JP2012094647A - Light-emitting device and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a light-emitting device in which variation in the light-emitting part can be addressed easily, problems of adhesion of dirt, or the like, over time are eliminated, and unevenness of color or luminance is reduced.SOLUTION: The light-emitting device comprises a light source 3, and a translucent member 5 arranged on the light source. The surface of the translucent member on the reverse side of the light source serves as a light emission surface. In the translucent member, light scattering portions consisting of a plurality of microcracks are provided while being distributed unevenly. The microcracks are formed by focusing laser light on the interior of the translucent member at any time before or after assembling the light-emitting device.

Description

  The present invention relates to a light emitting device including a light source and a translucent member disposed thereon, and in particular, light emission that suppresses occurrence of luminance unevenness and color unevenness in a light emitting device including a plurality of light sources such as LED elements. The present invention relates to an apparatus and a manufacturing method thereof.

  In recent years, LED chips are frequently used as light sources of light emitting devices. In such a light emitting device, a plurality of LED chips are usually arranged to constitute a light source, and in order to realize a predetermined color tone such as white light, the LED chip and a fluorescent light that emits different light by absorbing the light emitted from the LED chip. A light emitting device combined with a body or the like is also common.

  The LED chip is an extremely small semiconductor element having a side length of about 1.0 mm, and has optical characteristics close to a point light source. For this reason, in a light-emitting device in which a large number of LED chips are arranged and used as a light source, light emitted from each LED chip is guided in the light-transmitting material, and uniform from the light-emitting surface that is the surface of the light-transmitting material. Luminance light is emitted.

  However, even if a translucent material is used, it is difficult to completely eliminate the difference in luminance between the central portion and the peripheral portion of the LED chip. In addition, in a light emitting device in which an LED chip is sealed with a phosphor-containing resin, the color tone is different between a portion where the LED chip is located directly below the phosphor layer and a portion where the LED chip is not present when viewed from the light emitting surface side, and color unevenness occurs. Prone to occur. Furthermore, there is a problem of uneven color and uneven brightness due to variations in luminous efficiency and spectral characteristics of each LED chip.

  Conventionally, various techniques for solving these problems have been proposed. For example, in the technique described in Patent Document 1, in a light emitting device in which an LED chip is sealed with a translucent resin, a light emitting surface of the translucent resin is provided with a recess, and the light is emitted in the vicinity of the recess. By controlling the amount of light, uneven color tone and brightness are optimized. Further, in Patent Document 2, in a light emitting device in which a phosphor layer is provided on an LED chip, a light diffusion portion is provided on the phosphor layer, and light is diffused more than other portions in the upper center portion of the LED chip. Describes a technique for varying the thickness of the light diffusing part and the content of the light diffusing agent contained so that the number of the light diffusing parts increases.

JP 2006-303303 A JP 2010-56337 A

  However, the technology for forming irregularities on the light emitting surface of the translucent member provided on the LED chip needs to ensure a sufficient thickness to form a recess in the translucent member. receive. Further, when unevenness is formed on the surface, dirt and dust are likely to be accumulated on the surface of the light emitting surface, and with time, light emission and light distribution are likely to be hindered.

  In addition, the technology for providing a light diffusing portion containing a light diffusing agent is difficult to adjust the concentration and thickness of the light diffusing agent. When this technology is applied to a light emitting device in which a plurality of light emitting portions are arranged, a light emitting portion It is necessary to adjust the concentration and thickness of the light diffusing agent every time and to eliminate variations in the light emitting portion as a whole, and the response becomes extremely complicated.

  An object of the present invention is to provide a light-emitting device that can easily cope with variations in light-emitting portions, has no problem of adhesion such as dirt over time, and has suppressed color unevenness and brightness unevenness.

  The present invention provides a light emitting device in which a light source such as a plurality of LED chips and a light transmissive member are disposed thereon, and a light scattering portion formed using strong light energy such as a laser inside the light transmissive member. By providing, it becomes possible to give a desired light scattering property to a desired position without roughening the emission surface, and solve the above-mentioned problems.

  That is, the light-emitting device of the present invention is a light-emitting device that includes a light source and a translucent member disposed on the light source, and uses a surface of the translucent member opposite to the light source as a light emission surface. The light-transmitting member is a light-emitting device characterized in that a light scattering portion including a plurality of microcracks is unevenly provided therein.

