Method for manufacturing light emitting device

• US 10,283,670 B2
• Filed: 08/31/2016
• Issued: 05/07/2019
• Est. Priority Date: 08/31/2015
• Status: Active Grant

• Current Assignee: Nichia Corporation
• Original Assignee: Nichia Corporation
• Inventors: Hashimoto, Toru, Shibano, Yukihiro
• Primary Examiner(s): Bell, Lauren R
• Application Number:
  US15/252,219
• Publication Number:
  US 20170062671A1
• Time in Patent Office: 979 Days
• CPC Class Codes: H01L 2224/16225 the item being non-metallic, e.g. insulating substrate with or without metallisation
• CPC Class Codes: H01L 2224/97 the devices being connected to a common substrate, e.g. interposer, said common substrate being separable into individual assemblies after connecting
• CPC Class Codes: H01L 2933/0041 relating to wavelength conversion elements
• CPC Class Codes: H01L 2933/005 relating to encapsulations
• CPC Class Codes: H01L 2933/0058 relating to optical field-shaping elements
• CPC Class Codes: H01L 2933/0091 Scattering means in or on the semiconductor body or semiconductor body package H01L33/22 takes precedence
• CPC Class Codes: H01L 33/005 Processes
• CPC Class Codes: H01L 33/486 adapted for surface mounting
• CPC Class Codes: H01L 33/50 Wavelength conversion elements
• CPC Class Codes: H01L 33/505 characterised by the shape, e.g. plate or foil
• CPC Class Codes: H01L 33/52 Encapsulations
• CPC Class Codes: H01L 33/54 having a particular shape
• CPC Class Codes: H01L 33/58 Optical field-shaping elements
• CPC Class Codes: H01L 33/60 Reflective elements

Abstract

A soluble member is provided on a light emitting surface of a light emitting element. The soluble member is soluble in a solvent. The soluble member has a first surface facing the light emitting surface, a second surface opposite to the first surface in the light emitting direction, and a soluble member outer peripheral side surface provided between the first surface and the second surface. A light-blocking member made of a material which is not soluble in the solvent is provided to cover a light emitting element outer peripheral side surface and the soluble member outer peripheral side surface so that an inner side wall of the light-blocking member contacts the soluble member outer peripheral side surface. The soluble member is removed using the solvent to provide a recess surrounded by the inner side wall of the light-blocking member. A first light-transmissive member is provided in the recess.

Claims

1. A method for manufacturing a light emitting device, comprising:

providing a first support member;

providing a soluble member on the first support member such that a second surface of the soluble member directly contacts the first support member, the soluble member being soluble in a solvent and having a first surface opposite to the second surface;

providing a light emitting element on the first surface of the soluble member, the light emitting element having a light emitting surface from which the light emitting element is configured to emit light in a light emitting direction, a bottom surface opposite to the light emitting surface in the light emitting direction, and a light emitting element outer peripheral side surface provided between the light emitting surface and the bottom surface, the light emitting surface contacting the first surface of the soluble member;

providing a second light-transmissive member on the first surface of the soluble member to cover the light emitting element outer peripheral side surface, the second light-transmissive member having a first side surface contacting the light emitting element outer peripheral side surface, a second light-transmissive member upper surface facing toward the light emitting direction and contacting the first surface of the soluble member, and a second side surface connecting the first side surface and the second light-transmissive member upper surface, the soluble member including a peripheral portion surrounding a periphery of the second light-transmissive member upper surface when viewed in the light emitting direction;

removing the peripheral portion of the soluble member to provide a soluble member outer peripheral side surface provided between the first surface and the second surface of the soluble member;

providing a light-blocking member made of a material which is not soluble in the solvent to cover the second side surface of the second light-transmissive member and the soluble member outer peripheral side surface so that an inner side wall of the light-blocking member contacts the soluble member outer peripheral side surface and the second side surface of the second light-transmissive member;

removing the first support member from the soluble member after the light-blocking member is provided;

removing the soluble member using the solvent to provide a recess surrounded by the inner side wall of the light-blocking member; and

providing a first light-transmissive member in the recess.

2. The method according to claim 1,

wherein slurry of a liquid resin containing dispersed particles of a wavelength conversion substance is dropped in the recess and cured to provide the first light-transmissive member.

3. The method according to claim 2,

wherein the wavelength conversion substance includes KSF florescent material.

4. The method according to claim 1,

wherein the solvent comprises at least one of acetone, methyl ethyl ketone, another ketone-based organic solvent and water.

5. The method according to claim 1,

wherein a shape of the recess is a rectangular shape when viewed in a direction opposite to the light emitting direction.

6. The method according to claim 1,

wherein the second side surface is inclined toward the first side surface.

7. The method according to claim 1,

wherein the second light-transmissive member is made of resin.

8. The method according to claim 1, further comprising:

providing a second support member on the light emitting element such that the bottom surface of the light emitting element faces the second support member after the first support member is removed and before the soluble member is removed.

9. The method according to claim 1,

wherein the first support member has a support member peripheral portion overlapping with the peripheral portion of the soluble member when viewed in the light emitting direction,

wherein the support member peripheral portion of the first support member is not removed when the peripheral portion of the soluble member is removed, and

wherein the removing the first support member further includes removing the first support member from the light-blocking member after the light-blocking member is provided.

10. The method according to claim 1,

wherein a first electrode and a second electrode are provided on the bottom surface of the light emitting element,

wherein each of the first electrode and the second electrode comprises

an electrode top surface contacting the bottom surface of the light emitting element,

an electrode bottom surface opposite to the electrode top surface in a direction opposite to the light emitting direction, and

an electrode side surface provided between the electrode top surface and the electrode bottom surface, and

wherein the light-blocking member is provided to cover the electrode side surface of each of the first electrode and the second electrode.