Method to produce reflector with an outer peripheral edge portion of an upper surface uncovered by a reflection film and to produce a lightemitting device using the same reflector

A method to produce a light-emitting device with reflector comprising:

• providing a light emitters each including at least one light-emitting diode element mounted on a circuit board and a light-transmitting resin to seal the light-emitting diode element, and the circuit board having a substantially square or rectangular outline shape as viewed in plane;
• forming a reflector assembly in which a plurality of reflectors are arranged integrally in a grid pattern, each of the reflectors having a substantially same outline shape as the circuit board as viewed in plane, the reflector assembly having a plurality of openings, each passing through an upper surface and a lower surface at each reflector of the reflector assembly, and each of the openings having an inclined inner surface configured to be upwardly broadened;
• setting a mold jig to cover an outer peripheral edge portion of the upper surface around each opening partial adjacent upper surface portion adjacent to the outer peripheral edge portion of the upper surface around each opening in the reflector assembly, and
• providing a reflection film on the inclined inner surface of each opening and the upper surface except the outer peripheral edge portion around each opening and the partial adjacent upper surface portion;
• dicing the reflector assembly along outer peripheral edge portion of the upper surface around each opening to divide the reflector assembly into individual reflectors;
• and
• joining each of the divided reflectors to each of the circuit boards each on which the at least one light-emitting diode element mounted.

A method to produce a reflector comprising:

• forming a reflector assembly having a plurality of openings, each provided with an inclined inner surface, and each passing through an upper surface and a lower surface of the reflector assembly;
• providing a resist to the upper surface of the reflector assembly to cover an outer peripheral edge portion of the upper surface around each opening, and providing a reflection film on the inclined inner surface of each opening and the upper surface except the outer peripheral edge portion of the upper surface around each opening;
• and
• dicing the reflector assembly along the outer peripheral edge portion of the upper surface around each opening to divide the reflector assembly into individual reflectors.

A method to produce a light-emitting device with a reflector comprising:

• providing light emitters each including at least one light-emitting diode element mounted on a circuit board and a light-transmitting resin to seal the light-emitting diode element, and the circuit board having a substantially square or rectangular outline shape as viewed in plane;
• forming a reflector assembly in which a plurality of reflectors are arranged integrally in a grid pattern, each of the reflectors having a substantially same outline shape as the circuit board as viewed in plane, the reflector assembly having a plurality of openings, each passing through an upper surface and a lower surface at each reflector of the reflector assembly, and each of the openings having an inclined inner surface configured to be upwardly broadened;
• providing a resist to cover an outer peripheral edge portion of the upper surface around each opening and a partial adjacent upper surface portion adjacent to the outer peripheral edge portion of the upper surface around each opening in the reflector assembly, and providing a reflection film on the inclined inner surface of each opening and the upper surface except the outer peripheral edge portion around each opening and the partial adjacent upper surface portion;
• dicing the reflector assembly along the outer peripheral edge portion of the upper surface around each opening to divide the reflector assembly into individual reflectors;
• and
• joining each of the divided reflectors to each of the circuit boards on which the at least one light-emitting diode element is mounted.