  The light-emitting device of the present invention includes a light source and a translucent member disposed on the light source, and the translucent member includes a plurality of light scattering points formed by laser irradiation therein. The light-emitting device is characterized in that light scattering portions are provided unevenly.

  The method for manufacturing a light emitting device according to the present invention is the above-described method for manufacturing a light emitting device according to the present invention, wherein the step of disposing one or more light sources on a substrate and the disposition of the light sources inside the translucent member. Based on the above, the method includes a step of forming a light scattering portion, and a step of disposing a translucent member having the light scattering portion on the light source.

  Moreover, the manufacturing method of the light-emitting device of this invention is a manufacturing method of the light-emitting device of this invention mentioned above, Comprising: A 1 or several light source is arrange | positioned on a board | substrate, A translucent member is arrange | positioned on a light source A step of measuring the luminance and / or chromaticity of the light source after the translucent member is arranged, and a measurement result of the luminance and / or chromaticity of the translucent member arranged on the light source Forming a light scattering portion therein.

  The method for manufacturing a light-emitting device according to the present invention includes a step of measuring the luminance and / or chromaticity of the light-emitting device after the light-emitting device is assembled, and a transparent light source disposed on the light source based on the measurement result of the luminance and / or chromaticity. A step of additionally forming a light scattering portion inside the light member.

  According to the present invention, it is possible to form an arbitrary number of light diffusion points at arbitrary positions inside the light-transmitting member provided on the light source without roughening the surface. Therefore, it is possible to provide a light emitting device that is easy to adjust and excellent in color rendering.

BRIEF DESCRIPTION OF THE DRAWINGS It is a figure which shows the light-emitting device of 1st embodiment of this invention, (a) is a whole perspective view, (b) is a top view, (c) is A-A 'sectional drawing of (b). Diagram explaining the action of light diffusion points 2A and 2B are diagrams illustrating luminance unevenness and color unevenness of the light emitting device of FIG. 1, in which FIG. It is a figure which shows one Example of the crack pattern formed in the light-emitting device of FIG. 1, (a) is a top view, (b) is sectional drawing. (A)-(c) is a figure which shows the other Example of the crack pattern formed in the light-emitting device of FIG. 1, respectively. (A) And (b) is a figure which shows another Example of the crack pattern formed in the light-emitting device of FIG. 1, respectively. The figure which shows the example of a change of the light-emitting device of 1st embodiment of this invention. The figure which shows the light-emitting device of 2nd embodiment of this invention. (A)-(d) and (e)-(h) are figures which respectively show 3rd embodiment. It is a figure which shows one Example of the light-emitting device of 4th embodiment of this invention, (a), (b) is the figure which looked at arrangement | positioning of a light emitting element and a crack formation area from the top, (c) is a light emitting element and The figure explaining the superposition | stacking of a crack formation area, (d) is sectional drawing of a crack formation area. Sectional drawing which shows the other Example of the light-emitting device of the 4th embodiment of this invention. Sectional drawing which shows another Example of the light-emitting device of 4th embodiment of this invention. Sectional drawing which shows another Example of the light-emitting device of 4th embodiment of this invention. It is a figure which shows the light-emitting device of 5th embodiment of this invention, (a)-(d) is a figure which shows an Example from which each differs. The flowchart which shows an example of the procedure of the manufacturing method of the light-emitting device of this invention

  Embodiments of the present invention will be described below.

<First embodiment>
As a first embodiment of the present invention, a light emitting device in which a phosphor layer is formed on a plurality of LED chips and a translucent member is laminated thereon will be described. FIG. 1 is a diagram showing a first embodiment of a light emitting device of the present invention, where (a) is an overall perspective view, (b) is a top view, and (c) is an AA ′ cross section of (b). . In the figure, only two LED chips are shown for ease of explanation, but the number of LED chips is not limited to two.

  As shown in the figure, the light emitting device 10 includes a substrate 1 on which the light emitting element 3 is mounted, a light emitting element 3, a phosphor layer 4 covering the light emitting element 3, and a glass formed on the phosphor layer 4. And a cover 5. On the substrate 1, an electrode for connecting a light emitting element (not shown) is formed, and the light emitting element 3 is connected to the electrode by a gold bump 2.

