note that the light-emitting module 100 is not limited to multiple light-emitting regions 50A, but may also have a configuration with one light-emitting region 50A. Furthermore, having partition grooves 54 in the light guide member 50 makes it easier to improve the contrast ratio between a light-emitting region 50A that is emitting light and a light-emitting region 50A that is not emitting light. For example, some of the light from the light source 10 propagating laterally within the light guide member 50 is reflected or refracted by the surface of the light guide member 50 that defines the partition grooves 54. This makes it easier to reduce the incidence of light from the light source 10 propagating laterally within the light guide member 50 onto the light guide member 50 of an adjacent light-emitting region. This makes it easier to improve the contrast ratio between a light-emitting region 50A that is emitting light and a light-emitting region 50A that is not emitting light.

[0072] As shown in Figure 2, it is preferable that the partition groove 54 penetrates from the fifth surface 51 to the sixth surface 52 of the light guide member 50. This allows the light guide member 50 to be separated into multiple parts, thereby reducing the warping of the support member 200 caused by the difference in thermal expansion coefficients between the light guide member 50 and the support member 200 that supports the light guide member 50. Reducing the warping of the support member 200 reduces the likelihood of cracks occurring in the conductive member 80. The partition groove 54 may also be a recess that opens only on the fifth surface 51 side of the light guide member 50, or a recess that opens only on the sixth surface 52 side of the light guide member 50. When the partition groove 54 is a recess, the partition groove 54 has a bottom surface defined by the light guide member 50.

[0073] A component that is reflective to the light emitted by the light source 10 may be placed within the partition groove 54. This can improve the contrast ratio between the light-emitting region 50A in the light-emitting state and the light-emitting region 50A in the non-light-emitting state. However, a component that is reflective to the light emitted by the light source 10 does not necessarily have to be placed within the partition groove 54.

[0074] [First translucent member] The first light-transmitting member 21 is a member that propagates light from the light source 10 to the light guide member 50. The first light-transmitting member 21 is light-transmitting to the light emitted by the light source 10. The transmittance of the first light-transmitting member 21 with respect to the emission peak wavelength of the light source 10 is preferably 60% or more, and more preferably 80% or more.

[0075] As the material for the first light-transmitting member 21, for example, a material similar to that of the resin member of the light-reflecting member 15 can be used. The first light-transmitting member 21 may be composed of a single layer or a laminate of multiple layers in the third direction Z. The first light-transmitting member 21 may contain a phosphor or light-scattering particles. If the first light-transmitting member 21 is a laminate, each layer may contain a phosphor and / or light-scattering particles. Alternatively, the first light-transmitting member 21 may be composed of a layer containing a phosphor and a layer not containing a phosphor.

[0076] The first light-transmitting member 21 is positioned in the light source placement section 53 of the light guide member 50. The first light-transmitting member 21 is located between the side surface of the light source 10 and the light guide member 50. The first light-transmitting member 21 is in contact with the side surface of the light source 10. This makes it easier for light from the light source 10 to enter the first light-transmitting member 21. The light from the light source 10 that enters the first light-transmitting member 21 propagates laterally within the first light-transmitting member 21. It is preferable that the light guide member 50 is in contact with the side surface of the first light-transmitting member 21. This makes it easier for light from the light source 10 to propagate through the first light-transmitting member 21 and enter the light guide member 50. The light guide member 50 makes it easier for light from the light source 10 to propagate over a wider area laterally.

[0077] It is preferable that the first light-transmitting member 21 is positioned so as to expose at least a portion of the upper surface of the light source 10. This makes it easier to miniaturize the light-emitting module 100 in the third direction Z compared to when the first light-transmitting member 21 covers the entire upper surface of the light source 10. The first light-transmitting member 21 may also be positioned so as to expose the entire upper surface of the light source 10.

[0078] The first light-transmitting member 21 may cover the entire upper surface of the light source 10. By covering the entire upper surface of the light source 10 with the first light-transmitting member 21, it becomes easier to adjust the brightness in the region directly above the light source 10. For example, the brightness in the region directly above the light source 10 can be adjusted by changing the thickness of the portion of the first light-transmitting member 21 that covers the upper surface of the light source 10. By making it easier to adjust the brightness in the region directly above the light source 10, it becomes easier to reduce brightness unevenness in the light-emitting module 100.

