JP7610136B2 - Light emitting module manufacturing method and light emitting module - Google Patents

Description

The present invention relates to a method for manufacturing a light-emitting module and a light-emitting module.

Light-emitting modules that combine light-emitting elements such as light-emitting diodes with light-guiding members are widely used in planar light sources such as backlights for liquid crystal displays. For example, Patent Document 1 discloses a backlight device that includes an LED board on which a reflective sheet and multiple light-emitting diodes are provided, and a diffusion plate that faces the LED board.

JP 2019-61929 A

The present invention aims to provide a manufacturing method for a light-emitting module and a light-emitting module that can reduce brightness unevenness.

According to one aspect of the present invention, a method for manufacturing a light-emitting module includes a step of preparing an intermediate body having a plurality of light sources including at least a first light source and a second light source positioned adjacent to each other in a planar view, a first translucent member in contact with a side surface of the first light source, a second translucent member in contact with a side surface of the second light source, and a light adjustment intermediate member arranged across the first light source and the second light source in a planar view, the light adjustment intermediate member having a first light adjustment section positioned above the first light source and the first translucent member, a second light adjustment section positioned above the second light source and the second translucent member, a connection section connected to the first light adjustment section and the second light adjustment section, and a through section that penetrates from the upper surface to the lower surface and is defined by a part of the side surface of the connection section and the first light adjustment section, and a step of removing at least a part of the connection section to separate the first light adjustment section and the second light adjustment section.

According to one aspect of the present invention, the light-emitting module includes a light source, a translucent member in contact with a side surface of the light source, a light adjustment unit located above the light source and above the translucent member, and a translucent resin member located between the light source and the light adjustment unit and between the translucent member and the light adjustment unit in a cross-sectional view, and the translucent resin member has a first portion that covers the outer surface of the light adjustment unit with a first width in a cross-sectional view, and a second portion that covers the outer surface of the light adjustment unit with a second width that is thinner than the first width, or the entire outer surface of the light adjustment unit is exposed from the translucent resin member.

The present invention provides a manufacturing method for a light-emitting module and a light-emitting module that can reduce brightness unevenness.

4 is a schematic plan view for explaining one step of a method for manufacturing the light-emitting module according to the embodiment. FIG. FIG. 2 is a schematic cross-sectional view taken along line II-II in FIG. FIG. 2 is an enlarged plan view of a portion of FIG. 4 is a schematic plan view for explaining one step of a method for manufacturing the light-emitting module according to the embodiment. FIG. FIG. 5 is a schematic cross-sectional view taken along line VV in FIG. 4 . FIG. 2 is a schematic plan view of the light-emitting module according to the embodiment. FIG. 7 is a schematic cross-sectional view taken along line VII-VII in FIG. 6 . FIG. 7 is an enlarged plan view of a portion of FIG. 6. FIG. 9 is a schematic cross-sectional view taken along line IX-IX in FIG. 8 . 13 is a schematic plan view showing a modified example of the light adjusting intermediate member of the embodiment. FIG. 13 is a schematic plan view showing a modified example of the light adjusting intermediate member of the embodiment. FIG.

The following describes the embodiments with reference to the drawings. Unless otherwise specified, the dimensions, materials, shapes, relative positions, etc. of the components described in the embodiments are not intended to be limiting, but are merely illustrative examples. Note that the sizes and positional relationships of the components shown in each drawing may be exaggerated to clarify the explanation. In the following explanation, the same names and symbols indicate the same or similar components, and detailed explanations will be omitted as appropriate. In addition, as cross-sectional views, end views showing only the cut surface may be shown.

In the following description, terms indicating a specific direction or position (e.g., "upper", "lower", and other terms including these terms) may be used. However, these terms are merely used to make the relative direction or position in the referenced drawings easier to understand. As long as the relative direction or position relationship of terms such as "upper" and "lower" in the referenced drawings is the same, the arrangement in drawings other than this disclosure, in actual products, etc., does not have to be the same as in the referenced drawings. In this specification, the positional relationship expressed as "upper (or lower)" includes, for example, when there are two members, a case in which the two members are in contact with each other, and a case in which the two members are not in contact with each other and one member is located above (or below) the other member. In addition, unless otherwise specified, a member covering an object to be covered includes a case in which the member is in contact with the object to be covered and directly covers the object to be covered, and a case in which the member indirectly covers the object to be covered without contacting the object to be covered.

In the figures shown below, directions may be indicated by the X-axis, Y-axis, and Z-axis. The X-axis, Y-axis, and Z-axis are mutually orthogonal. The light-emitting surface of the light-emitting module of the embodiment is parallel to the XY plane, and the Z-axis is orthogonal to the XY plane. The arrow direction of the Z-axis is the upward direction, and the direction opposite to the arrow direction of the Z-axis is the downward direction. The direction inclined at an angle of 0° or more and less than 360° from the X-direction in the XY plane is the horizontal direction. For example, in this specification, the direction along the X-axis is the first direction X, the direction along the Y-axis is the second direction Y, and the direction along the Z-axis is the third direction Z. The third direction Z is the thickness direction of the light-emitting module and the surface light source of the embodiment. In this specification, unless otherwise specified, the thickness of each member is the value when the distance from the upper surface of each member to the lower surface of each member in the third direction Z is maximum.

The manufacturing method of the light emitting module 100 of the embodiment will be described below with reference to Figures 1 to 9.

The manufacturing method of the light emitting module 100 of the embodiment includes a step of preparing an intermediate body 400, as shown in Figures 1 and 2.

[Intermediate]
The intermediate body 400 has a plurality of light sources 10. As shown in Fig. 1, the plurality of light sources 10 at least have a first light source 10A and a second light source 10B positioned adjacent to each other in a plan view. The first light source 10A and the second light source 10B are positioned adjacent to each other in a first direction X, for example. Fig. 2 is a schematic cross-sectional view of a region where the first light source 10A and a first light adjustment unit 30A described later are arranged. Fig. 3 is an enlarged plan view of a region where the first light source 10A and the first light adjustment unit 30A are arranged.

In the example shown in FIG. 1, four light sources 10 are shown. In this example, in addition to the first light source 10A and the second light source 10B positioned adjacent to each other in the first direction X, a third light source 10C is further provided. The first light source 10A and the third light source 10C are positioned adjacent to each other in the second direction Y. When the intermediate body 400 has three or more light sources 10, one of the two light sources positioned adjacent to each other in the first direction X among the three or more light sources 10 is the first light source 10A, and the other is the second light source 10B. In addition, the light source positioned adjacent to the first light source 10A in the second direction Y is the third light source 10C. In FIG. 1, for convenience, the light source on the lower left is the first light source 10A, the light source to the right of the first light source 10A is the second light source 10B, and the light source adjacent to the upper side of the first light source 10A is the third light source 10C. The first light source 10A, the second light source 10B, and the third light source 10C are not limited to the three light sources denoted by symbols 10A, 10B, and 10C in FIG. 1, but represent any three light sources among three or more light sources that satisfy the above-mentioned arrangement relationship.

The intermediate body 400 may have five or more light sources 10. In this specification, the first light source 10A, the second light source 10B, the third light source 10C, and other light sources may be simply referred to as light sources 10 without distinguishing between them. Each light source 10 has the configuration described below.

<Light source>
As shown in FIG. 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, a substrate such as sapphire or gallium nitride, an n-type semiconductor layer disposed on the substrate, a p-type semiconductor layer, and a light emitting layer sandwiched between the n-type semiconductor layer and the p-type semiconductor layer. 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. Furthermore, the light source 10 includes a pair of positive and negative electrodes 12. The pair of positive and negative electrodes 12 constitute a part of the lower surface of the light source 10. One of the pair of electrodes 12 is electrically connected to the p-side electrode, and the other is electrically connected to the n-side electrode. The light source 10 may not include the electrode 12. When the light source 10 does not include the electrode 12, the n-side electrode and the p-side electrode of the light emitting element 11 constitute a part of the lower surface of the light source 10. Furthermore, the light source 10 does not need to include a substrate such as sapphire or gallium nitride, which makes it easier to reduce the size of the light source 10 in the third direction Z.

The structure of the light emitting layer may be a structure having a single active layer such as a double heterostructure or a single quantum well structure (SQW), or a structure having a group of active layers such as a multiple quantum well structure (MQW). The light emitting layer can emit visible light or ultraviolet light. The light emitting layer can emit visible light from blue to red. An example of a semiconductor structure including such a light emitting layer may include In _x Al _y Ga _1-x-y N (0≦x, 0≦y, x+y≦1). The semiconductor structure may include at least one light emitting layer capable of emitting the above-mentioned light. For example, the semiconductor structure may include one or more light emitting layers between an n-type semiconductor layer and a p-type semiconductor layer, or may include a structure in which a structure including an n-type semiconductor layer, a light emitting layer, and a p-type semiconductor layer in order is repeated multiple times. When the semiconductor structure includes multiple light emitting layers, the semiconductor structure may include light emitting layers having different emission peak wavelengths, or may include light emitting layers having the same emission peak wavelength. The same emission peak wavelength may vary by, for example, about several nm. Such a combination of light-emitting layers can be appropriately selected, and for example, when the semiconductor structure includes two light-emitting layers, the light-emitting layers can be selected from combinations of 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, etc. Furthermore, the light-emitting layer may include a plurality of active layers having different emission peak wavelengths, or may include a plurality of active layers having the same emission peak wavelength.