  The light emitting element 3 is made of a semiconductor element such as a blue LED. The phosphor layer 4 is mainly composed of a resin and a phosphor, and the phosphor absorbs light emitted from the light emitting element 3 and emits light having a different wavelength. Thereby, the light which synthesize | combined the light from the light emitting element 3 and the light from fluorescent substance is radiate | emitted from a light-emitting device. The glass cover 5 is a translucent member that guides light generated from the light emitting element 3 and the phosphor layer 4. In addition to inorganic materials such as optical glass, sapphire, and quartz, an acrylic resin or polycarbonate plate is used. It is also possible to use it.

  A large number of light diffusion points are partially formed inside the glass cover 5. “Partially” means a state in which a region where a light diffusion point is formed is unevenly distributed in either the thickness direction or the surface direction of the cover, and depends on the characteristics and arrangement of the light emitting elements 3. Thus, a predetermined pattern is formed at an arbitrary position. The shape and pattern of the region where the light diffusion point is formed will be described in detail later.

  The light diffusing point can be formed by irradiating a material constituting the glass cover with strong energy such as a laser to generate a fine crack (microcrack) inside. When powerful energy such as laser is condensed on a material such as glass, thermal distortion occurs due to the multiphoton absorption process, and fine cracks are generated. In this embodiment, such a crack is used as a light diffusion point. The size of the crack is preferably several μm to several tens of μm, more preferably several μm to several tens of μm, and can be adjusted by controlling the intensity of the laser. Further, it is possible to form a crack at an arbitrary position by adjusting the focus of the laser.

  In order to irradiate a laser beam at a desired position, a laser engraving machine constituted by an optical system in which a galvanometer mirror, a focus lens, or the like is combined with a laser such as a YAG laser or a YVO4 laser can be used. As the laser, an infrared laser, a visible light laser using the second harmonic (532 nm), an ultraviolet laser using the third harmonic (355 nm), and the like can be used, and in particular, the second harmonic having a high peak value. Visible light lasers using waves (532 nm) are preferred.

  In this way, when the light diffusion point (crack) is formed by a laser, the formation time may be before or after the assembly of the light emitting device, and a glass cover having a light diffusion part previously formed at a predetermined position is prepared. The light emitting device may be assembled, or after assembling the light emitting device using a glass cover on which the light diffusing portion is not formed, it is possible to form a light diffusing portion consisting of cracks in the glass cover.

  As shown in FIG. 2, the crack formed in the glass cover 5 functions as a light scattering point. By controlling the arrangement of the individual cracks 50 and the positions of the areas where the cracks are formed, the straightness of the light (Directivity) can be controlled and blended with diffused light. For example, when viewed from above the light exit surface, by forming cracks in the glass cover area where the brightness is higher than other parts, the brightness of the cracked area is suppressed, and as a whole The luminance distribution can be leveled. Also, when viewed from above the light exit surface, by forming cracks in the glass cover area corresponding to the part where the change in color tone is conspicuous (boundary area), the change in color tone is made smooth and the color unevenness becomes inconspicuous. be able to.

  In general, when a light diffusing agent is contained in a translucent member to form a light scattering point, it is extremely difficult to make the light scattering point unevenly distributed in a desired limited region. Since microcracks serving as light scattering points are generated inside the glass cover 5 which is a translucent member by an external energy such as a laser, the position, number and size of the light scattering points can be easily controlled. Light scattering points can be provided so as to eliminate variations in characteristics of the light emitting element 3.

  Next, regarding the light emitting device shown in FIG. 1, generation of uneven color and uneven brightness and a crack pattern for suppressing the unevenness (a pattern in a region where a large number of cracks are formed are referred to as a crack pattern) will be described. 3A and 3B are a top view and a cross-sectional view of the light emitting device according to the present embodiment, as in FIG. 1, and show differences in luminance and color tone by shading. As shown in the figure, for example, when two light emitting elements 3a and 3b are arranged side by side, the areas 51a and 51b above the centers of the light emitting elements 3a and 3b have high luminance, but the surrounding areas 52a and 52b are high. Is less bright than the center. When there are variations in the light emission characteristics of the two light emitting elements 3a and 3b, the high luminance areas 51a and 51b above the centers are different between the right side and the left side. Further, in the region 53 between the two light emitting elements, the amount of the phosphor is larger than that of the phosphor layer 4 existing above the light emitting elements 3a and 3b, and the amount of light generated from the phosphor layer 4 is increased. For this reason, the color tone of light determined by the balance between the light from the light emitting element and the light from the phosphor layer is different, and the phosphor emits light having a stronger phosphor color than the designed wavelength.