[0079] [Second translucent member] The second light-transmitting member 22 is a member that adheres the light-adjusting member 30 to, for example, the light source 10, the first light-transmitting member 21, etc. The second light-transmitting member 22 is light-transmitting to the light emitted by the light source 10. The transmittance of the second light-transmitting member 22 with respect to the emission peak wavelength of the light source 10 is preferably 60% or more, and more preferably 80% or more.

[0080] As the material for the second translucent member 22, for example, the same material as the resin member of the first translucent member 21 can be used. In this case, the refractive index difference between the first translucent member 21 and the second translucent member 22 can be reduced. This reduces the reflection of light at the interface between the first translucent member 21 and the second translucent member 22, making it easier to improve the amount of light extracted upward. The second translucent member 22 may contain phosphors or light-scattering particles.

[0081] The second light-transmitting member 22 is positioned between the light source 10 and the light-adjusting member 30, and between the first light-transmitting member 21 and the light-adjusting member 30. The second light-transmitting member 22 adheres the light source 10 and the light-adjusting member 30, and adheres the first light-transmitting member 21 and the light-adjusting member 30. The second light-transmitting member 22 is in contact with the upper surface of the light source 10, the upper surface of the first light-transmitting member 21, and the lower surface of the light-adjusting member 30.

[0082] The maximum thickness of the second translucent member 22 is thinner than the maximum thickness of the first translucent member 21. Specifically, the maximum thickness of the second translucent member 22 is preferably 0.005 mm or more and 0.05 mm or less, and more preferably 0.01 mm or more and 0.03 mm or less.

[0083] [Light adjustment component] The light adjustment member 30 is a member that adjusts the amount of light emitted upward from the light source 10. The light-emitting surface of the light-emitting module 100 includes the fifth surface 51 of the light guide member 50 and the upper surface of the light adjustment member 30. The light adjustment member 30 has reflectivity and light transmission properties to the light emitted from the light source 10. A portion of the light emitted from the light source 10 is reflected by the light adjustment member 30, and another portion is transmitted through the light adjustment member 30. The transmittance of the light adjustment member 30 with respect to the peak wavelength of the light source 10 is preferably 1% or more and 50% or less, and more preferably 3% or more and 30% or less.

[0084] The light-adjusting member 30 can be composed of, for example, a resin member (hereinafter referred to as the light-adjusting resin member) and a reflector contained in the light-adjusting resin member (hereinafter referred to as the light-adjusting reflector). The material of the light-adjusting resin member can be the same as the material of the resin member of the light source light reflector 15. The material of the light-adjusting reflector can be the same as the material of the light scattering particles of the light source light reflector 15. A gas such as nitrogen or oxygen may be used as the light-adjusting reflector. The light-adjusting member 30 may contain both light scattering particles and a gas. The light-adjusting member 30 may be composed of a single layer or a laminate of multiple layers.

[0085] The light adjustment member 30 is positioned above the light source 10. As shown in Figure 1, in a plan view, the light adjustment member 30 and the light source 10 overlap. By positioning the light adjustment member 30 above the light source 10, it is possible to reduce excessive brightness in the area directly above the light source 10, and to reduce brightness unevenness on the light-emitting surface of the light-emitting module 100.

[0086] The light adjustment member 30 is positioned on the first light-transmitting member 21 via the second light-transmitting member 22. In a plan view, the light adjustment member 30, the second light-transmitting member 22, and the first light-transmitting member 21 overlap. By positioning the light adjustment member 30 on the first light-transmitting member 21, it is possible to reduce the excessive brightness in the area directly above the first light-transmitting member 21 (the area surrounding the light source 10), and it becomes easier to reduce brightness unevenness on the light-emitting surface of the light-emitting module 100.

[0087] Next, with reference to Figures 5 to 10, a method for manufacturing the light-emitting module 100 and the planar light source 300 according to the embodiment will be described.

[0088] A method for manufacturing the light-emitting module 100 and the planar light source 300 according to the embodiment includes a step of preparing a structure having a hole. The step of preparing a structure having a hole includes a step of preparing the structure 400 shown in Figure 5. The structure 400 has at least a light-reflective sheet 40. In the example shown in Figure 5, the structure 400 includes a light-reflective sheet 40 and a substrate 61 that supports the light-reflective sheet 40.