One light source 10 includes one light-emitting element 11. One light source 10 may include multiple light-emitting elements 11. The emission peak wavelengths of the multiple light-emitting elements 11 included in one light source 10 may be the same or different. For example, when one 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, when one 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, green light, and red light, ultraviolet light, green light, and red light, ultraviolet light, blue light, and green light, ultraviolet light, blue light, and red light, and ultraviolet light, green light, and red light.

In the example shown in FIG. 2, the light source 10 may further include a light-transmissive member 13 (hereinafter referred to as the light-source light-transmissive member). The light-source light-transmissive member 13 covers the upper and side surfaces of the light-emitting element 11. The light-source light-transmissive member 13 can protect the light-emitting element 11. The light-source light-transmissive member 13 may be arranged so as to expose at least a portion of the upper surface of the light-emitting element 11. This makes it easier to miniaturize the light source 10 in the third direction Z.

The light source translucent member 13 has translucency to the light emitted by the light emitting element 11. For example, the light source translucent member 13 includes a translucent resin and may further include a phosphor. As the translucent resin, for example, a silicone resin, an epoxy resin, or the like can be used. Examples of phosphors include yttrium aluminum garnet phosphors (e.g., (Y,Gd) ₃ (Al,Ga) _5O12 :Ce), lutetium aluminum garnet phosphors (e.g., _Lu3 (Al,Ga) _5O12 :Ce), terbium aluminum garnet phosphors (e.g., _Tb3 (Al, _Ga ) _5O12 :Ce), CCA phosphors (e.g. _{, Ca10 (PO4 ) 6Cl2 :} Eu), SAE phosphors ( _e.g. , _{Sr4Al14O25 :} Eu), _{chlorosilicate} phosphors (e.g., _{Ca8MgSi4O16Cl2} :Eu), silicate phosphors (e.g. _, (Ba, _Sr ,Ca,Mg) _{2SiO 4} :Eu), β-sialon phosphor (for example, (Si,Al) ₃ (O,N) ₄ :Eu) or α-sialon phosphor (for example, Ca(Si,Al) ₁₂ (O,N) ₁₆ :Eu), nitride phosphors such as LSN phosphor (for example, (La,Y) ₃ Si ₆ N ₁₁ :Ce), BSESN phosphor (for example, (Ba,Sr) ₂ Si ₅ N ₈ :Eu), SLA phosphor (for example, SrLiAl ₃ N ₄ :Eu), CASN phosphor (for example, CaAlSiN ₃ :Eu) or SCASN phosphor (for example, (Sr,Ca)AlSiN ₃ :Eu), KSF phosphor (for example, K ₂ SiF ₆ Fluoride-based phosphors such as KSAF-based phosphors (e.g., _K2 (Si1 _{-xAlx ) F6-x} :Mn, where x satisfies 0<x< ₁ ) or 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 , where FA and MA represent formamidinium and methylammonium, respectively), II-VI quantum dots (e.g., CdSe), 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. The phosphor added to the light source transmissive member 13 may be one type of phosphor or a plurality of types of phosphors.

The light source 10 may further include a covering member 15. The covering member 15 is disposed on the underside of the light-emitting element 11. The covering member 15 is disposed so that the underside of the electrode 12 of the light source 10 is exposed from the covering member 15. The covering member 15 is also disposed on the underside of the light source translucent member 13 that covers the side surface of the light-emitting element 11.

The covering member 15 has reflectivity to the light emitted by the light emitting element 11. For example, a resin member containing a gas such as nitrogen or oxygen, or a resin member containing light scattering particles can be used for the covering member 15. For example, a thermoplastic resin such as an acrylic resin, a polycarbonate resin, a cyclic polyolefin resin, a polyethylene terephthalate resin, or a polyester resin, or a thermosetting resin such as an epoxy resin or a silicone resin can be used for the resin member of the covering member 15. For example, particles of 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 for the light scattering particles of the covering member 15. The covering member 15 may contain both a gas and light scattering particles.

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 arranged on the upper side of the light emitting element 11. In a plan view, the light source light adjustment member 14 and the light emitting element 11 overlap, and the light source light adjustment member 14 is located on the upper side of the light emitting element 11 at the overlapping portion. The light source light adjustment member 14 is arranged on the upper side of the light source translucent member 13 and adjusts the amount and emission direction of light emitted from the upper surface of the light source translucent member 13. The light source light adjustment member 14 has reflectivity and translucency with respect to the light emitted by the light emitting element 11. A part of the light emitted from the upper surface of the light source translucent member 13 is reflected by the light source light adjustment member 14, and the other part is transmitted through the light source light adjustment member 14. The transmittance of the light source light adjustment member 14 with respect to the peak wavelength of the light emitting element 11 is, for example, preferably 1% to 50%, more preferably 3% to 30%. By including the light source light adjustment member 14 in the light source 10, it is possible to prevent the area directly above the light source 10 from becoming too bright. This reduces uneven brightness in the light-emitting module 100.

The light source light adjustment member 14 can be made of, for example, 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 covering 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 covering member 15. The light source light adjustment member 14 can also be made of, for example, a metal member such as aluminum or silver, or a dielectric multilayer film.

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

The light source 10 does not need to include the light source light adjustment member 14. This makes it easier to make the light source 10 smaller in size in the third direction Z than when the light source 10 includes the light source light adjustment member 14 arranged above the light emitting element 11.

The light source 10 does not need to include the covering member 15. For example, the bottom surface of the light source 10 may be formed by the bottom surface of the light-emitting element 11, the bottom surfaces of the pair of electrodes 12, and the bottom surface of the light source translucent member 13.

The light source 10 may consist of only a single light-emitting element 11.

The light source 10 may not include the covering member 15 and the light source translucent member 13, and may have a light source light adjustment member 14 disposed on the upper surface of the light emitting element 11.

The light source 10 may not include a light source translucent member 13, and may have a light source light adjustment member 14 disposed on the upper surface of the light emitting element 11 and a covering member 15 disposed on the lower surface of the light emitting element 11.

The shape of the light source 10 in a planar view is not particularly limited. The shape of the light source 10 in a planar view can be, for example, a circle, a triangle, a rectangle, a hexagon, or an octagon. When the shape of the light source 10 in a planar view is a rectangle, a pair of parallel outer edges of the light source 10 may be parallel to the first direction X, or may be inclined with respect to the first direction X. In this embodiment, as shown in Figures 1 and 3, a pair of parallel outer edges of the light source 10 are inclined at 45° with respect to the first direction X.

<Light-transmitting member>
The intermediate body 400 further includes a plurality of light-transmissive members 21. The light-transmissive members 21 are in contact with the side surfaces of the plurality of light sources 10. The plurality of light-transmissive members 21 include at least a first light-transmissive member 21A in contact with the side surface of the first light source 10A and a second light-transmissive member 21B in contact with the side surface of the second light source 10B. When the intermediate body 400 includes the third light source 10C, the plurality of light-transmissive members 21 include a third light-transmissive member 21C in contact with the side surface of the third light source 10C. In this specification, the first light-transmissive member 21A, the second light-transmissive member 21B, the third light-transmissive member 21C, and other light-transmissive members may be simply referred to as light-transmissive members 21 without distinguishing them from one another. Each light-transmissive member 21 has a configuration described below.

The light-transmitting member 21 is translucent to the light emitted by the light source 10. The transmittance of the light-transmitting member 21 to the emission peak wavelength of the light source 10 is, for example, preferably 60% or more, and more preferably 80% or more.

By contacting the side surface of the light source 10 with the translucent member 21, light from the light source 10 can easily enter the translucent member 21. The light from the light source 10 that enters the translucent member 21 propagates laterally within the translucent member 21. In a plan view, the translucent member 21 continuously surrounds the periphery of the light source 10. This makes it easier for light from the light source 10 to enter the translucent member 21 in all 360° directions around the light source 10.

The translucent member 21 is preferably arranged so as to expose at least a portion of the upper surface of the light source 10. This makes it easier to reduce the size of the light-emitting module 100 in the third direction Z than if the translucent member 21 covered the entire upper surface of the light source 10.