  FIG. 4 shows an example of a crack pattern corresponding to such color unevenness and brightness unevenness. 4A is a view of a crack formation region as viewed from the light emitting surface side, and FIG. 4B is a view as viewed from the side surface. When viewed from the light emitting surface, a large number of cracks are arranged within a substantially circular or polygonal outline so as to cover the regions 51a and 51b (FIG. 3A) above the center of the light emitting element. When viewed from the side, the crack region disposed above the centers of the light emitting elements 3a and 3b is formed so as to be thickest at the center of the light emitting elements and thin toward the periphery. In addition, as shown in FIG. 2, the crack arrangement shifts the position of the crack for each column in the thickness direction to enhance the light diffusibility.

  When the crack region is formed in this way, more light traveling in the vertical direction from the central portion of the light emitting element is scattered, so that the luminance of the central portion can be suppressed and the luminance of the peripheral portion can be increased. As a result, luminance unevenness between the central portion and the peripheral portion is reduced, and a more uniform luminance distribution can be obtained. Further, when there is a variation in light emission intensity between the light emitting elements 3a and 3b, the variation can be eliminated by making the volume of the crack region provided above the central portion different. The volume of the crack region can be varied, for example, by changing the thickness of the rhombus shape as viewed from the side or by changing the shape itself.

  FIG. 5 shows a three-dimensional relationship between the light emitting source 300 and a crack region formed thereon. As shown in FIG. 5A, the crack formation position is designed inside the contour (crack formation region) 510 of the pyramid. At that time, the thickness of the crack formation region is made thicker in a place where the luminance difference or color difference from the light source 300 is high. In FIG. 5 (a), two pyramids are combined, but as shown in FIGS. 5 (b) and 5 (c), one pyramid region 520, 530 has a top as a crack formation region. Or you may arrange | position so that it may face downward.

  In the crack pattern of FIG. 4, in addition to the crack region made of a pyramid, one or more rows of cracks are formed along the region boundary between the region 53 with different light emission color tone and the adjacent regions 52 a and 52 b. 50 is arranged. One or more rows of crack regions formed along the region 53 are also arranged in the thickness direction of the glass cover 5. The position in the thickness direction is not limited. However, as shown in FIG. 4B, when the position is in the lower side in the thickness direction, that is, on the side closer to the light emitting element, the crack formation pattern is the glass cover 5. It is possible to prevent the light from being conspicuous from the light exit surface. Further, when provided in the upper direction of the thickness direction, it is possible to eliminate color unevenness and luminance unevenness due to light color mixing.

  Due to the crack 50 arranged at the boundary with the region 53, light having a different color tone (for example, light with strong yellowness) emitted from the region 53 side having a large amount of phosphor and light emitted from the regions 52a and 52b above the light emitting element. (For example, light with a strong bluish color) is mixed, so that a change in color tone at the boundary can be reduced.

  Another embodiment of the crack formation pattern is shown in FIGS. FIG. 6A shows a crack formation region as viewed from the side of the light emitting device, and FIG. 6B shows only the pattern on one light emitting element, with elements other than the glass cover 5 omitted. The structure of the light emitting device is the same as that shown in FIG.

  Also in the embodiment shown in FIG. 6A, a crack pattern 501 similar to the embodiment shown in FIGS. 3 and 5 is formed in the glass cover 5 in the region above the center of the light emitting elements 3a and 3b. On the other hand, in the region 53 corresponding to the space between the light emitting elements 3 a and 3 b, an inverted triangular crack region 502 centering on the center in the width direction of the region 53 is formed across the region 53. The crack region 502 is similarly formed along the longitudinal direction of the region 53 and has a flat triangular prism shape parallel to the region 53 as a whole.