[0089] The mechanical strength of the substrate 61 is higher than that of the light-reflective sheet 40. Specifically, the mechanical strength of the substrate 61 is, for example, 50 N / mm². 2 More than 600N / mm 2 The following are preferred, and more preferably 100 N / mm 2 More than 400N / mm 2 The following applies. The mechanical strength of the light-reflective sheet 40 can be measured, for example, by a tensile test. By supporting the light-reflective sheet 40 on such a substrate 61, the process of forming holes in the light-reflective sheet 40 can be easily carried out.

[0090] The process of preparing a structure having holes includes the step of forming holes in the structure 400. Alternatively, the process of preparing a structure having holes may involve purchasing a structure with holes already formed in it.

[0091] As shown in Figure 6, the hole 70 has a first portion 71 and a second portion 72. The first portion 71 penetrates from the first surface 40a of the light-reflective sheet 40 to the fourth surface 61b of the substrate 61. The second portion 72 does not reach from the first surface 40a to the second surface 40b of the light-reflective sheet 40. The depth of the second portion 72 from the first surface 40a is shallower than the depth of the first portion 71 from the first surface 40a. The bottom of the second portion 72 is defined by a surface that forms a step between it and the first surface 40a of the light-reflective sheet 40. In the example shown in Figure 6, the surface defining the bottom of the second portion 72 is located in the second layer 42.

[0092] In a plan view, the area of ​​the openings in the hole portion 70 that open on the first surface 40a side of the light-reflective sheet 40 (the opening of the first portion 71 and the opening of the second portion 72) is larger than the area of ​​the opening that opens on the fourth surface 61b side of the substrate 61 (the opening of the first portion 71). Furthermore, the opening of the first portion 71 is formed in a plan view to be inside the outer edge of the light source 10 which will be placed in a process described later, and to overlap with the electrodes 12 of the light source 10. In addition, the opening of the second portion 72 is formed in a plan view to be narrower than the lower surface 10a of the light source 10 which will be placed in a process described later.

[0093] The holes 70 can be formed by, for example, laser processing, punching, drilling, etc. For example, the first portion 71 and the second portion 72 can be formed by laser processing. To shorten the processing time, it is preferable to perform the laser processing of the first portion 71 and the second portion 72 by irradiating them with a laser from the first surface 40a side. Alternatively, the first portion 71 may be formed by punching or drilling, and the second portion 72 may be formed by laser processing. The order in which the first portion 71 and the second portion 72 are formed is not particularly limited.

[0094] As shown in Figure 7, the second portion 72 may have a depth that extends from the first surface 40a of the light-reflective sheet 40 to the substrate 61. When forming the hole 70, a portion of the third surface 61a of the substrate 61 is also processed using the method described above. The surface defining the bottom of the second portion 72 is located at a depth that is deeper than the third surface 61a of the substrate 61 but does not reach the fourth surface 61b. Because the second portion 72 extends from the first surface 40a of the light-reflective sheet 40 to the substrate 61, which has higher mechanical strength than the light-reflective sheet 40, the shape of the second portion 72 is more easily maintained without being crushed, thereby improving reliability.

[0095] The manufacturing method for the light-emitting module 100 and the planar light source 300 according to the embodiment includes the step of preparing a structure having a hole 70, and then placing a light guide member 50 on the first surface 40a of the light-reflective sheet 40, as shown in Figure 8.

[0096] The sixth surface 52 of the light guide member 50 is bonded to the first surface 40a of the light reflective sheet 40. The light guide member 50 has a light source placement section 53 that penetrates from the fifth surface 51 to the sixth surface 52. In the light source placement section 53, the hole 70 is exposed from the light guide member 50.

[0097] The manufacturing method for the light-emitting module 100 and the planar light source 300 according to the embodiment includes the step of placing a light guide member 50 on the light-reflective sheet 40, and then placing a light source 10 on the first surface 40a of the light-reflective sheet 40, as shown in Figure 9.

