METHOD OF MANUFACTURING LIGHT-EMITTING DEVICE

• US 20160268485A1
• Filed: 02/25/2016
• Published: 09/15/2016
• Est. Priority Date: 03/09/2015
• Status: Active Grant

• Current Assignee: Toyoda Gosei Company Limited (Toyota Motor Corporation)
• Original Assignee: Toyoda Gosei Company Limited (Toyota Motor Corporation)
• Inventors: MORIMURA, Yuta, ITO, Yuhki
• Granted Patent: US 10,461,225 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: H01L 2224/48091 Arched
• CPC Class Codes: H01L 2924/00014 the subject-matter covered by the group, the symbol of which is combined with the symbol of this group, being disclosed without further technical details
• CPC Class Codes: H01L 2924/181 Encapsulation
• CPC Class Codes: H01L 2933/0041 relating to wavelength conversion elements
• CPC Class Codes: H01L 33/501 characterised by the materials, e.g. binder
• CPC Class Codes: H01L 33/504 Elements with two or more wavelength conversion materials
• CPC Class Codes: H01L 33/508 having a non-uniform spatial arrangement or non-uniform concentration, e.g. patterned wavelength conversion layer, wavelength conversion layer with a concentration gradient of the wavelength conversion material
• CPC Class Codes: H05B 33/04 Sealing arrangements , e.g. against humidity
• CPC Class Codes: H05B 33/10 Apparatus or processes specially adapted to the manufacture of electroluminescent light sources

Abstract

A method of manufacturing a light-emitting device includes providing a case including a recessed portion and mounting a light-emitting element on a bottom of the recessed portion, putting a first sealing material including a first phosphor particle into the recessed portion, putting a second sealing material including a second phosphor particle on the first sealing material in the recessed portion, and precipitating the second phosphor particle before the second sealing material cures. The second phosphor particle is located above the first phosphor particle after the first and second sealing materials cure.

Claims

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

providing a case comprising a recessed portion and mounting a light-emitting element on a bottom of the recessed portion;

putting a first sealing material comprising a first phosphor particle into the recessed portion,

putting a second sealing material comprising a second phosphor particle on the first sealing material in the recessed portion; and

precipitating the second phosphor particle before the second sealing material cures,

wherein the second phosphor particle is located above the first phosphor particle after the first and second sealing materials cure.

2. The method according to claim 1, wherein the second sealing material is put after the first sealing material cures.

3. The method according to claim 1, wherein the second sealing material is put before the first sealing material cures.

4. The method according to claim 2, wherein the first sealing material comprises a dispersant that improves dispersibility of the first phosphor particle.

5. The method according to claim 1, wherein the first sealing material has a lower refractive index than a top layer of the light-emitting element, and wherein the second sealing material has a lower refractive index than the first sealing material.

6. The method according to claim 1, wherein the first phosphor particle has a longer fluorescence wavelength than the second phosphor particle.