Method of manufacturing light emitting device

• US 10,429,011 B2
• Filed: 03/07/2018
• Issued: 10/01/2019
• Est. Priority Date: 06/05/2013
• Status: Active Grant

• Current Assignee: Nichia Corporation
• Original Assignee: Nichia Corporation
• Inventors: Miyoshi, Tomonori, Ozeki, Kenji
• Primary Examiner(s): Garlen, Alexander K
• Assistant Examiner(s): Eide, Eric T
• Application Number:
  US15/914,190
• Publication Number:
  US 20180195675A1
• Time in Patent Office: 573 Days
• CPC Class Codes: F21K 9/68 Details of reflectors forming part of the light source
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H01L 2224/16 of an individual bump connector
• CPC Class Codes: H01L 25/0753 the devices being arranged next to each other
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/0002 Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
• CPC Class Codes: H01L 2933/0058 relating to optical field-shaping elements
• CPC Class Codes: H01L 33/56 Materials, e.g. epoxy or silicone resin
• CPC Class Codes: H01L 33/58 Optical field-shaping elements
• CPC Class Codes: H01L 33/60 Reflective elements

Abstract

A method of manufacturing a light emitting device includes: mounting a plurality of light emitting elements on a base material; joining a plurality of translucent members respectively on upper surfaces of the light emitting elements; covering side surfaces of the light emitting elements and side surfaces of the translucent members with a light reflecting member at once; and forming a groove in the light reflecting member between adjacent ones of the light emitting elements.

Claims

1. A method of manufacturing a light emitting device comprising:

mounting a plurality of light emitting elements on a base material;

joining a plurality of translucent members respectively on upper surfaces of the light emitting elements after the mounting of the plurality of light emitting elements on the base material;

covering side surfaces of the light emitting elements and side surfaces of the translucent members with a light reflecting member at once by arranging the light reflecting member to be in contact with at least a part of each of the side surfaces of the light emitting elements after the joining of the plurality of translucent members respectively on upper surfaces of the light emitting elements;

forming cuts in the light emitting device to provide grooves in the light reflecting member between adjacent ones of the light emitting elements, respectively after the covering of the side surfaces of the light emitting elements and the side surfaces of the translucent members with the light reflecting member; and

filling the grooves with a light blocking member after the forming of the cuts.

2. The method of manufacturing a light emitting device according to claim 1, wherein

the forming of the cuts includes cutting the light reflecting member between the adjacent ones of the light emitting elements from one end of the light reflecting member to the other end of the light reflecting member.

3. The method of manufacturing a light emitting device according to claim 2, further comprising

forming a frame on the base material so that the frame integrally surrounds the one end of the light reflecting member and the other end of the light reflecting member.

4. The method of manufacturing a light emitting device according to claim 3, wherein

the filling of the grooves with the light blocking member includes filling an inside of the frame with the light blocking member to place the light blocking member in the grooves.

5. The method of manufacturing a light emitting device according to claim 4, further comprising

removing the frame.

6. The method of manufacturing a light emitting device according to claim 1, wherein

the mounting of the light emitting elements on the base material includes spacing the light emitting elements so that a distance between adjacent ones of the light emitting elements is less than a length of one side of each of the light emitting elements.

7. The method of manufacturing a light emitting device according to claim 1, wherein

the filling of the groove with the light blocking member includes arranging the light blocking member to extend in a straight line in plan view.

8. The method of manufacturing a light emitting device according to claim 1, wherein

the light blocking member is arranged between every pair of adjacent ones of the light emitting elements mounted on the base material.

9. The light emitting device according to claim 1, wherein

the translucent member contains a fluorescent material.

13. The method of manufacturing a light emitting device according to claim 1, wherein

the forming of the cuts includes cutting the light reflecting member so that the grooves do not reach the base material.

16. The method of manufacturing a light emitting device according to claim 1, wherein

the covering of the side surfaces of the light emitting elements and the side surfaces of the translucent members with the light reflecting member includes providing the light reflecting member that is configured to substantially reflect light emitted from the light emitting elements.

10. A method of manufacturing a light emitting device comprising:

mounting a plurality of light emitting elements on a base material;

joining a single translucent member on upper surfaces of the light emitting elements after the mounting of the plurality of light emitting elements on the base material;

cutting the translucent member between adjacent ones of the light emitting elements after the joining of the single translucent member on the upper surfaces of the light emitting elements;

covering side surfaces of the light emitting elements and side surfaces of divided portions of the translucent member with a light reflecting member by arranging the light reflecting member to be in contact with at least a part of each of the side surfaces of the light emitting elements after the cutting of the translucent member;

forming cuts in the light emitting device to form grooves in the light reflecting member between adjacent ones of the light emitting elements after the covering of the side surfaces of the light emitting elements and the side surfaces of the divided portions of the translucent member with the light reflecting member; and

filling the grooves with a light blocking member after the forming of the cuts.

14. The method of manufacturing a light emitting device according to claim 10, wherein

the forming of the cuts includes cutting the light reflecting member so that the grooves do not reach the base material.

11. A method of manufacturing a light emitting device comprising:

mounting a plurality of light emitting elements on a base material;

covering side surfaces of the light emitting elements with a light reflecting member by arranging the light reflecting member to be in contact with at least a part of each of the side surfaces of the light emitting elements after the mounting of the plurality of light emitting elements on the base material;

forming cuts in the light emitting device to form grooves in the light reflecting member between adjacent ones of the light emitting elements after the covering of the side surfaces of the light emitting elements with the light reflecting member;

filling the grooves with a light blocking member after the forming of the cuts.

12. The method of manufacturing a light emitting device according to claim 11, further comprising

arranging a single translucent member on upper surfaces of the light emitting elements.

15. The method of manufacturing a light emitting device according to claim 11, wherein

the forming of the cuts includes cutting the light reflecting member so that the grooves do not reach the base material.