[0098] A portion of the lower surface 10a of the light source 10 (the portion other than the part that overlaps with the hole 70 in a plan view) is bonded to the first surface 40a of the light-reflective sheet 40. For example, the lower surface 10a of the light source 10 is bonded to the first surface 40a of the light-reflective sheet 40 located around the hole 70. The adhesive force between the lower surface 10a of the light source 10 and the first surface 40a is weaker than the adhesive force between the conductive member 80 formed in the hole 70 in the next step and the first surface 40a, and the light source 10 is fixed to the light-reflective sheet 40 until the conductive member 80 is formed.

[0099] The light source 10 is positioned such that at least a portion of the electrode 12 overlaps the first portion 71 of the hole 70 in a plan view. The second portion 72 of the hole 70 has an inner opening 72a that opens to the first surface 40a of the light-reflective sheet 40 inside the outer edge of the lower surface 10a of the light source 10, and an outer opening 72b that opens to the first surface 40a of the light-reflective sheet 40 outside the outer edge of the lower surface 10a of the light source 10. In a plan view, the first portion 71 and the inner opening 72a overlap the lower surface 10a of the light source 10, and the outer opening 72b is exposed from the light source 10. In the hole 70, the opening in the first portion 71 that opens to the fourth surface 61b of the substrate 61 is continuous to the outer opening 72b that opens to the first surface 40a of the light-reflective sheet 40.

[0100] The manufacturing method for the light-emitting module 100 and the planar light source 300 according to the embodiment includes the step of placing the light source 10 on the light-reflective sheet 40, and then forming a conductive member 80 in the hole 70, as shown in Figure 10.

[0101] With the light-reflective sheet 40's first surface 40a positioned downwards and the substrate 61's fourth surface 61b positioned upwards relative to the direction of gravity, a fluid, paste-like conductive material 80 is supplied to the hole 70 by printing, for example, using a metal mask. At this time, since a portion of the lower surface 10a of the light source 10 is adhered to the first surface 40a of the light-reflective sheet 40, the light source 10 does not fall off the light-reflective sheet 40.

[0102] The paste-like conductive material 80 is supplied onto the fourth surface 61b of the substrate 61, and then poured into the hole 70 by a squeegee 600 through an opening in the first portion 71 of the hole 70 that is open on the fourth surface 61b. At this time, the inside of the hole 70 is evacuated through the outer opening 72b.

[0103] After supplying a paste-like conductive member 80 into the hole 70, the conductive member 80 is heat-cured. For example, the heating temperature at this time is 100°C to 120°C, and the heating time is 0.5 hours to 1 hour. The conductive member 80 placed in the first portion 71 of the hole 70 is connected to the electrode 12 of the light source 10. The conductive member 80 is also placed on the fourth surface 61b of the substrate 61 and is connected to the wiring layer 62 placed on the fourth surface 61b as shown in Figure 2. The electrode 12 of the light source 10 is electrically connected to the wiring layer 62 via the conductive member 80. In addition, the conductive member 80 placed in the first portion 71 is in contact with the lower surface 10a of the light source 10. This makes it possible to increase the connection strength between the light source 10 and the conductive member 80. The conductive member 80 also functions as a connecting member that fixes the light source 10 to the light-reflective sheet 40.

[0104] In the process of supplying the paste-like conductive material 80 to the hole 70, the air inside the hole 70 can be released to the outside through the outer opening 72b. The air inside the hole 70 can easily escape to the outside through the outer opening 72b due to the difference in flow resistance between the air and the paste-like conductive material 80. This makes it possible to fill the hole 70 with the conductive material 80 while making it less likely to generate voids, and thus improves the reliability of the electrical connection between the light source 10 and the wiring layer 62 through the conductive material 80.

[0105] The paste-like conductive member 80 supplied into the hole 70 is easily attracted by the negative pressure of the vacuum drawn through the outer opening 72b, and reaches the second part 72 via the first part 71. As a result, the conductive member 80 can come into contact with the lower surface 10a of the light source 10 at the inner opening 72a of the second part 72, thereby increasing the bonding strength between the light source 10 and the conductive member 80.

[0106] Furthermore, the paste-like conductive member 80 may be pulled by the negative pressure of the vacuum and exit the hole 70 through the outer opening 72b, forming on the side surface of the light source 10. In this case, a planar light source as shown in Figure 11, which will be described later, can be obtained.