The 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 light-transmitting member 21, it becomes easier to adjust the brightness in the area directly above the light source 10. For example, the brightness in the area directly above the light source 10 can be adjusted by changing the thickness of the part of the light-transmitting member 21 that covers the upper surface of the light source 10. By making it easier to adjust the brightness in the area directly above the light source 10, it becomes easier to reduce brightness unevenness in the light-emitting module 100.

The light-transmitting member 21 may be composed of a single layer in the third direction Z, or may be composed of a laminate of multiple layers. The light-transmitting member 21 may also contain phosphors and light-scattering particles. When the light-transmitting member 21 is a laminate, each layer may or may not contain phosphors and/or light-scattering particles. For example, the light-transmitting member 21 may be composed of a layer containing phosphors and a layer not containing phosphors. For example, the same material as the resin member of the covering member 15 can be used as the material of the light-transmitting member 21.

<Light Adjustment Intermediate Member>
The intermediate body 400 further includes a light adjusting intermediate member 130. The light adjusting intermediate member 130 is disposed across the plurality of light sources 10 in a planar view. As shown in Fig. 1, the light adjusting intermediate member 130 is disposed across at least the first light source 10A and the second light source 10B in a planar view. When the intermediate body 400 includes the third light source 10C, the light adjusting intermediate member 130 is disposed across the first light source 10A, the second light source 10B, and the third light source 10C in a planar view.

The light adjustment intermediate member 130 has a plurality of light adjustment units 30. The light adjustment unit 30 is located above the light source 10 and the translucent member 21. The plurality of light adjustment units 30 has at least a first light adjustment unit 30A located above the first light source 10A and the first translucent member 21A, and a second light adjustment unit 30B located above the second light source 10B and the second translucent member 21B. When the intermediate body 400 has a third light source 10C, the plurality of light adjustment units 30 have a third light adjustment unit 30C located above the third light source 10C and the third translucent member 21C. In this specification, the first light adjustment unit 30A, the second light adjustment unit 30B, the third light adjustment unit 30C, and the other light adjustment units may be simply referred to as light adjustment units 30 without distinguishing them from one another.

The light adjusting intermediate member 130 is reflective and translucent to the light emitted by the light source 10. A portion of the light emitted from the light source 10 is reflected by the light adjusting intermediate member 130, and another portion is transmitted through the light adjusting intermediate member 130. The transmittance of the light adjusting intermediate member 130 for the peak wavelength of the light source 10 is preferably, for example, 1% to 50%, and more preferably 3% to 30%.

The light adjusting intermediate member 130 can be composed of, for example, a resin member (hereinafter referred to as the light adjusting resin member) and a reflector (hereinafter referred to as the light adjusting reflector) contained in the light adjusting resin member. The material of the light adjusting resin member can be the same as that of the resin member of the covering member 15. The material of the light adjusting reflector can be the same as that of the light scattering particles of the covering member 15. A gas such as nitrogen or oxygen may be used as the light adjusting reflector. The light adjusting intermediate member 130 may contain both light scattering particles and a gas. The light adjusting intermediate member 130 may be composed of a single layer, or may be composed of a laminate of multiple layers.

The light adjustment section 30 of the light adjustment intermediate member 130 is disposed above the light source 10. As shown in FIG. 1, the light adjustment section 30 and the light source 10 overlap in a plan view. By positioning the light adjustment section 30 above the light source 10, it is possible to prevent the area directly above the light source 10 from becoming too bright, and it is possible to easily reduce brightness unevenness on the light-emitting surface of the light-emitting module 100.

The light adjustment unit 30 is disposed above the light-transmissive member 21. In a plan view, the light adjustment unit 30 and the light-transmissive member 21 overlap. By positioning the light adjustment unit 30 above the light-transmissive member 21, it is possible to prevent the area directly above the light-transmissive member 21 (the area surrounding the light source 10) from becoming too bright, and it is possible to easily reduce uneven brightness on the light-emitting surface of the light-emitting module 100.

The light adjustment intermediate member 130 has a connection portion 31 connected to the light adjustment unit 30. The light adjustment intermediate member 130 has at least a connection portion 31 connected to the first light adjustment unit 30A and the second light adjustment unit 30B.

The connection portion 31 has a first connection portion 31A connected to the first light adjustment portion 30A and a second connection portion 31B connected to the second light adjustment portion 30B. The light adjustment intermediate member 130 further has a support portion 35 connected to the first connection portion 31A and the second connection portion 31B. The first light adjustment portion 30A is connected to the support portion 35 via the first connection portion 31A, and the second light adjustment portion 30B is connected to the support portion 35 via the second connection portion 31B.

When the light adjusting intermediate member 130 has the third light adjusting section 30C, the connection section of the light adjusting intermediate member 130 has the third connection section 31C connected to the third light adjusting section 30C. The third light adjusting section 30C is connected to the support section 35 via the third connection section 31C. Note that in this specification, the first connection section 31A, the second connection section 31B, the third connection section 31C, and other connection sections may be referred to simply as connection sections 31 without distinguishing one from another.

As shown in FIG. 1, multiple connection parts 31 including a first connection part 31A, a second connection part 31B, and a third connection part 31C are connected to one support part 35. In a plan view, one support part 35 arranged around multiple light adjustment parts 30 including a first light adjustment part 30A, a second light adjustment part 30B, and a third light adjustment part 30C supports the multiple light adjustment parts 30 via the connection parts 31. One light adjustment part 30 is supported by the support part 35 via, for example, multiple connection parts 31. FIG. 3 shows one first light adjustment part 30A supported by the support part 35 via four first connection parts 31A.

The light adjusting intermediate member 130 further has a through-hole 32. The through-hole 32 penetrates the light adjusting intermediate member 130 from the top to the bottom, and is defined by the side of the connection portion 31 and a part of the side of the light adjusting portion 30. In a plan view, the through-hole 32 is located between the light adjusting portion 30 and the support portion 35. The light adjusting portion 30 is separated from the support portion 35 at the through-hole 32, and is connected to the support portion 35 at the connection portion 31.

In the plan view shown in Figs. 1 and 3, the outer edge of the light source 10 is represented by, for example, a dashed rectangular line. For example, in the plan view, at least a part of the outer edge of the opposing through-holes 32 is parallel to a part of the outer edge of the light source 10. In the plan view, for example, four through-holes 32 are arranged around one light adjustment unit 30. A connection portion 31 is located at the end of each of the four through-holes 32 in the extension direction.

The light adjustment unit 30 may further have a plurality of through holes 36. The through holes 36 penetrate the light adjustment unit 30 from the upper surface to the lower surface. In a plan view, the through holes 36 are located inside the outer edge of the light adjustment unit 30. In a plan view, the through holes 32 are located outside the outer edge of the light adjustment unit 30 and are defined by a part of the outer edge of the light adjustment unit 30. In the light adjustment unit 30, the through holes 36 transmit light more easily than the part in which the through holes 36 are not arranged. By arranging a plurality of through holes 36 in the light adjustment unit 30, it becomes easy to adjust the brightness in the area directly above the light adjustment unit 30. For example, by changing at least one of the lateral size (diameter or maximum width), position, and number of the through holes 36, it is possible to adjust the light from the light source 10 that is blocked by the light adjustment unit 30. This makes it easy to adjust the brightness in the area directly above the light adjustment unit 30, making it easier to reduce brightness unevenness on the light-emitting surface of the light-emitting module 100.

<Light guiding member>
2, the intermediate 400 may further include a light guiding member 50. The light guiding member 50 is translucent to the light emitted by the light source 10. The transmittance of the light guiding member 50 for the emission peak wavelength of the light source 10 is higher than the transmittance of the light adjustment unit 30 for the emission peak wavelength of the light source 10. The transmittance of the light guiding member 50 for the emission peak wavelength of the light source 10 is, for example, preferably 60% or more, and more preferably 80% or more.

The light-guiding member 50 has a first surface 51 and a second surface 52 located on the opposite side of the first surface 51 in the third direction Z. The first surface 51, together with the upper surface of the light adjustment unit 30, constitutes the light-emitting surface of the light-emitting module 100.

The light-guiding member 50 has a plurality of storage sections 53 penetrating from the first surface 51 to the second surface 52. The plurality of storage sections 53 have at least a first storage section 53A in which the first light source 10A is arranged and a second storage section 53B in which the second light source 10B is arranged. In addition, the light-transmitting member 21 is arranged in the storage section 53.

In the cross-sectional view shown in FIG. 2, the light-transmitting member 21 is located between the side surface of the light source 10 and the light-guiding member 50. The light-guiding member 50 makes it easier for the light from the light source 10 to propagate across a wider area in the lateral direction. It is preferable that the light-guiding member 50 contacts the light-transmitting member 21. This makes it easier for the light from the light source 10 to propagate through the light-transmitting member 21 and enter the light-guiding member 50.