  By forming such a crack region 502, the light emitted from the region 53 and having a color tone different from that of the periphery is diffused in the crack region 502 and mixed with the light emitted from the periphery. Similar to the crack pattern, the change in the color tone of the boundary, that is, the color unevenness can be made inconspicuous, the light diffusibility with respect to the light emission from the region 53 with a large amount of phosphor is enhanced, and the light emission with a strong phosphor color is suppressed as a whole can do.

  In the example shown in FIG. 6B, in order to make the crack pattern formed in Example 1 and Example 2 inconspicuous, a uniform crack region 503 was formed in a region relatively close to the surface of the glass cover. Is a feature. FIG. 6B shows a pattern viewed from the side, but when viewed from the light exit surface, the cracks are uniformly formed in the region 503 in the surface direction. Although the figure shows a case where two layers of cracks are formed, the number of layers may be one or more than two. However, in order to maintain the luminous efficiency, one or two layers are preferable.

  According to the present embodiment, in a light emitting device in which a phosphor layer is provided on a plurality of LED chip arrays, an LED is provided by providing a crack region inside a translucent member provided on the phosphor layer. It is possible to suppress the difference in brightness between the center and the periphery of the chip, the brightness and color tone difference between the area between adjacent LED chips and the area where the LED chip exists, and the variation in characteristics of each LED chip. In addition, a light emitting device with uniform luminance and color tone can be provided.

  In addition, each Example of the crack formation pattern demonstrated in the said embodiment is a mere illustration, and about the shape and magnitude | size of the area | region which provides a crack, and the position of the thickness direction / surface direction of a translucent member, it is an arrangement | sequence of a light emitting element. And can be changed as appropriate in consideration of individual variations.

  1 and 3 to 6 show the light emitting device including the phosphor layer 4 for sealing the light emitting element. As shown in FIG. 7, the phosphor layer 40 is disposed on the lower surface of the glass cover 5. The present embodiment can be similarly applied to the light emitting device 100 arranged in a film shape.

<Second Embodiment>
As a second embodiment of the present invention, a light emitting device in which a translucent member is arranged on a plurality of LED chips without arranging a phosphor layer will be described. FIG. 8 is a cross-sectional view showing a second embodiment of the light emitting device of the present invention, and the same elements as those in the first embodiment are indicated by the same numbers. In this figure, only two LED chips are shown for simplicity of explanation, but the number of LED chips is not limited to two.

  The light emitting device 150 includes a substrate 1, a plurality of light emitting elements 3 a and 3 b connected to the substrate 1 through gold bumps 2, and a glass cover 5. The glass cover 5 is fixed on the substrate 1. It is supported by a side plate (shielding plate, reflection plate) 6 and covers the upper portions of the light emitting elements 3a and 3b. The inner surface of the side plate 6 is a reflective surface, which prevents light from the light emitting element from leaking outside through the side plate, and allows as much light as possible from the light emitting element to be emitted from the surface of the glass cover 5. Yes.

  Since the light emitting device of this embodiment does not have a phosphor layer as compared with the first embodiment, there is no problem that the color tone changes in the region between the light emitting elements 3a and 3b, but the luminance is low. The light emitting elements 3a and 3b are different from each other above the central part, above the peripheral part of the light emitting element, and between the light emitting elements. Specifically, the luminance is highest at the upper part of the central portion, decreases along the peripheral portion, and becomes lowest among the light emitting elements.

  The crack pattern of the present embodiment is uniform when viewed from the light emitting surface, but when viewed from the side, the above-described luminance difference is eliminated by varying the thickness of the crack region depending on the region. Specifically, the number of light diffusion points (in the example shown, three layers in the thickness direction) is increased in the upper central portion 81 of the light emitting element, and the luminance is increased by diffusing light upward from the central portion to the surroundings. Suppress. In addition, the number of light diffusion points is also increased at the upper end portion 83 of the light emitting element, and the luminance difference between the upper end portion 83 and the region outside it is reduced by the light diffusibility. However, the interval between the light diffusing points is made wider than the interval between the light diffusing points provided above the central portion to prevent the light amount from being reduced due to the light diffusion. Between the central portion 81 and the end portion 83, a smaller number of light diffusion points than the number of light diffusion points in both are disposed. Further, a light diffusion point is arranged above the region 84 between the light emitting elements so that the decrease in the amount of light is minimized.