[0107] After forming the conductive member 80 in the hole 70, as shown in Figure 2, the process involves forming the first light-transmitting member 21 in the light source placement portion 53 of the light guide member 50, and forming the light adjustment member 30 on the light source 10 and on the first light-transmitting member 21 via the second light-transmitting member 22.

[0108] As mentioned above, the depth of the second portion 72 from the first surface 40a is shallower than the length in the third direction Z of the light-reflective sheet 40 and the side surface of the substrate 61 that define the first portion 71. As a result, the paste-like conductive member 80 supplied from the opening in the first portion 71 that opens to the fourth surface 61b of the substrate 61 is more likely to fill the first portion 71 before the second portion 72. Therefore, the conductive member 80 can be brought into contact with the electrode 12 in a state where voids are less likely to occur before the second portion 72 is closed with the conductive member 80, and a highly reliable conductive member 80 can be electrically connected to the electrode 12.

[0109] As described above, in a plan view, the maximum width of the second portion 72 in a direction perpendicular to the direction in which the second portion 72 extends is smaller than the maximum width of the first portion 71. This makes it easier for the paste-like conductive member 80 supplied to the first portion 71 to fill the first portion 71 before the second portion 72, and allows the conductive member 80 to come into contact with the electrode 12 in a state where voids are less likely to occur before the second portion 72 is closed by the conductive member 80.

[0110] The paste-like conductive material 80 is supplied from the first portion 71 to the hole 70, and the air in the hole 70 is pushed out from the first portion 71 to the second portion 72 by the conductive material 80. In a plan view, the corner portion 10b of the outer edge of the lower surface 10a of the light source 10 tends to be further from the first portion 71 than the edges, making it difficult for air to escape from the hole 70. By extending the second portion 72 toward the corner portion 10b where air is difficult to escape, and by opening the outer opening 72b of the second portion 72 outside the outer edge of the lower surface 10a of the light source 10, it is possible to make it difficult for air to remain in the first portion 71 when the conductive material 80 is supplied to the hole 70.

[0111] In the example shown in Figure 4A, the conductive member 80 supplied to the first portion 71 tends to spread more towards the edges than towards the corners of the first portion 71. By extending the second portion 72 from the corner 71a of the first portion 71, the conductive member 80 spreads over a wide area towards the edges of the first portion 71 before flowing from the corner 71a into the second portion 72. This makes it easier to increase the contact area between the conductive member 80 placed in the first portion 71 and the lower surface 10a of the light source 10, thereby increasing the connection strength between the light source 10 and the conductive member 80.

[0112] As described above, in a plan view, the second portion 72 of the first hole 70A and the second portion 72 of the second hole 70B extend into the region between the first portion 71 of the first hole 70A and the first portion 71 of the second hole 70B, thereby making it difficult for a short circuit to occur between the conductive member 80 located in the second portion 72 of the first hole 70A and the conductive member 80 located in the second portion 72 of the second hole 70B.

[0113] As shown in Figures 4B and 4C above, increasing the number of second parts 72 makes it easier for air to escape from the holes 70 when supplying the conductive member 80 to the holes 70. In addition, increasing the number of second parts 72 makes it possible to increase the bonding strength between the light source 10 and the conductive member 80 by having the conductive member 80 located in the second parts 72.

[0114] As shown in Figures 4D to 4F above, by making the shape of the first part 71 in plan view circular, the processing of the first part 71 can be easily carried out. In addition, the external stress on the conductive member 80 is reduced, and the bonding strength between the light source 10 and the conductive member 80 can be increased.

[0115] Figure 11 is a schematic cross-sectional view showing another example of a planar light source according to the embodiment. The conductive member 80 has a first conductive portion 81 located in the first portion 71, a second conductive portion 82 located in the second portion 72, and a third conductive portion 83 located on the side surface of the light source 10, outside the outer edge of the lower surface 10a of the light source 10. Since the light source 10 is also connected to the conductive member 80 on the side surface of the light source 10, the bonding strength between the light source 10 and the conductive member 80 can be further increased.

[0116] Preferably, the upper end of the third conductive portion 83 is positioned in the third direction Z at a height between the lower surface of the light-emitting element 11 and the first surface 40a of the light-reflective sheet 40. This makes it less likely for the light emitted by the light-emitting element 11 to be blocked by the third conductive portion 83, thereby improving the brightness of the light-emitting module 100.