1 and 3, the outer edge of the storage section 53 is represented by, for example, a circular dashed line. In a plan view, the storage section 53 may be an ellipse or a polygonal shape such as a triangle, a rectangle, a hexagon, or an octagon. The storage section 53 may be a recess that opens only on the second surface 52 side of the light-guiding member 50. When the storage section 53 is a recess, the storage section 53 has a bottom surface defined by the light-guiding member 50. When the storage section 53 is a recess, the translucent member 21 covers at least the side surface of the light source 10 within the recess.

The light-guiding member 50 may be made of the same material as the resin member of the covering member 15. The light-guiding member 50 may also be made of glass or the like. The light-guiding member 50 may contain phosphors or light-scattering particles.

The thickness of the light-guiding member 50 in the third direction Z is preferably, for example, 150 μm or more and 800 μm or less. The light-guiding member 50 may be composed of a single layer in the third direction Z, or may be composed of a laminate of multiple layers. When the light-guiding member 50 is composed of a laminate, a translucent adhesive may be placed between each layer. It is not necessary to place an adhesive between each layer. Each layer of the laminate may use a different type of main material or the same type of main material.

The process of preparing the intermediate body 400 includes a process of arranging the light adjustment intermediate member 130 on a plurality of light sources 10 including at least a first light source 10A and a second light source 10B, and on a plurality of light-transmissive members 21 including at least a first light-transmissive member 21A and a second light-transmissive member 21B. When the intermediate body 400 has a light-guiding member 50, the light adjustment intermediate member 130 is also arranged on the first surface 51 of the light-guiding member 50.

For example, as shown in FIG. 2, the light adjustment intermediate member 130 is disposed on the plurality of light sources 10, the plurality of light-transmissive members 21, and the first surface 51 of the light-guiding member 50 via the light-transmissive resin member 22. In this case, the intermediate body 400 further includes the light-transmissive resin member 22.

<Light-transmitting resin member>
The light-transmitting resin member 22 is translucent to the light emitted by the light source 10. The transmittance of the light-transmitting resin member 22 to the emission peak wavelength of the light source 10 is, for example, preferably 60% or more, and more preferably 80% or more.

The translucent resin member 22 is disposed between the light source 10 and the light adjustment intermediate member 130 and/or between the translucent member 21 and the light adjustment intermediate member 130 in a cross-sectional view. The translucent resin member 22 located between the light source 10 and the light adjustment intermediate member 130 in a cross-sectional view bonds the light source 10 and the light adjustment section 30 of the light adjustment intermediate member 130. That is, the translucent resin member 22 located between the light source 10 and the light adjustment intermediate member 130 in a cross-sectional view contacts the upper surface of the light source 10 and the lower surface of the light adjustment section 30. Note that when the translucent member 21 covers the upper surface of the light source 10, the translucent resin member 22 located between the light source 10 and the light adjustment intermediate member 130 in a cross-sectional view contacts the upper surface of the translucent member 21 and the lower surface of the light adjustment section 30. In a cross-sectional view, the translucent resin member 22 located between the translucent member 21 and the light adjusting intermediate member 130 bonds the translucent member 21 and the light adjusting section 30. In other words, in a cross-sectional view, the translucent resin member 22 located between the translucent member 21 and the light adjusting intermediate member 130 contacts the upper surface of the translucent member 21 and the lower surface of the light adjusting section 30.

The maximum thickness of the translucent resin member 22 in the third direction Z is thinner than the maximum thickness of the translucent member 21 in the third direction Z.

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

After forming the through-holes 32 and the through-holes 36, the light adjustment intermediate member 130 is placed on the light source 10, the translucent member 21, and the first surface 51 of the light-guiding member 50. The through-holes 32 and the through-holes 36 are formed, for example, by irradiation with laser light.

Before arranging the light adjustment intermediate member 130, at least the uncured light-transmitting resin member 22 is supplied on the light source 10 and the light-transmitting member 21. Then, the light adjustment intermediate member 130 is arranged on the light-transmitting resin member 22 and on the first surface 51 of the light-guiding member 50. The light-transmitting resin member 22 may be supplied on the first surface 51 of the light-guiding member 50. At this time, the uncured light-transmitting resin member 22 may be arranged in the through portion 32 and the through hole 36. After arranging the light adjustment intermediate member 130 on the uncured light-transmitting resin member 22, the uncured light-transmitting resin member 22 is cured, for example, by heating.

According to this embodiment, a light adjustment intermediate member 130 including a plurality of light adjustment units 30 arranged above each of the plurality of light sources 10 and each of the plurality of light-transmissive members 21 (hereinafter collectively referred to as light adjustment regions) is arranged across the plurality of light sources 10. This makes it possible to reduce the manufacturing time of the light-emitting module compared to the case where the light adjustment units 30 are individually arranged in each light adjustment region.

In the example shown in FIG. 1, in a plan view, one support 35 that continuously surrounds the periphery of the multiple light adjustment units 30 supports the light adjustment units 30 via multiple connection parts 31. It is preferable that a part of the support 35 located between the through-hole 32 that defines a part of the side surface of the first light adjustment unit 30A and the through-hole 32 that defines a part of the side surface of the second light adjustment unit 30B does not have a hole that penetrates from the upper surface to the lower surface of the support 35. This makes it easier to increase the strength of the light adjustment intermediate member 130, making it easier to place the light adjustment intermediate member 130 on the translucent resin member 22. It is preferable that a part of the support 35 located between the through-hole 32 that defines a part of the side surface of the first light adjustment unit 30A and the through-hole 32 that defines a part of the side surface of the third light adjustment unit 30C does not have a hole that penetrates from the upper surface to the lower surface of the support 35. This makes it easier to increase the strength of the light adjustment intermediate member 130.

The support portion 35 preferably supports the light adjustment portion 30 via a plurality of first connection portions 31A. This makes it possible to prevent the light adjustment portion 30 from falling off the light adjustment intermediate member 130 when the light adjustment intermediate member 130 is positioned.

The minimum width of the connection portion 31 is not particularly limited. The minimum width of the connection portion 31 here refers to the length of the connection portion 31 when the line segment connecting one point of one through-hole 32 to one point of the other through-hole 32 is the smallest in a plane in a pair of through-holes 32 sandwiching the connection portion 31. The minimum width of the connection portion 31 is preferably 0.2 to 2 times the maximum width of the through-hole 36. By making the minimum width of the connection portion 31 0.2 or more times the maximum width of the through-hole 36, the strength of the connection portion 31 can be easily increased. This makes it easier to place the light adjustment intermediate member 130 on the translucent resin member 22. By making the minimum width of the connection portion 31 2 or less times the maximum width of the through-hole 36, it becomes easier to remove the connection portion 31 by irradiating it with laser light, etc.

Figure 3 shows an example of the arrangement of multiple first connection parts 31A connected to the first light adjustment unit 30A. This example arrangement also applies to multiple connection parts 31 connected to light adjustment units other than the first light adjustment unit 30A.

The multiple first connection parts 31A have a first connection element 31A1 and a second connection element 31A2 located on either side of the center C of the first light source 10A in a plan view. In this specification, the first connection element 31A1 and the second connection element 31A2 located on either side of the center C of the first light source 10A means that at least one straight line among multiple straight lines connecting the first connection element 31A1 and the second connection element 31A2 passes through the center C of the first light source 10A. The first connection element 31A1 and the second connection element 31A2 are located on either side of the center C of the first light source 10A in the first direction X. This distributes the load of the first light adjustment unit 30A and makes it easier for it to be applied to the support unit 35, making it easier for the support unit 35 to stably support the first light adjustment unit 30A.

The multiple first connection parts 31A further have a third connection element 31A3 and a fourth connection element 31A4 located on either side of the center C of the first light source 10A in a plan view. A first virtual straight line L1 connecting the first connection element 31A1 and the second connection element 31A2 and a second virtual straight line L2 connecting the third connection element 31A3 and the fourth connection element 31A4 are perpendicular to each other. As a result, the load of the first light adjustment unit 30A is distributed and more easily applied to the support part 35 than when there are two first connection parts 31A, so that the support part 35 can more easily support the first light adjustment unit 30A stably. For example, four first connection parts 31A (the first connection element 31A1, the second connection element 31A2, the third connection element 31A3, and the fourth connection element 31A4) are arranged point-symmetrically with respect to the center C of the first light source 10A.

The number of connection parts 31 connected to one light adjusting unit 30 may be five or more. As the number of connection parts 31 connected to one light adjusting unit 30 increases, the strength with which the support part 35 supports the light adjusting unit 30 increases. Conversely, the fewer the number of connection parts 31, the fewer the number of connection parts 31 that need to be removed when separating the multiple light adjusting units 30 in the next process, making it easier to shorten the manufacturing time.