<Third embodiment>
In the present embodiment, the present invention is applied to a light-emitting device using a plurality of light-emitting elements that emit different colors as light-emitting elements. As such a light emitting device, for example, there is a light emitting device using a three-color light source (R / G / B) as a light source as shown in FIG. FIGS. 9A to 9D are examples in which two green light sources G, a red light source R, and a blue light source B, a total of four light sources, are arranged. FIG. 9A shows the arrangement of the light sources, and FIG. Is a diagram of the arrangement of crack patterns as seen from above, (c) is a diagram showing the relationship between the light source and the crack pattern, and (d) is a sectional view of the crack pattern. FIGS. 9E to 9H show an example in which a total of three light sources, a green light source G, a red light source R, and a blue light source B, are arranged, (e) is the arrangement of the light sources, and (f) is a crack. FIG. 5 is a diagram showing the arrangement of patterns from the top, (g) is a diagram showing the relationship between the light source and the crack pattern, and (h) is a sectional view of the crack pattern.

  In the example shown in FIGS. 9A to 9D, the light diffusion point is formed so that the crack region is thickest at the center of the arrangement of the four light sources. In the example shown in FIGS. 9E to 9H, the light diffusion point is formed so that the crack region is thickest at the center of each of the three light sources. By arranging the light diffusing points in this way, it is possible to eliminate the luminance difference due to the emission color when each light source is driven alone, and to obtain a desired color tone even when light emission is caused by a mixture of a plurality of light sources. Can be realized.

  Furthermore, by designing the number and position of the light diffusion points, the amount and direction of light leakage can be designed. Thereby, the color balance and color mixture ratio of a multicolor light source can be adjusted. Note that the adjustment of the color balance of the multicolor light source can be performed together with the formation of a light diffusion point and electrical adjustment.

<Fourth embodiment>
As a fourth embodiment of the present invention, a light emitting device using a glass cover having a shape different from those of the first and second embodiments will be described with reference to FIGS. FIG. 10A is a view of the arrangement of the light emitting elements in this embodiment as viewed from above, FIG. 10B is a view of the crack formation region as viewed from above, and FIG. 10C is a diagram illustrating the relationship between the light emitting element and the crack formation region. (D) is sectional drawing of a crack formation area. 11 to 13 are cross-sectional views of the light emitting device according to the present embodiment. FIG. 11 illustrates a case where a phosphor layer is not provided. FIG. 12 illustrates that a phosphor layer having a uniform thickness is disposed on a plurality of light emitting elements. FIG. 13 shows a cross-sectional view when a plurality of light emitting elements are sealed with a phosphor resin to form a phosphor layer, and the glass cover is not a flat plate, but a lens. The point which is a shape is common.

  In the light emitting device shown in FIG. 10, a crack forming region is formed on two light emitting elements so as to cover them. FIG. 10D shows the case where a crack is formed so as to be thicker between the end portion of the light emitting element and the two light emitting elements, but various changes can be made to the shape and size of the crack forming region. Is possible.

  For example, since the light emitting device 110 shown in FIG. 11 does not have a phosphor layer, a crack formation pattern that mainly eliminates luminance unevenness related to the arrangement of the light emitting elements is formed. Therefore, the pattern is the same as the pattern shown in FIG. 8, and is uniform when viewed from the light emitting surface side, and a pattern having different points in the thickness direction of the crack is formed depending on the position in the surface direction. .

  A light-emitting device 120 illustrated in FIG. 12 is a light-emitting device in which a phosphor layer is arranged in a film shape on the lower surface of a glass cover, and the luminance difference between the center and the periphery of the light-emitting element and the fluorescence between the light-emitting element and the light-emitting element. A crack formation pattern that eliminates the color unevenness that occurs in the region of the body layer is formed. Therefore, the pattern is the same as the pattern shown in FIG. 4, and a disc-shaped crack region in which the thickness of the central portion is the thickest and becomes thinner toward the periphery is provided above the central portion of each light emitting element. In addition, a crack pattern is formed above the region between the light emitting elements so as to enhance the light diffusibility on the boundary between the regions and make the boundary inconspicuous. Specifically, as shown in the figure, the crack pattern is formed so that the thickness is thickest above the boundary and becomes thinner toward the center of the region. Alternatively, as shown in FIG. 5, a flat triangular prism-shaped crack region parallel to the region may be provided.

