Method for manufacturing light emitting device comprising lens with tapered profile
AssigneeNichia Corporation
InventorYuta Oka
Life of this patent
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Abstract
A manufacturing method for a light emitting device can include providing a bonding layer over a base, and disposing a shim plate with an opening over the bonding layer. A light emitting body is disposed over the bonding layer exposed from the opening of the shim plate. A lens is formed by approaching a die having a concave portion at its surface, to the shim plate, covering an upper surface of the light emitting body and an upper surface of the shim plate with a lens formation material within the concave portion, and then hardening the lens formation material.
Claims12
A method for manufacturing a light emitting device, the light emitting device including a light emitting body with a light emitting element, and a lens sealing an upper surface of the light emitting body, wherein a lower surface of the light emitting body is exposed from a bottom surface of the lens, and the bottom surface extends to an outside of the light emitting body in a top view from a direction vertical to the lower surface of the light emitting body, the method comprising:
- providing a bonding layer on an upper surface of a base;
- disposing a shim plate with an opening on an upper surface side of the bonding layer;
- disposing the light emitting body on the upper surface side of the bonding layer exposed from the opening of the shim plate;
- and
- forming the lens by approaching a mold having a concave portion at a surface thereof, to the shim plate, covering an upper surface of the light emitting body and an upper surface of the shim plate with a lens formation material within the concave portion, and then hardening the lens formation material,
- wherein the shim plate has a tapered part, and at least a portion of the shim plate has an upper surface located between an upper surface of a mounting substrate of the light emitting body and a lower surface of the mounting substrate in a cross-section view,
- wherein at least a part of the bottom surface extending to an outside of the light emitting body is located between an upper surface of the mounting substrate of the light emitting body and a lower surface of the mounting substrate in a cross-section view, and
- wherein the method further comprises
- removing the shim plate after forming the lens, such that the part of the bottom surface extending to the outside of the light emitting body and located between an upper surface of the mounting substrate of the light emitting body and a lower surface of the mounting substrate in a cross-section view is exposed,
- filling a gap between a side surface of the shim plate at the tapered part and a side surface of the light emitting body with a resin, wherein the gap is filled with the resin from the lower surface of the mounting substrate up to the upper surface of the shim plate, and
- removing all of the resin after forming the lens.
A method for manufacturing a light emitting device, the method comprising:
- providing a bonding layer on an upper surface of a base;
- disposing a shim plate with an opening on an upper surface side of the bonding layer;
- disposing a light emitting body having a light emitting element on the upper surface side of the bonding layer exposed from the opening of the shim plate;
- forming a lens, said lens sealing an upper surface of the light emitting body, by approaching a mold having a concave portion at a surface thereof, to the shim plate, covering an upper surface of the light emitting body and an upper surface of the shim plate with a lens formation material within the concave portion;
- and
- hardening the lens formation material,
- wherein a bottom surface of the lens extends to an outside of the light emitting body in a top view from a direction vertical to a lower surface of the light emitting body,
- wherein the shim plate has a tapered part and at least a portion of the shim plate has an upper surface located between an upper surface of a mounting substrate of the light emitting body and a lower surface of the mounting substrate in cross section view,
- wherein at least a part of the bottom surface extending to the outside of the light emitting body is located between an upper surface of the mounting substrate of the light emitting body and a lower surface of the mounting substrate in a cross-section view, and
- wherein the method further comprises
- removing the shim plate after forming the lens, such that the part of the bottom surface extending to the outside of the light emitting body and located between an upper surface of the mounting substrate of the light emitting body and a lower surface of the mounting substrate in a cross-section view is exposed;
- filling a gap between a side surface of the shim plate at the tapered part and a side surface of the light emitting body with a resin, wherein the gap is filled with the resin from the lower surface of the mounting substrate up to the upper surface of the shim plate, and
- removing all of the resin after forming the lens.
Dependencies are inferred from the claim text.