The manufacturing method of the light emitting module 100 includes a step of preparing an intermediate 400, and then removing at least a portion of the connection portion 31 to separate a plurality of light adjustment portions 30 including at least a first light adjustment portion 30A and a second light adjustment portion 30B.

For example, the connection portion 31 is removed by irradiation with laser light. By removing the connection portion 31, the light adjustment portion 30 is separated from the support portion 35 and the other light adjustment portions 30, as shown in Figures 4 and 5.

For example, all of the connection portion 31 is removed by irradiation with laser light, and as shown in FIG. 4, a separation portion 37 is formed in the portion where the connection portion 31 was located. The separation portion 37 penetrates the light adjustment portion 30 from the upper surface to the lower surface. The separation portion 37 is continuous with the through portion 32. In a plan view, a continuous hole portion composed of the separation portion 37 and the through portion 32 is formed around the light adjustment portion 30. The hole portion penetrates the light adjustment portion 30 from the upper surface to the lower surface. The irradiation area of the laser light is, for example, circular in a plan view. Furthermore, the irradiation area of the laser light may be linear extending in one direction in a plan view, or may be curved.

It is not limited to removing all of the connection portion 31, but it is also possible to remove a part of the connection portion 31, with the unremoved part of the connection portion 31 remaining connected to the light adjustment portion 30 and/or the support portion 35. In addition, the connection portion 31 may be removed by mechanical processing using a cutting tool or the like, not limited to irradiation with laser light.

According to this embodiment, before the light adjustment intermediate member 130 is placed on the light source 10 and the translucent member 21, the light adjustment intermediate member 130 is processed to form the through-hole 32 and the through-hole 36. After the light adjustment intermediate member 130 is placed on the light source 10 and the translucent member 21, only the process of removing the connection portion 31 is required. This reduces damage to the translucent member 21 caused by processing the light adjustment intermediate member 130. For example, when a laser beam is used to process the light adjustment intermediate member 130, damage to the translucent member 21 caused by irradiation with the laser beam can be reduced. In addition, when the light adjustment intermediate member 130 is processed using a cutting tool or the like, damage to the translucent member 21 caused by the cutting tool or the like can be reduced. In addition, before placing the light adjusting intermediate member 130 on the light source 10 and the translucent member 21, the light adjusting intermediate member 130 may be processed to form all of the through-holes 32 and the through-holes 36, or the light adjusting intermediate member 130 may be processed to form a part of the through-holes 32 and the through-holes 36. If the light adjusting intermediate member 130 is processed to form a part of the through-holes 32 and the through-holes 36 before placing the light adjusting intermediate member 130 on the light source 10 and the translucent member 21, the light adjusting intermediate member 130 may be processed to form the other part of the through-holes 32 and the through-holes 36 after placing the light adjusting intermediate member 130 on the light source 10 and the translucent member 21. This also makes it easier to reduce damage to the translucent member 21 caused by processing the light adjusting intermediate member 130.

When the light adjustment intermediate member 130 has a support portion 35, the manufacturing method for the light emitting module 100 further includes a step of removing the support portion 35 after the step of removing the connection portion 31.

By removing the support portion 35, the first surface 51 of the light guide member 50 is exposed in areas other than the area where the light adjustment portion 30 is arranged, as shown in Figures 6 and 7. In this way, a light emitting module 100 is obtained in which the light adjustment portion 30 is arranged in the required position (directly above the light source 10 and above the periphery of the light source 10). The light emitting surface of the light emitting module 100 includes the upper surface of the light adjustment portion 30 and the first surface 51 of the light guide member 50.

The light adjustment unit 30 is disposed directly above the light source 10 and above the periphery of the light source 10 to prevent the areas directly above the light source 10 and above the periphery of the light source 10 from becoming too bright, while the light adjustment unit is not disposed in other areas to improve the brightness of the light extracted from the first surface 51 of the light-guiding member 50. This reduces uneven brightness on the light-emitting surface of the light-emitting module 100.

The support portion 35 is peeled off from the first surface 51 of the light-guiding member 50 without using laser light, a cutting tool, or the like. This allows the support portion 35 to be removed without damaging the light-guiding member 50. For example, the support portion 35 is grasped and peeled off from the first surface 51 of the light-guiding member 50. The support portion 35 may also be peeled off using an adsorption member that adheres to the support portion 35.

For example, the entire support portion 35 is removed. Alternatively, depending on the luminance distribution on the light-emitting surface of the light-emitting module 100, a portion of the support portion 35 may be left on the first surface 51 of the light-guiding member 50 other than the position where the light adjustment portion 30 is disposed.

In the process of preparing the light adjustment intermediate member 130, the different light adjustment members 30 may be connected to each other by directly connecting the connection members 31 connected to the different light adjustment members 30. For example, as shown in FIG. 11, the connection members 31 connected to two adjacent light adjustment members 30 in the first direction X may be extended in the first direction X to connect them, and the connection members 31 connected to two adjacent light adjustment members 30 in the second direction Y may be extended in the second direction Y to connect them. That is, the multiple light adjustment members 30 may be connected to each other via the multiple connection members 31 extending in the first direction X and the second direction Y. In this case, the multiple light adjustment members 30 are separated from each other by removing the connection members 31. Therefore, the process of removing the portions other than the connection members 31 in the light adjustment intermediate member 130 can be eliminated.

Figure 10 is a schematic plan view showing a modified example of the light adjustment intermediate member 130. Figure 10 is an enlarged schematic plan view of a portion where, for example, the first light adjustment unit 30A, the support unit 35, and the two first connection units 31 (31A) that connect the first light adjustment unit 30A and the support unit 35 are arranged. Note that the features shown in Figure 10 can also be applied to a portion where a light adjustment unit 30 other than the first light adjustment unit 30A and a connection unit 31 other than the first connection unit 31A are arranged.

The through portion 32 has a first portion 32a and a second portion 32b. The first portion 32a extends parallel to a part of the outer edge of the light source 10 in a plan view. The second portion 32b is connected to the first portion 32a, is inclined with respect to the extension direction of the first portion 32a in a plan view, and extends in a direction away from the first light adjustment unit 30A. The second portion 32b is defined by a part of the side surface of the connection portion 31 and a part of the side surface of the support portion 35. In the extension direction of the second portion 32b, the second portion 32b of one of the pair of through portions 32 sandwiching the connection portion 31 is located away from the other through portion 32.

For example, when forming the through-hole 32, the laser light irradiation is turned on and the laser light is scanned in the direction in which the first portion 32a extends, and the laser light irradiation is turned off at a position where a part of the light-adjusting intermediate member 130 is left as the connection portion 31. At this time, just before the position where the connection portion 31 is to be formed, the laser light is tilted with respect to the direction in which the first portion 32a extends and scanned in a direction away from the first light adjustment unit 30A to turn off the laser light irradiation, making it easier to control the width W1 of the connection portion 31 than when the laser light is scanned in the direction in which the first portion 32a extends and the laser light irradiation is turned off. For example, even if the position at which the laser light irradiation is turned off varies, the variation in the width W1 of the connection portion 31 can be reduced by scanning the laser light in a direction away from the first light adjustment unit 30A at an angle with respect to the direction in which the first portion 32a extends and turning off the laser light irradiation, compared to when the laser light is scanned in the direction in which the first portion 32a extends and the laser light irradiation is turned off. Here, the width W1 of the connection portion 31 represents the minimum width of the connection portion 31 in the direction in which the first portion 32a extends.

In addition, the through portion 32 has a first through portion 32A and a second through portion 32B that are adjacent to each other via the connection portion 31 in a plan view. The tip portion 32Aa of the first through portion 32A is located away from the first light adjustment portion 30A and is defined by a part of the side surface of the connection portion 31 and a part of the side surface of the support portion 35. In a plan view, the direction in which the first through portion 32A extends is inclined with respect to the direction in which the second through portion 32B extends. In addition, in a plan view, the tip portion 32Aa of the first through portion 32A and the second through portion 32B are located away from each other in the direction in which the first through portion 32A extends. This makes it easier to control the width W2 of the connection portion 31 than when the direction in which the first through portion 32A extends and the direction in which the second through portion 32B extends are the same direction. Here, the width W2 of the connection portion 31 represents the width in the direction connecting the first through portion 32A and the second through portion 32B at the shortest distance in a plan view.

Next, the light-emitting module 100 and surface light source 300 of the embodiment will be described.

The light emitting module 100 shown in Figures 6 to 9 is obtained by the above-mentioned process. The light emitting module 100 includes a light source 10, a light-transmitting member 21 that contacts the side surface of the light source 10, a light adjustment section 30 located above the light source 10 and above the light-transmitting member 21, and a light-transmitting resin member 22 located between the light source 10 and the light adjustment section 30 and between the light-transmitting member 21 and the light adjustment section 30 in a cross-sectional view. The light emitting module 100 can further include a light-guiding member 50 having a housing section 53 in which the light source 10 is disposed.