  A light-emitting device 130 shown in FIG. 13 is a light-emitting device having a structure in which a light-emitting element is sealed with a phosphor-containing resin, and has the highest light diffusibility at the central portion of the light-emitting device with the largest amount of phosphor. A crack pattern is formed. Further, taking advantage of the fact that the glass cover is lens-shaped and there are few restrictions on the thickness, two crack regions 505 and 506 are provided in the thickness direction. A crack region 505 having a large spread is arranged on the lower side in the thickness direction of the glass cover to eliminate luminance unevenness as a whole, and a crack region 506 having a small spread is arranged on the upper side in the thickness direction. Diffusing color development with different color tones, eliminating uneven color. Note that even this type of light-emitting device can have a crack pattern similar to that of the glass cover of the light-emitting device 120 shown in FIG.

<Fifth embodiment>
The first to fourth embodiments described above have mainly described the light-emitting device having a glass cover on which a crack pattern for the purpose of eliminating color unevenness and luminance unevenness has been described. In addition to eliminating unevenness of brightness and brightness, the present invention can be applied to a light-emitting device intended to improve light distribution and color rendering. Such an embodiment is shown in FIGS. FIG. 14 illustrates a light emitting device of a type that does not have the same phosphor layer as that in FIG. 8, but this embodiment can be applied to any type of light emitting device.

In addition to functioning as a light diffusion point, the crack formed in the glass cover appears to emit light by diffusing light incident on the glass cover from the outside. The light-emitting device 140 shown in FIG. 14A is combined with a crack pattern that eliminates uneven brightness around the light-emitting element, and forms a crack on the entire surface parallel to the plate surface of the glass cover, resulting in a design effect. It has been made.
In addition, in the light emitting device 160 shown in FIGS. 14B to 14D, the positions of the cracks in the thickness direction of the glass cover of the crack pattern that eliminates the luminance unevenness around the light emitting element are different. When the position in the thickness direction for forming the crack pattern is different, the external light is taken into the glass cover, and different design effects can be obtained.

  Next, a method for manufacturing a light emitting device according to the present invention will be described by taking a light emitting device using an LED element as an example. FIG. 15 is a flowchart showing an embodiment of the procedure of the manufacturing method.

  First, corresponding to the arrangement of a plurality of light emitting elements, the light emitting elements are connected to the substrate 1 on which the electrode portions for connecting the light emitting elements are formed, and connected to the two electrodes of the light emitting elements and the electrode portions formed on the substrate, respectively. (Step 151). The connection between the light emitting element and the substrate 1 varies depending on the type of the light emitting element. When the light emitting element is fixed to the substrate with an adhesive and the electrode is electrically connected using wire bonding, or a conductive material such as a gold bump. In some cases, electrical connection and fixation are realized at the same time, and it is selected according to the type of the light emitting element.

  Next, the current-carrying check of the light-emitting element is performed, and it is confirmed that there is no defect in the die bonding and wire bonding performed in the previous process and the LED element. After confirming that there is no defect, the phosphor is placed on the light-emitting element. The containing resin (adhesive) is applied (step 152).

  A crack pattern matching the light source is formed on the glass cover having a size corresponding to the light emitting device created in step 151 using a laser engraving machine (step 153). For example, for a light emitting element of the same size, the crack pattern is measured in advance by measuring the luminance difference between the central part and the peripheral part and the color difference between the upper part of the light emitting element and the upper part of the area between the light emitting elements. It can be set as the crack pattern designed based on the measured value. For example, a crack pattern as shown in FIG. Alternatively, after forming the phosphor layer in the step, the light emitting element may be energized again to measure the luminance and the color tone, and the result may be used. The glass cover on which such a crack pattern is formed is placed on the phosphor-containing adhesive of the light emitting device created in the step (step 154). Next, the phosphor-containing adhesive is cured (step 155).

  Thereafter, the light emitting device is energized, and the luminance unevenness and the color unevenness are inspected (step 156). As a result of the inspection, if necessary, for example, an additional crack is formed in a portion where the luminance is too high, an additional crack is formed in the boundary of the portion where the color unevenness is conspicuous, and finally the color unevenness, A light emitting device with improved luminance unevenness is obtained (steps 157 and 158). In this case, since the crack is formed by laser irradiation focused on the inside of the glass cover, the crack can be formed at a desired position without damaging the light emitting element and the phosphor layer thereon. .

