# US 12,183,862 B2 · Light emitting device > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,183,862 B2 - Document ID: US12183862B2 - Status: Granted - Kind: B2 - Application number: 17/709,250 - Filed: 2022-03-30 - Published: 2022-10-06 - Granted: 2024-12-31 - Earliest claimed: 2021-03-31 - Assignees: Nichia Corporation - Applicants: Nichia Corporation - Inventors: Akira Hori; Tomokazu Maruyama - Web page: https://patentgrep.com/patent/US12183862B2 ## CPC - H10H 20/8506: {Containers} - H10H 20/855: Optical field-shaping means, e.g. lenses - H10H 20/8514: {characterised by their shape, e.g. plate or foil} - H10H 20/853: characterised by their shape - H10H 20/036: {of packages} - H10H 20/0361: {of wavelength conversion means} - H10H 20/0362: {of encapsulations} - H10H 20/0363: {of optical field-shaping means} - H10H 20/8516: {having a non-uniform spatial arrangement or non-uniform concentration, e.g. patterned wavelength conversion layer or wavelength conversion layer with a concentration gradient} - H10H 20/857: Interconnections, e.g. lead-frames, bond wires or solder balls - H10H: INORGANIC LIGHT-EMITTING SEMICONDUCTOR DEVICES HAVING POTENTIAL BARRIERS ## Abstract A method of manufacturing a light emitting device including: providing an intermediate structure including an light emitting element and a support body; securing a plate-shaped intermediate resin member and the light emitting element with a light-transmissive member such that the intermediate resin member includes first resin extended portions extending outwardly in the first direction respectively from both short sides of the light emitting element in a plan view; cutting the intermediate resin member at cutting positions along the second direction to obtain a resin member with a concave lower surface, a maximum distance from the light emitting element to a respective one of the cutting positions in the first direction being longer than a maximum length of the light emitting element in the second direction; and forming a covering member to cover lateral surfaces of the resin member such that an upper surface of the resin member is exposed. ## Claims ### Claim 1 A method of manufacturing a light emitting device, the method comprising: providing an intermediate structure including at least one light emitting element having an upper surface extending in a first direction and a second direction perpendicular to the first direction, the first direction being a longitudinal direction, and the second direction being a transverse direction, and a support body on which the at least one light emitting element is disposed; securing a plate-shaped intermediate resin member and the at least one light emitting element with a light-transmissive member such that the intermediate resin member is disposed over the at least one light emitting element and includes first resin extended portions extending outwardly in the first direction respectively from both short sides of the at least one light emitting element in a plan view; cutting the intermediate resin member at cutting positions along the second direction to obtain at least one resin member with a concave lower surface, the cutting positions respectively overlapping spaces between the first resin extended portions and the support body in the plan view, a maximum distance from the at least one light emitting element to a respective one of the cutting positions in the first direction being longer than a maximum length of the at least one light emitting element in the second direction; and forming a covering member to cover lateral surfaces of the at least one resin member such that an upper surface of the at least one resin member is exposed from the covering member. ### Claim 2 (depends on 1) The method of manufacturing a light emitting device according to claim 1, wherein the cutting of the intermediate resin member includes forming a light-transmissive extended portion in the light-transmissive member to be located outward of the resin member in the plan view. ### Claim 3 (depends on 2) The method of manufacturing a light emitting device of claim 2, wherein the light-transmissive extended portion is located below a plane including the upper surface of the at least one light emitting element. ### Claim 4 (depends on 1) The method of manufacturing a light emitting device of claim 1, wherein the securing of the intermediate resin member includes securing the intermediate resin member and the at least one light emitting element with the light-transmissive member such that the intermediate resin member includes a second resin extended portions extending outwardly in the second direction respectively from both long sides of the at least one light emitting element in the plan view, and the cutting of the intermediate resin member further includes cutting the second resin extended portion of the intermediate resin member along the first direction before the cutting of the intermediate resin member along the second direction. ### Claim 5 (depends on 1) The method of manufacturing a light emitting device of claim 1, wherein a portion of the at least one resin member is located below a plane including the upper surface of the at least one light emitting element. ### Claim 6 (depends on 1) The method of manufacturing a light emitting device of claim 1, wherein in a cross-sectional view, a maximum thickness of the light-transmissive member at a corresponding end of the at least one resin member is in a range of 0.01 times to 0.1 times a maximum distance between the at least one