The outer surface 38 of the light adjusting section 30 has a portion that defined the through-hole 32 and a portion formed by removing the connection section 31. The translucent resin member 22 has a first portion 22a located on the outer surface 38 of the light adjusting section 30 that defined the through-hole 32, and a second portion 22b located on the outer surface 38 of the light adjusting section 30 that was formed by removing the connection section 31.

9 is a schematic cross-sectional view taken along line IX-IX in FIG. 8, and includes a cross-section of the outer surface 38 of the light adjusting portion 30 of the portion that defined the through-hole 32 in the light adjusting intermediate member 130. After the light adjusting intermediate member 130 is placed on the uncured light-transmitting resin member 22, the uncured light-transmitting resin member 22 may protrude from the region between the first surface 51 of the light-guiding member 50 and the lower surface of the light adjusting portion 30 onto the outer surface 38 of the light adjusting portion 30. In this case, the first portion 22a of the cured light-transmitting resin member 22 covers the outer surface 38 of the light adjusting portion 30 with a first width in a cross-sectional view. The first width is a width in the horizontal direction. Note that the uncured light-transmitting resin member 22 may protrude from the through-hole 36 onto the upper surface of the light adjusting portion 30 and cover at least a part of the upper surface of the light adjusting portion 30.

The connection portion 31 is removed after the light adjustment intermediate member 130 is placed on the uncured light-transmitting resin member 22 and the light-transmitting resin member 22 is cured. Therefore, the second portion 22b of the light-transmitting resin member 22 located on the outer surface 38 of the light adjustment portion 30 formed by removing the connection portion 31 is a portion where the entire outer surface 38 of the light adjustment portion 30 is exposed from the light-transmitting resin member 22, as shown in FIG. 7. In addition, when the connection portion 31 is removed by the laser light, the connection portion 31 and the light-transmitting resin member 22 are melted by the heat of the laser light. Therefore, a very small amount of the melted light-transmitting resin member 22 may adhere to the outer surface 38 of the light adjustment portion 30. In this case, the second portion 22b of the light-transmitting resin member 22 is a portion that covers the outer surface 38 of the light adjustment portion 30 with a second width (width in the horizontal direction) that is thinner than the first width.

9, in the outer surface 38 of the light adjusting unit 30 that is covered by the first portion 22a of the translucent resin member 22 with a first width, the light from the light source 10 is easily extracted to the outside of the light adjusting unit 30 via the translucent resin member 22, and the brightness can be increased. In contrast, in the portion of the outer surface 38 of the light adjusting unit 30 that is exposed from the translucent resin member 22 or the portion that is covered with a second width that is thinner than the first width, the brightness is lower than that of the outer surface covered by the first portion 22a of the translucent resin member 22. By mixing portions with relatively high brightness and portions with low brightness on the outer surface 38 of the light adjusting unit 30, it is possible to easily reduce brightness unevenness on the light emitting surface of the light emitting module 100.

For example, when the connection portion 31 is removed by irradiation with laser light, the portion from which the connection portion 31 has been removed includes a curve in plan view. When the support portion 35 is subsequently removed, the outer surface 38 of the light adjustment portion 30 formed by removing the connection portion 31 has a recess that is recessed laterally as shown in FIG. 8. Therefore, the second portion 22b of the light-transmitting resin member 22 is located in the recess that is recessed laterally in the outer surface 38 of the light adjustment portion 30.

8, the outer surface 38 of the light adjustment unit 30 on which the second portion 22b of the light-transmitting resin member 22 is located has a first outer surface 38A located on the third imaginary straight line L3 that connects the center C of the light source 10 and the outer edge of the light-guiding member 50 at the shortest distance in a plan view. At the outer edge of the light-guiding member 50, the outer edge of the light-guiding member 50 located at the shortest distance from the center C of the light source 10 is likely to have higher brightness than the outer edge of the light-guiding member 50 that is not located at the shortest distance. In other words, the outer edge of the light-guiding member 50 located on the third imaginary straight line L3 is likely to have higher brightness. For this reason, a part of the outer edge of the light-guiding member 50, which is likely to have higher brightness, and the second portion 22b of the light-transmitting resin member 22, which is likely to have lower brightness than the first portion 22a of the light-transmitting resin member 22, are located on the third imaginary straight line L3. As a result, a portion of the outer edge of the light-guiding member 50, which is prone to high brightness, and the second portion 22b of the translucent resin member 22, which is prone to low brightness, are located on the third virtual straight line L3, making it easier to reduce brightness unevenness on the light-emitting surface of the light-emitting module 100.

The outer surface 38 of the light adjustment section 30 on which the second portion 22b of the light-transmitting resin member 22 is located further has a second outer surface 38B located on the opposite side of the first outer surface 38A across the center C of the light source 10 in a plan view and located on the extension line L5 of the third imaginary straight line L3. This makes it easier to reduce the excessive brightness on the extension line L5 of the third imaginary straight line L3.

The outer surface 38 of the light adjustment unit 30 on which the second portion 22b of the light-transmitting resin member 22 is located further includes a third outer surface 38C and a fourth outer surface 38D. In a plan view, a fourth imaginary straight line L4 connecting the third outer surface 38C and the fourth outer surface 38D passes through the center C of the light source 10 and is perpendicular to the third imaginary straight line L3. This makes it easier to reduce excessive brightness on the fourth imaginary straight line L4.

6, the light guide member 50 can be divided into a plurality of light emitting regions 50A by partition grooves 54 extending in the first direction Z and the second direction Y. One light emitting region 50A can be used as a driving unit for local dimming. The light emitting module 100 is not limited to a plurality of light emitting regions 50A, and may be configured to have one light emitting region 50A. In addition, by having the partition grooves 54 of the light guide member 50, it is easy to 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. For example, a part of the light from the light source 10 propagating laterally in the light guide member 50 is reflected or refracted by the surface of the light guide member 50 that defines the partition grooves 54. Therefore, it is easy to reduce the incidence of the light from the light source 10 propagating laterally in the light guide member 50 into the light guide member 50 of the light emitting region located adjacently. This makes it easy to 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.

As shown in FIG. 7, the partition groove 54 preferably penetrates from the first surface 51 to the second surface 52 of the light guide member 50. This allows the light guide member 50 to be separated into a plurality of parts, so that, for example, warping of the support member 200 caused by the difference in thermal expansion coefficient between the light guide member 50 and the support member 200 (described later) that supports the light guide member 50 can be reduced. By reducing the warping of the support member 200, it is possible to reduce the occurrence of cracks in the conductive member 67 (described later). In addition, the partition groove 54 may be a recess that opens only on the first surface 51 side of the light guide member 50, or may be a recess that opens only on the second 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.

A member having reflectivity to the light emitted by the light source 10 may be disposed 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. Note that a member having reflectivity to the light emitted by the light source 10 does not have to be disposed within the partition groove 54.

The surface light source 300 of the embodiment further includes a support member 200 in addition to the light emitting module 100 described above. As shown in FIG. 7, the light emitting module 100 is disposed on the support member 200, and the support member 200 supports the light emitting module 100. The light guide member 50 is disposed on the support member 200 with the second surface 52 facing the upper surface of the support member 200.

The support member 200 has a wiring board 60. The wiring board 60 has an insulating base material 61 and at least one wiring layer 62 arranged on at least one surface of the insulating base material 61. The insulating base material 61 may be a rigid board or a flexible board. In order to make the surface light source 300 thinner, it is preferable that the insulating base material 61 is a flexible board. The insulating base material 61 may be composed of a single layer in the third direction Z, or may be composed of a laminate of multiple layers. For example, the insulating base material 61 may be composed of a single-layer flexible board or may be composed of a laminate of multiple rigid boards. For example, a resin such as polyimide can be used as the material of the insulating base material 61. The wiring layer 62 is a metal film, for example, a copper film.

The support member 200 further includes a first adhesive layer 63 disposed on the wiring board 60, a reflective member 64 disposed on the first adhesive layer 63, and a second adhesive layer 65 disposed on the reflective member 64.

The first adhesive layer 63 is disposed between the wiring board 60 and the reflective member 64, and bonds the wiring board 60 and the reflective member 64. The first adhesive layer 63 can be made of, for example, a resin member containing light scattering particles. For example, the same material as the resin member of the covering member 15 can be used as the resin member of the first adhesive layer 63. For example, the same material as the light scattering particles of the covering member 15 can be used as the light scattering particles of the first adhesive layer 63. A sheet-shaped optical transparent adhesive can be used as the first adhesive layer 63.