[0117] In the example shown in Figure 11, the upper end of the third conductive portion 83 is positioned at a height between the interface between the light-transmitting member 13 and the light-reflecting member 15 and the first surface 40a of the light-reflecting sheet 40 in the third direction Z. This makes it less likely for the light emitted from the light-transmitting member 13 to be blocked by the third conductive portion 83, thereby improving the brightness of the light-emitting module 100.

[0118] Embodiments of the present invention include the following light-emitting module and planar light source.

[0119] [Section 1] A light-reflective sheet having a first surface and a second surface located opposite the first surface, and a support member having a hole, A light source is disposed on the first surface of the light-reflective sheet and has electrodes on the lower surface facing the first surface, A conductive member is placed in the holes of the light-reflective sheet and connected to the electrodes of the light source, Equipped with, The aforementioned hole is A first portion that penetrates from the first surface to the second surface of the light-reflective sheet, is located inward from the outer edge of the lower surface of the light source in a plan view, and overlaps with the electrode, A second portion continuous with the first portion, having, in a plan view, an inner opening that opens to the first surface inward from the outer edge of the lower surface of the light source, and an outer opening that opens to the first surface outward from the outer edge of the lower surface of the light source, It has, The conductive member is a light-emitting module that is in contact with the lower surface of the light source at the inner opening. [Section 2] The light-emitting module according to item 1, wherein the depth of the second portion from the first surface is shallower than the depth of the first portion from the first surface. [Section 3] In a plan view, the outer edge of the lower surface of the light source has a light source corner, and the second portion extends from the first portion toward the light source corner, as described in item 1 or 2 above, the light-emitting module. [Section 4] A light-emitting module according to any one of items 1 to 3, wherein, in a plan view, the first portion has a corner, and the second portion extends continuously from the corner of the first portion and outward beyond the outer edge of the lower surface of the light source. [Section 5] The light-emitting module according to any one of items 1 to 4 above, wherein, in a direction perpendicular to the direction in which the second portion extends in a plan view, the maximum value of the width of the second portion is smaller than the maximum value of the width of the first portion. [Section 6] The electrodes of the light source include a first electrode and a second electrode located away from the first electrode in a first direction in a plan view. The aforementioned hole has a first hole and a second hole. The first portion of the first hole overlaps the first electrode in a plan view, The first portion of the second hole is located, in a plan view, at a distance from the first portion of the first hole in a first direction, and overlaps the second electrode. The light-emitting module according to any one of items 1 to 5, wherein the second portion of the first hole and the second portion of the second hole do not extend in a plan view into the region between the first portion of the first hole and the first portion of the second hole. [Section 7] The light-emitting module according to any one of the above claims 1 to 6, wherein the conductive member comprises a first conductive portion disposed in the first portion, a second conductive portion disposed in the second portion, and a third conductive portion disposed on the side surface of the light source outside the outer edge of the lower surface of the light source. [Section 8] The light-emitting module according to item 7, wherein the upper end of the third conductive portion is located at a height between the lower surface and the first surface of the light-emitting element. [Section 9] The aforementioned light source is Light-emitting element and A light-transmitting member covering the side surface of the light-emitting element, A light-reflecting member is disposed on the lower surface of the light-transmitting member, It has, The light-emitting module according to item 7, wherein the upper end of the third conductive portion is located at a height between the interface between the light-transmitting member and the light-reflecting member and the first surface. [Section 10] A planar light source comprising a light-emitting module as described in any one of items 1 to 9 above, The support member is a substrate disposed on the second surface side of the light-reflective sheet, and further comprises a substrate having a third surface facing the second surface and a fourth surface located on the opposite side of the third surface. The first portion penetrates from the first surface of the light-reflective sheet to the fourth surface of the substrate, The second part is a planar light source having a depth that extends from the first surface to the substrate.