light emitting element and the corresponding end of the at least one resin member in the first direction. ### Claim 7 (depends on 1) The method of manufacturing a light emitting device of claim 1, wherein the providing of the intermediate structure includes providing the intermediate structure including a first light emitting element and a second light emitting element as the at least one light emitting element, the securing of the intermediate resin member includes bringing the light-transmissive member into contact with the first light emitting element, the second light emitting element, and the intermediate resin member, and the cutting of the intermediate resin member includes cutting the intermediate resin member along the second direction at the cutting positions including a position between the first light emitting element and the second light emitting element. ### Claim 8 (depends on 1) The method of manufacturing a light emitting device of claim 1, wherein the forming of the covering member includes disposing an intermediate covering member to cover the upper surface of the at least one resin member and then removing a portion of the intermediate covering member to obtain the covering member. ### Claim 9 (depends on 1) The method of manufacturing a light emitting device of claim 1, further comprising after the forming of the covering member, performing singulation by removing at least a portion of each of the support body and the covering member. ### Claim 10 (depends on 1) The method of manufacturing a light emitting device of claim 1, wherein the forming of the covering member includes forming the covering member so that a portion of an upper surface of the covering member is located higher than an upper surface of the at least one resin member. ### Claim 11 A light emitting device comprising: a support body; a light emitting element disposed on the support body, the light emitting element having an upper surface extending in a first direction and a second direction perpendicular to the first direction, the first direction being a longitudinal direction, and the second direction being a transverse direction; a light-transmissive member covering lateral surfaces of the light emitting element; a resin member covering the upper surface of the light emitting element and an upper surface of the light-transmissive member, the resin member having a concave lower surface; and a covering member covering lateral surfaces of the resin member with an upper surface of the resin member being exposed from the covering member, wherein a maximum length of each of portions of the resin member disposed outward of the light emitting element in the first direction is greater than a maximum length of the light emitting element in the second direction in a plan view, wherein the light-transmissive member includes a light-transmissive extended portion located outward of the resin member in the plan view, and the light-transmissive extended portion is disposed between portions of the covering member in a third direction perpendicular to the first direction and the second direction. ### Claim 12 (depends on 11) The light emitting device of claim 11, wherein the light-transmissive extended portion is located below a plane including the upper surface of the light emitting element. ### Claim 13 (depends on 11) The light emitting device of claim 11, wherein the light-transmissive extended portion is located above a plane including the lower surface of the light emitting element. ### Claim 14 (depends on 11) The light emitting device of claim 11, wherein in a cross-sectional view, a maximum thickness of the light-transmissive member at a corresponding end of the resin member is in a range of 0.01 times to 0.1 times a maximum distance between the light emitting element and the corresponding end of the resin member in the first direction. ### Claim 15 (depends on 11) The light emitting device of claim 11, wherein a portion of the resin member between an uppermost portion of the concave lower surface and a lowermost portion of the concave lower surface in the third direction has a length in a range of 20 μm to 100 μm. ### Claim 16 (depends on 11) The light emitting device of claim 11, wherein a maximum length from the light emitting element to a corresponding end of the resin member in the second direction is shorter than a maximum length of the light emitting element in the second direction. ### Claim 17 (depends on 12) The light emitting device of claim 12, wherein the light-transmissive extended portion is located above a plane including the lower surface of the light emitting element. ### Claim 18 (depends on 12) The light emitting device of claim 12, wherein in a cross-sectional view, a maximum thickness of the light-transmissive member at a corresponding end of the resin member is in a range of 0.01 times to 0.1 times a maximum distance between the light emitting element and the corresponding end of the resin member in the first direction. ### Claim 19 (depends on 12) The light emitting device of claim 12, wherein a portion of the resin member between an uppermost portion of the concave lower surface and a lowermost portion of the concave lower surface in the third direction has a length in a range of 20 μm to 100 μm. ### Claim 20 (depends on 12) The light emitting device of claim 12, wherein a maximum length from the light emitting element to a corresponding end of the resin member in the second direction is shorter than a maximum length of the light emitting element in the second direction.