Method of manufacturing light emitting module

Patent metadata

Field	Value
Publication number	US-11740401-B2
Application number	US-202117446505-A
Country	US
Kind code	B2
Filing date	Aug 31, 2021
Priority date	Aug 31, 2020
Publication date	Aug 29, 2023
Grant date	Aug 29, 2023

Abstract

A method of manufacturing a light emitting module includes: providing an intermediate that includes a light guide having a first principal face and a second principal face opposing the first principal face, a plurality of light sources disposed on the second principal face of the light guide, and a wiring layer disposed on the second principal face and electrically connected to the plurality of light sources; allowing the plurality of light sources to emit light and measuring optical characteristics of the emitted light; and forming an optical characteristic correcting element in the intermediate based on the measured optical characteristics.

First claim

What is claimed is:

1. A method of manufacturing a light emitting module comprising:
providing an intermediate, the intermediate including:
a light guide having a first principal face and a second principal face opposing the first principal face,
a plurality of light sources disposed on the second principal face of the light guide, and
a wiring layer disposed on the second principal face and electrically connected to the plurality of light sources;

allowing the plurality of light sources in the intermediate to emit light and measuring optical characteristics of the emitted light; and
after the measuring, forming an optical characteristic correcting element in the intermediate based on the measured optical characteristics.

2. The method of manufacturing a light emitting module according to claim 1 , wherein
the process of forming the optical characteristic correcting element includes forming a plurality of sectioning grooves on the light guide to compartmentalize regions including at least one of the plurality of light sources.

3. The method of manufacturing a light emitting module according to claim 1 , wherein
the light guide includes a plurality of sectioning grooves compartmentalizing regions including at least one of the plurality of light sources, and
the process of forming the optical characteristic correcting element includes forming a light adjusting hole in the light guide between one of the plurality of sectioning grooves and one of the plurality of light sources in a top view.

4. The method of manufacturing a light emitting module according to claim 1 , wherein
the process of forming the optical characteristic correcting element includes forming a light adjusting member above at least one of the plurality of light sources, the light adjusting member reflecting at least a portion of the light emitted by the at least one of the plurality of light sources.

5. The method of manufacturing a light emitting module according to claim 1 , wherein
the process of forming the optical characteristic correcting element includes forming a phosphor layer above or in a vicinity of at least one of the plurality of light sources.

6. The method of manufacturing a light emitting module according to claim 1 , wherein
the intermediate further includes a wiring substrate including an insulation base that supports the wiring layer,
the light guide is disposed on the wiring substrate such that the second principal face faces the wiring substrate,
the light guide has a plurality of first holes extending through from the first principal face to the second principal face, and
the light sources are disposed on the wiring substrate in the first holes.

7. The method of manufacturing a light emitting module according to claim 6 , wherein
the process of forming the optical characteristic correcting element includes forming a light reflecting member on the wiring substrate between an inner lateral face of at least one of the plurality of first holes and a lateral face of at least one of the plurality of light sources disposed therein.

8. The method of manufacturing a light emitting module according to claim 7 , wherein
at least one of the plurality of first holes includes:
a first region having a first distance between the inner lateral face of the first hole and the lateral face of the light source disposed therein; and
a second region having a second distance which is larger than the first distance between the inner lateral face of the first hole and another lateral face of the light source disposed therein, and

the light reflecting member is formed on the wiring substrate in the first region.

9. The method of manufacturing a light emitting module according to claim 7 , wherein
the light guide has:
a third region having a third distance between adjacent ones of the plurality of light sources; and
a fourth region having a fourth distance which is larger than the third distance between other adjacent ones of the plurality of light sources, and

the light reflecting member is formed on the wiring substrate in the third region.

10. The method of manufacturing a light emitting module according to claim 6 , wherein
at least one of the plurality of first holes includes:
a first region having a first distance between the inner lateral face of the first hole and a lateral face of the light source disposed therein; and
a second region having a second distance which is larger than the first distance between the inner lateral face of the first hole and another lateral face of the light source disposed therein, and

the process of forming the optical characteristic correcting element includes forming a groove in a part of the light guide on a first region side in a cross section that includes the first region, the second region, and the light source located between the first region and the second region.

11. The method of manufacturing a light emitting module according to claim 10 , further comprising forming a light reflecting member in the grooves.

12. The method of manufacturing a light emitting module according to claim 6 , wherein
the light guide has:
a third region having a third distance between adjacent ones of the plurality of light sources; and
a fourth region having a fourth distance which is larger than the third distance between other adjacent ones of the plurality of light sources, and

the process of forming the optical characteristic correcting element includes forming a groove in the light guide in the third region at a position closer to one of the adjacent ones of the plurality of light sources than to a midpoint between the adjacent ones of the plurality of light sources.

13. The method of manufacturing a light emitting module according to claim 6 , wherein
the process of forming the optical characteristic correcting element includes forming a light transmissive member in at least one of the plurality of first holes.

14. The method of manufacturing a light emitting module according to claim 13 , wherein
a refractive index of the light transmissive member is selected based on the measured optical characteristics.

15. The method of manufacturing a light emitting module according to claim 13 , wherein
the process of forming the optical characteristic correcting element includes forming an oblique face oblique to the first principal face at an upper face of the light transmissive member.

16. The method of manufacturing a light emitting module according to claim 13 , wherein
the process of forming the optical characteristic correcting element further includes forming a groove in the light transmissive member.

17. The method of manufacturing a light emitting module according to claim 16 , wherein
the process of forming the optical characteristic correcting element further includes forming a light reflecting member in the groove of the light transmissive member.

18. The method of manufacturing a light emitting module according to claim 1 , further comprising, based on the measured optical characteristics, replacing one of the plurality of light sources with other one of the plurality of light sources together with a portion of the light guide surrounding the light source.

19. The method of manufacturing a light emitting module according to claim 1 , wherein
the light guide has recesses that are open on a second principal face side, and
at least some of the plurality of light sources are disposed in the recesses.

20. The method of manufacturing a light emitting module acc

Assignees

• Nichia Corp

Inventors

• Emura Keiji
• Nakabayashi Takuya
• Hashimoto Toru

Classifications

• G02B6/0065 Primary

  Manufacturing aspects; Material aspects · CPC title

• G02B6/0055

  Reflecting element, sheet or layer · CPC title

• G02B6/0068 Primary

  Arrangements of plural sources, e.g. multi-colour light sources · CPC title

• G02B6/0083

  Details of electrical connections of light sources to drivers, circuit boards, or the like · CPC title

• G02F1/1336 Primary

  Illuminating devices · CPC title