The refractive index of the resin member of the first adhesive layer 63 is preferably lower than the refractive index of the resin member of the reflective member 64. By making the refractive index of the resin member of the first adhesive layer 63 lower than the refractive index of the resin member of the reflective member 64, a portion of the light traveling from the reflective member 64 to the first adhesive layer 63 is more likely to be totally reflected at the interface between the reflective member 64 and the first adhesive layer 63. This makes it possible to reduce the light that escapes downward from the light-emitting module 100, which makes it easier to improve the light extraction efficiency of the light-emitting module 100.

The reflecting member 64 is disposed below the light guide member 50, below the light source 10, below the translucent member 21, and below the partition groove 54. The reflecting member 64 is reflective to the light emitted by the light source 10. The reflecting member 64 can be composed of a resin member and a reflector contained in the resin member. For example, the same material as the resin member of the covering member 15 can be used as the resin member of the reflecting member 64. The same material as the light scattering particles of the covering member 15 can be used as the material of the reflector of the reflecting member 64. A gas such as nitrogen or oxygen may be used as the reflector of the reflecting member 64. The reflecting member 64 may also contain both light scattering particles and a gas as the reflector.

The refractive index of the reflector of the reflecting member 64 is preferably lower than the refractive index of the resin member of the reflecting member 64. By making the refractive index of the reflector of the reflecting member 64 lower than the refractive index of the resin member of the reflecting member 64, a portion of the light from the light source 10 that is incident on the reflecting member 64 is more likely to be totally reflected at the interface between the resin member of the reflecting member 64 and the reflector of the reflecting member 64. This reduces the amount of light that escapes downward from the reflecting member 64, making it easier to improve the light extraction efficiency of the light-emitting module 100.

When the refractive index of the reflector of the reflecting member 64 is lower than the refractive index of the resin member of the reflecting member 64, it is preferable that the refractive index of the resin member of the reflecting member 64 is higher than the refractive index of the light-guiding member 50. This makes it easier to increase the refractive index difference between the resin member of the reflecting member 64 and the reflector of the reflecting member 64, and makes it easier for a portion of the light from the light source 10 that is incident on the reflecting member 64 to be totally reflected at the interface between the resin member of the reflecting member 64 and the reflector of the reflecting member 64.

The second adhesive layer 65 is disposed between the reflecting member 64 and the second surface 52 of the light guide member 50, and bonds the reflecting member 64 and the light guide member 50. The light source 10 is disposed on the second adhesive layer 65 in the housing portion 53 of the light guide member 50. The second adhesive layer 65 can be formed, for example, of a resin member containing light scattering particles. For example, the same material as the resin member of the covering member 15 can be used as the resin member of the second adhesive layer 65. For example, the same material as the light scattering particles of the covering member 15 can be used as the light scattering particles of the second adhesive layer 65. A sheet-shaped optical transparent adhesive can be used as the second adhesive layer 65.

The refractive index of the resin member of the second adhesive layer 65 is preferably lower than that of the light-guiding member 50. By making the refractive index of the resin member of the second adhesive layer 65 lower than that of the light-guiding member 50, a portion of the light traveling from the light-guiding member 50 to the second adhesive layer 65 is more likely to be totally reflected at the interface between the light-guiding member 50 and the second adhesive layer 65. This makes it possible to reduce the amount of light that escapes downward from the light-emitting module 100, which makes it easier to improve the light extraction efficiency of the light-emitting module 100.

The refractive index of the resin member of the second adhesive layer 65 is preferably lower than that of the translucent member 21. By making the refractive index of the resin member of the second adhesive layer 65 lower than that of the translucent member 21, a portion of the light traveling from the translucent member 21 to the second adhesive layer 65 is more likely to be totally reflected at the interface between the translucent member 21 and the second adhesive layer 65. This makes it possible to reduce the amount of light that escapes downward from the light-emitting module 100, which makes it easier to improve the light extraction efficiency of the light-emitting module 100.

The support member 200 further includes a conductive member 67. The conductive member 67 includes, for example, a resin and metal particles contained in the resin. For example, an epoxy resin or a phenolic resin can be used as the resin of the conductive member 67. For example, copper or silver particles can be used as the metal particles of the conductive member 67.

The conductive member 67 has a connection portion 67a and a wiring portion 67b. The connection portion 67a penetrates the second adhesive layer 65, the reflective member 64, the first adhesive layer 63, and the insulating base material 61 in the third direction Z. The wiring portion 67b is disposed on the surface of the wiring board 60 on which the wiring layer 62 is disposed, and is connected to the connection portion 67a. The connection portion 67a and the wiring portion 67b can be integrally formed from the same material. A portion of the wiring portion 67b is connected to the wiring layer 62.

A pair of conductive members 67 are arranged apart from each other in correspondence with the pair of positive and negative electrodes 12 of the light source 10. Of the pair of conductive members 67, the connection portion 67a of one conductive member 67 is connected to the positive electrode 12 below the light source 10, and the connection portion 67a of the other conductive member 67 is connected to the negative electrode 12 below the light source 10. The electrodes 12 of the light source 10 are electrically connected to the wiring layer 62 via the conductive members 67.

The support member 200 further includes an insulating layer 66. The insulating layer 66 is disposed on the lower surface of the wiring substrate 60 and covers the wiring layer 62. The insulating layer 66 may be made of, for example, epoxy resin, urethane resin, or acrylic resin.

Embodiments of the present invention include the following light emitting module manufacturing method and light emitting module.

[Item 1]
a step of preparing an intermediate body having a plurality of light sources including at least a first light source and a second light source positioned adjacent to each other in a planar view, a first light-transmissive member in contact with a side surface of the first light source, a second light-transmissive member in contact with a side surface of the second light source, and a light adjusting intermediate member arranged across the first light source and the second light source in a planar view, the light adjusting intermediate member having a first light adjusting portion positioned above the first light source and the first light-transmissive member, a second light adjusting portion positioned above the second light source and the second light-transmissive member, a connecting portion connected to the first light adjusting portion and the second light adjusting portion, and a through portion penetrating from an upper surface to a lower surface and defined by a part of a side surface of the connecting portion and the first light adjusting portion;
removing at least a portion of the connection portion to separate the first light adjustment unit and the second light adjustment unit;
A method for manufacturing a light emitting module comprising:
[Item 2]
In the step of preparing the intermediate,
the connection portion includes a first connection portion connected to the first light adjustment portion and a second connection portion connected to the second light adjustment portion,
the light adjusting intermediate member has a support portion connected to the first connection portion and the second connection portion,
2. The method for manufacturing a light emitting module according to claim 1, further comprising the step of removing the supporting portion after the step of removing the connecting portion.
[Item 3]
In the step of preparing the intermediate,
the plurality of light sources includes a third light source positioned adjacent to the first light source,
The method for manufacturing the light-emitting module described in paragraph 2 above, wherein the light adjusting intermediate member has a third light adjusting portion located above the third light source, a third connection portion included in the connection portion and connected to the third light adjusting portion, and one support portion connected to the first connection portion, the second connection portion, and the third connection portion.
[Item 4]
In the step of preparing the intermediate,
A method for manufacturing an optical emitting module described in any one of items 1 to 3 above, wherein the through portion has a first portion and a second portion that is connected to the first portion, is inclined with respect to the direction in which the first portion extends in a planar view, and extends in a direction away from the first light adjustment portion.
[Item 5]
In the step of preparing the intermediate,
The through portion includes a first through portion and a second through portion positioned adjacent to each other with the connection portion interposed therebetween,
A method for manufacturing an optical emitting module described in any one of items 1 to 4 above, wherein a tip portion of the first penetrating portion is located away from the first light adjustment portion and is defined by a portion of a side surface of the connection portion and a portion of a side surface of the support portion.
[Item 6]
In the step of preparing the intermediate body, the support portion supports the first light adjustment portion via the plurality of first connection portions;
A method for manufacturing a light-emitting module described in any one of items 1 to 5 above, wherein the multiple first connection portions have a first connection element and a second connection element positioned on either side of the center of the first light source in a planar view.
[Item 7]
the first connection portions further include a third connection element and a fourth connection element positioned on either side of the center of the first light source in a plan view,
7. The method for manufacturing a light-emitting module described in item 6 above, wherein a first virtual line connecting the first connection element and the second connection element and a second virtual line connecting the third connection element and the fourth connection element are perpendicular to each other.
[Item 8]
8. The method for manufacturing a light emitting module according to any one of items 1 to 7, wherein in the step of preparing the intermediate body, the first light adjustment section has a plurality of through holes.
[Item 9]
9. A method for manufacturing a light-emitting module described in any one of items 1 to 8, wherein in the step of preparing the intermediate body, the intermediate body further has a light-guiding member having a first storage portion in which the first light source is arranged and a second storage portion in which the second light source is arranged.
[Item 10]
A light source;
a light-transmitting member in contact with a side surface of the light source;
a light adjusting unit located above the light source and above the light-transmitting member;
a translucent resin member located between the light source and the light adjustment unit and between the translucent member and the light adjustment unit in a cross-sectional view;
Equipped with
The light-transmitting resin member is
A first portion covering an outer surface of the light adjusting member with a first width in a cross-sectional view;
a second portion that covers an outer surface of the light adjusting portion with a second width that is thinner than the first width, or the entire outer surface of the light adjusting portion is exposed from the light-transmitting resin member;
A light emitting module having
[Item 11]
The outer surface of the light adjustment unit has a recess that is recessed in the lateral direction,
11. The light emitting module according to item 10, wherein the second portion of the light-transmitting resin member is located in the recess.
[Item 11]
12. The light emitting module according to claim 10 or 11, further comprising a light guiding member having a housing portion in which the light source is disposed.
[Item 13]
The light-emitting module described in item 12 above, wherein the outer surface of the light adjustment portion on which the second portion of the translucent resin member is located has a first outer surface that, in a planar view, is located on a third virtual straight line that connects the center of the light source and the outer edge of the light-guiding member by the shortest distance.
[Item 14]
The light-emitting module described in paragraph 13 above, wherein the outer surface of the light adjustment section on which the second part of the translucent resin member is located is located on the opposite side of the first outer surface across the center of the light source in a planar view, and further has a second outer surface located on an extension of the third virtual straight line.
[Item 15]
an outer surface of the light adjustment unit where the second portion of the light-transmitting resin member is located further includes a third outer surface and a fourth outer surface;
15. The light-emitting module according to item 14, wherein in a plan view, a fourth virtual line connecting the third outer surface and the fourth outer surface passes through the center of the light source and is perpendicular to the third virtual line.