  According to this embodiment, a light emitting device is manufactured using a glass cover in which a pattern of light diffusion points is formed based on color unevenness and luminance unevenness measured in advance, and the light emitting device after completion is further provided with a light emitting element. Therefore, it is possible to improve color unevenness and brightness unevenness due to variations in color, and thus a light emitting device with extremely excellent color rendering can be manufactured.

  In the above description, the case where a glass cover having a crack pattern formed in advance is used as the glass cover. However, in step 154, a glass cover in which no crack pattern is formed is used, and after the optical inspection in step 156. A crack pattern may be formed. That is, step 153 may be omitted. In this case, the formation of a crack pattern as shown in FIG. 4 and the formation of a crack for improving the variation of individual light emitting elements are performed simultaneously.

  In the above description, the light emitting device in which the phosphor layer for sealing the light emitting element is provided has been described. However, the type of light emission in which the phosphor layer is placed on the light emitting element as shown in FIG. The same applies to the light emitting device of the type not equipped with the phosphor layer as shown in FIG. 8 or the lens cover as shown in FIGS. Can do.

  ADVANTAGE OF THE INVENTION According to this invention, the light-emitting device excellent in the color rendering property without a brightness nonuniformity and color nonuniformity can be provided. Further, according to the present invention, it is possible to eliminate luminance unevenness and color unevenness after the light emitting device is assembled.

DESCRIPTION OF SYMBOLS 1 ... Board | substrate, 3, 3a, 3b ... Light emitting element 4, 40 ... Phosphor layer, 5 ... Glass cover, 50 ... Micro crack, 501-506 ... Crack pattern, 10, 100, 110, 120, 130, 140, 150, 160...

Claims (9)

A light-emitting device comprising a light source and a translucent member disposed on the light source, the light-emitting surface being a surface of the translucent member opposite to the light source,
The light-transmitting member is characterized in that a light scattering portion including a plurality of microcracks is unevenly distributed therein. A light emitting device comprising a light source and a translucent member disposed on the light source,
The light-transmitting member is characterized in that a light-scattering portion including a plurality of light-scattering points formed by laser irradiation is unevenly provided in the translucent member. The light-emitting device according to claim 1 or 2,
The light source includes one or more LED elements and a phosphor layer covering the LED elements, and the light-transmitting member is disposed on the phosphor layer. The light emitting device according to any one of claims 1 to 3,
When a direction perpendicular to the surface on which the light source is arranged is a main emission direction, a portion where the light scattering portion is present is unevenly distributed on a virtual projection surface obtained by projecting the translucent member along the main emission direction. A light emitting device characterized by comprising: The light emitting device according to any one of claims 1 to 4,
Existence of the light scattering portion on a virtual projection plane obtained by projecting the translucent member along one direction orthogonal to the main emission direction when a direction perpendicular to the surface on which the light source is disposed is a main emission direction A light emitting device characterized in that a portion to be distributed is unevenly distributed. The light-emitting device according to any one of claims 1 to 5,
When the direction perpendicular to the surface on which the light source is disposed is a main emission direction, the light scattering portion is present on the entire surface of the virtual projection surface obtained by projecting the translucent member along the main emission direction. A light emitting device. A method for manufacturing a light emitting device according to claim 1 or 2,
Placing one or more light sources on a substrate;
A step of forming a light scattering portion inside the translucent member based on the arrangement of the light sources;
Placing a light transmissive member having a light scattering portion on the light source;
A method for manufacturing a light-emitting device including: A method for manufacturing a light emitting device according to claim 1 or 2,
Placing one or more light sources on a substrate;
Placing a translucent member on the light source;
Measuring the luminance and / or chromaticity of the light source after placing the translucent member;
Forming a light scattering portion inside the translucent member disposed on the light source based on the measurement result of the luminance and / or chromaticity;
A method for manufacturing a light-emitting device including: The method for manufacturing a light emitting device according to claim 7 or 8, further comprising:
Measuring the luminance and / or chromaticity of the light emitting device after the light emitting device is assembled;
A step of additionally forming a light scattering portion inside the translucent member disposed on the light source based on the measurement result of luminance and / or chromaticity;
A method for manufacturing a light-emitting device, comprising:

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