[0120] The embodiments of the present invention have been described above with reference to specific examples. However, the present invention is not limited to these specific examples. All forms that a person skilled in the art can implement by appropriately modifying the design based on the above-described embodiments of the present invention also fall within the scope of the present invention, insofar as they encompass the gist of the present invention. Furthermore, within the scope of the idea of ​​the present invention, a person skilled in the art can conceive of various modifications and alterations, and these modifications and alterations also fall within the scope of the present invention. [Explanation of Symbols]

[0121] 10...Light source, 10a...Bottom surface, 10b...Light source corner, 11...Light emitting element, 12...Electrode, 12A...First electrode, 12B...Second electrode, 13...Translucent member, 15...Light reflecting member, 21...First translucent member, 22... Second translucent member, 30...Light adjustment member, 40...Light reflective sheet, 40a...First surface, 40b...Second surface, 41...First layer, 42...Second layer, 43...Third layer, 50...Light guide member, 51...Fifth surface, 52...Sixth surface 53...Light source placement section, 61...Substrate, 61a...Third surface, 61b...Fourth surface, 62...Wiring layer, 70...Hole, 70A...First hole, 70B...Second hole, 71...First part, 72...Second part, 72a...Inner opening, 72b...Outer opening, 80...Conductive member, 81...First conductive part, 82...Second conductive part, 83...Third conductive part, 84...Fourth conductive part, 100...Light-emitting module, 200...Support member, 300...Planar light source

Claims

1. A light-reflective sheet having a first surface and a second surface located opposite the first surface, and a support member having a hole, A light source is disposed on the first surface of the light-reflective sheet and has electrodes on the lower surface facing the first surface, A conductive member is disposed in the holes of the light-reflective sheet, connected to the electrodes of the light source, and comprises a resin and metal particles contained in the resin. Equipped with, The aforementioned hole is The first portion penetrates from the first surface to the second surface of the light-reflective sheet, and in a plan view, is located inside the outer edge of the lower surface of the light source and overlaps with the electrode, A second portion continuous with the first portion, having, in a plan view, an inner opening that opens to the first surface inward from the outer edge of the lower surface of the light source, and an outer opening that opens to the first surface outward from the outer edge of the lower surface of the light source, It has, The conductive member is a light-emitting module that is in contact with the lower surface of the light source at the inner opening.

2. The light-emitting module according to claim 1, wherein the depth of the second portion from the first surface is shallower than the depth of the first portion from the first surface.

3. The light-emitting module according to claim 1 or 2, wherein, in a plan view, the outer edge of the lower surface of the light source has a light source corner, and the second portion extends from the first portion toward the light source corner.

4. The light-emitting module according to claim 1 or 2, wherein, in a plan view, the first portion has a corner, and the second portion extends continuously from the corner of the first portion and outward beyond the outer edge of the lower surface of the light source.

5. The light-emitting module according to claim 1 or 2, wherein in a direction perpendicular to the direction in which the second portion extends in a plan view, the maximum width of the second portion is smaller than the maximum width of the first portion.

6. The electrodes of the light source include a first electrode and a second electrode located away from the first electrode in a first direction in a plan view. The aforementioned hole has a first hole and a second hole. The first portion of the first hole overlaps the first electrode in a plan view, The first portion of the second hole is located, in a plan view, at a distance from the first portion of the first hole in a first direction, and overlaps the second electrode. The light-emitting module according to claim 1 or 2, wherein the second portion of the first hole and the second portion of the second hole do not extend in a plan view into the region between the first portion of the first hole and the first portion of the second hole.

7. The light-emitting module according to claim 1 or 2, wherein the conductive member comprises a first conductive portion disposed in the first portion, a second conductive portion disposed in the second portion, and a third conductive portion disposed on the side surface of the light source outside the outer edge of the lower surface of the light source.

8. The light-emitting module according to claim 7, wherein the upper end of the third conductive portion is located at a height between the lower surface and the first surface of the light source.

9. The aforementioned light source is Light-emitting element and A light-transmitting member covering the side surface of the light-emitting element, A light-reflecting member is disposed on the lower surface of the light-transmitting member, It has, The light-emitting module according to claim 7, wherein the upper end of the third conductive portion is located at a height between the interface between the light-transmitting member and the light-reflecting member and the first surface.

10. A planar light source comprising the light-emitting module according to claim 1 or 2, The support member is a substrate disposed on the second surface side of the light-reflective sheet, and further comprises a substrate having a third surface facing the second surface and a fourth surface located on the opposite side of the third surface. The first portion penetrates from the first surface of the light-reflective sheet to the fourth surface of the substrate, The second part is a planar light source having a depth that extends from the first surface to the substrate.

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