The above describes the embodiments of the present invention 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 as long as they include the gist of the present invention. In addition, a person skilled in the art can come up with various modifications and alterations within the scope of the concept of the present invention, and these modifications and alterations also fall within the scope of the present invention.

DESCRIPTION OF SYMBOLS 10...Light source, 10A...First light source, 10B...Second light source, 10C...Third light source, 21...Transparent member, 21A...First light-transmitting member, 21B...Second light-transmitting member, 21C...th 3 Translucent member, 22... Transparent resin member, 22a... First portion of the translucent resin member, 22b... Second portion of the translucent resin member, 30... Light adjustment section, 30A... First light adjustment Department, 30B...Second light adjustment section, 30C...Third light adjustment section, 31...Connection section, 31A...First connection section, 31A1...First connection element, 31A2...Second connection element, 31A3...Third connection Connection element, 31A4... Fourth connection element, 31B... Second connection part, 31C... Third connection part, 32... Penetration part, 32a... First part of penetration part, 32b... Second part of penetration part, 32 A: first penetrating portion; 32Aa: tip portion of first penetrating portion; 32B: second penetrating portion; 35: support portion; 36: through hole; 38: outer surface; 38A: first outer surface; 38B: second Outer surface, 38C... third outer surface, 38D... fourth outer surface, 50... light guide member, 53... storage portion, 54... partition groove, 60... wiring board, 61... insulating base material, 62... wiring layer, 63 . . . First adhesive layer, 64... Reflective member, 65... Second adhesive layer, 66... Insulating layer, 67... Conductive member, 130... Light adjusting intermediate member, 100... Light emitting module, 200... Support member, 300... Planar light source , 400... intermediate body, L1... first virtual line, L2... second virtual line, L3... third virtual line, L4... fourth virtual line, L5... extension line of the third virtual line

Claims (13)

A process for preparing an intermediate body including a plurality of light sources including at least a first light source and a second light source positioned adjacent to each other in a plan view, a first light-transmitting member in contact with a side surface of the first light source, a second light-transmitting member in contact with a side surface of the second light source, and a light adjusting intermediate member arranged across the first light source and the second light source in a plan view, the light adjusting intermediate member including a first light adjusting section positioned above the first light source and the first light-transmitting member, a second light adjusting section positioned above the second light source and the second light-transmitting member, and a periphery of the first light adjusting section and the second light adjusting section in a plan view. a connecting portion having a supporting portion arranged around the supporting portion, a first connecting portion connecting the first light adjusting portion and the supporting portion, and a second connecting portion connecting the second light adjusting portion and the supporting portion, and a through portion located between the first light adjusting portion and the supporting portion and between the second light adjusting portion and the supporting portion in a planar view, wherein the first light adjusting portion is connected to the supporting portion at the first connecting portion while being separated from the supporting portion at the through portion, and the second light adjusting portion is connected to the supporting portion at the second connecting portion while being separated from the supporting portion at the through portion;
After preparing the intermediate body, removing the connection portion to separate the first light adjusting portion and the second light adjusting portion from the support portion;
removing the connecting portion to separate the first light adjusting portion and the second light adjusting portion from the supporting portion, and then removing the supporting portion from the intermediate body;
A method for manufacturing a light emitting module comprising: In the step of preparing the intermediate,
the plurality of light sources includes a third light source positioned adjacent to the first light source,
The method for manufacturing a light-emitting module according to claim 1 , wherein the light adjusting intermediate member has a third light adjusting portion located above the third light source, and a third connection portion connecting the third light adjusting portion and the support portion. In the step of preparing the intermediate,
The method for manufacturing an optical emission module according to claim 1 or 2, wherein the through portion has a first portion and a second portion that is connected to the first portion, is inclined with respect to the direction in which the first portion extends in a planar view, and extends in a direction away from the first light adjustment portion. In the step of preparing the intermediate,
The through portion includes a first through portion and a second through portion positioned adjacent to each other with the connection portion interposed therebetween,
The method for manufacturing a light-emitting module according to claim 1 or 2, wherein a tip of the first penetrating portion is located away from the first light adjustment portion and is defined by a part of a side surface of the connection portion and a part of a side surface of the support portion. In the step of preparing the intermediate body, the support portion is connected to the first light adjustment portion via a plurality of the first connection portions;
The method for manufacturing a light-emitting module according to claim 1 , wherein the plurality of first connection portions have a first connection element and a second connection element positioned on either side of the center of the first light source in a plan view. the first connection portions further include a third connection element and a fourth connection element positioned on either side of the center of the first light source in a plan view,
The method for manufacturing a light-emitting module according to claim 5 , wherein a first virtual line connecting the first connection element and the second connection element and a second virtual line connecting the third connection element and the fourth connection element are perpendicular to each other. The method for manufacturing a light-emitting module according to claim 1 or 2, wherein in the step of preparing the intermediate body, the first light adjustment section has a plurality of through holes. In the step of preparing the intermediate body, the intermediate body further includes a light guide member having a first accommodation portion in which the first light source and the first light-transmissive member are arranged, and a second accommodation portion in which the second light source and the second light-transmissive member are arranged,
The method for manufacturing a light emitting module according to claim 1 , wherein the supporting portion is located on the light guiding member. A light emitting module having a light emitting surface,
A light source;
a light-transmitting member in contact with a side surface of the light source;
a light guide member having a housing portion in which the light source and the light-transmitting member are disposed;
a light adjustment unit located on an upper side of the light source, which is the light emitting surface side, and an upper side of the light-transmitting member, which is the light emitting surface side ;
a light-transmitting resin member located between the light source and the light adjustment unit, between the light-transmitting member and the light adjustment unit, and between the light-guiding member and the light adjustment unit, in a cross-sectional view perpendicular to the light-emitting surface;
Equipped with
The light-transmitting resin member is
a first portion covering, with a first width, a part of an outer surface of the light adjustment portion located on the light guiding member in the cross - sectional view;
a second portion that covers another part of the outer surface of the light adjustment portion with a second width that is thinner than the first width, or another part of the outer surface of the light adjustment portion is exposed from the light-transmitting resin member;
A light emitting module having the other part of the outer surface of the light adjustment unit has a recess that is recessed in a lateral direction that is a direction parallel to the light emitting surface ,
The light emitting module according to claim 9 , wherein the second portion of the light-transmitting resin member is located in the recess. The light-emitting module described in claim 9 or 10, wherein the other part of the outer surface of the light adjustment section where the second part of the translucent resin member is located has a first outer surface located on a third virtual straight line connecting the center of the light source and the outer edge of the light-guiding member at the shortest distance in a planar view of the light-emitting surface from a direction perpendicular to the light-emitting surface. The light-emitting module described in claim 11 , wherein the other part of the outer surface of the light adjustment section on which the second part of the translucent resin member is located is located on the opposite side of the first outer surface across the center of the light source in the planar view, and further has a second outer surface located on an extension of the third virtual straight line. the other part of the outer surface of the light adjustment portion where the second portion of the light-transmitting resin member is located further has a third outer surface and a fourth outer surface,
The light-emitting module according to claim 12 , wherein in the plan view, a fourth imaginary line connecting the third outer surface and the fourth outer surface passes through the center of the light source and is perpendicular to the third imaginary line.

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