JP2012130855A - Cartridge and coating device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a cartridge capable of suppressing concentration change caused when replenishing fluorescent material dispersion and precursor solution into a coating device; and to provide the coating device capable of suppressing the change and fluctuation of color when a light-emitting device emits light by forming a fluorescent material dispersion film where the fluorescent material is evenly dispersed in the light-emitting device using the fluorescent material dispersion and the precursor solution fed from the cartridge.SOLUTION: The cartridge supplies a coating liquid containing the fluorescent material to the coating device for coating the fluorescent material dispersion film for forming the wavelength converting part on the light-emitting surface of the light-emitting device. The cartridge includes, in a one-to-one manner: a first filling chamber filled with the fluorescent material dispersion containing the fluorescent material with wavelength converting characteristic; and the second filling chamber filled with the precursor solution containing the precursor composition of translucent ceramics.

Description

  The present invention relates to a coating apparatus that coats a phosphor-dispersed film on a light-emitting device, and more particularly to a cartridge that supplies a coating liquid containing a phosphor and a coating apparatus that includes the cartridge.

  In recent years, phosphors such as YAG (yttrium, aluminum, garnet) phosphors are arranged in the vicinity of a gallium nitride (GaN) blue LED (Light Emitting Diode) chip, and blue light emitted from the blue LED chip. In addition, a technique for obtaining a white light emitting device by color mixture of yellow light emitted when the phosphor receives blue light and emits secondary light is widely used. In addition, a technique for obtaining a white light emitting device by mixing blue light emitted from a blue LED chip and red light and green light emitted by each phosphor receiving blue light and secondary light emission is also used. Yes.

  Such white light emitting devices have various uses, for example, there is a demand as an alternative to fluorescent lamps and incandescent lamps. In addition, it is also being used for lighting devices such as automobile headlights that require extremely high luminance. Since the headlight is required to have high visibility with respect to an object such as a distant sign, high performance is also required in terms of the color of the white light emitting device and the color uniformity of the irradiation range.

  In such a white light emitting device, there is a method of sealing an LED chip or a mounting portion using a ceramic (glass) containing a phosphor. For example, in Patent Document 1, phosphor particles are dispersed in a precursor solution containing a ceramic precursor composition, and this is applied to an LED chip and heated, so that the ceramic (glass) containing the phosphor is heated. A method for sealing is disclosed. In addition, a method of forming a sealed body in which phosphor particles are dispersed by separately applying a phosphor dispersion liquid for dispersing phosphor particles and a precursor solution containing a metal alkoxide or a ceramic precursor composition. It's being used.

Japanese Patent No. 3307316

  However, in the coating apparatus that separately applies the phosphor dispersion liquid and the precursor solution to the light emitting device, when only one of the phosphor dispersion liquid and the precursor solution is supplied when the coating liquid is replenished, the supplied coating is applied. Unexpected changes in concentration may occur in the liquid. In this case, since the uniformity of the phosphor in the formed sealing body is impaired, chromaticity changes and variations occur in the light emitting device. Therefore, when replenishing the coating liquid, the phosphor dispersion liquid and the precursor solution in which the concentration is adjusted and the supply amount is set under the condition that it is confirmed in advance that no change in chromaticity or variation occurs in the light emitting device. Needed to be supplied in pairs.

  The present invention provides a cartridge capable of suppressing a concentration change that occurs when a phosphor dispersion liquid and a precursor solution are replenished to a coating apparatus, and further, a phosphor dispersion liquid and a precursor solution supplied from the cartridge. The present invention provides a coating device capable of forming a phosphor dispersion film in which phosphors are uniformly dispersed in a light emitting device and suppressing chromaticity changes and variations when the light emitting device emits light. Objective.

  In order to achieve the above object, the present invention provides a cartridge for supplying a coating solution containing a phosphor to a coating device that coats a phosphor dispersion film for forming a wavelength conversion portion on a light emitting surface of a light emitting device. A first filling chamber filled with a phosphor dispersion liquid containing a phosphor having wavelength conversion characteristics, a second filling chamber filled with a precursor solution containing a precursor composition of a translucent ceramic, Are provided in a pair.

  According to the above configuration, the supply body that supplies the coating liquid containing the phosphor to the coating device that coats the phosphor dispersion film on the light emitting surface of the light emitting device is filled with the phosphor dispersion liquid containing the phosphor. A cartridge in which a first filling chamber and a second filling chamber filled with a precursor solution containing a light-transmitting ceramic precursor composition are integrally provided can be obtained. Therefore, when the cartridge is replaced, the phosphor dispersion liquid and the precursor solution can be supplied in pairs to the coating apparatus. Therefore, it is possible to suppress the concentration change that occurs when the phosphor dispersion liquid and the precursor solution are replenished to the coating apparatus. The coating device can form a phosphor dispersion film in which the phosphor is uniformly dispersed in the light emitting device by using the phosphor dispersion liquid and the precursor solution supplied from the cartridge, so that the light emitting device emits light. Changes in chromaticity and variations can be suppressed.

  Further, in the above configuration, the phosphor dispersion liquid and the precursor solution are set to a concentration and a filling amount according to a ratio between a consumption rate of the phosphor dispersion liquid and a consumption rate of the precursor solution in the coating apparatus. May be. With this configuration, the concentration and filling amount of the phosphor dispersion liquid and the precursor solution can be set so that the phosphor dispersion liquid and the precursor solution can be used up simultaneously. Therefore, the phosphor dispersion liquid and the precursor solution can be efficiently used without excess or deficiency in the coating apparatus.

  In the above configuration, a first opening for sending the phosphor dispersion liquid is formed in the first filling chamber, and a second opening for sending the precursor solution is formed in the second filling chamber. May be. Furthermore, a first connection pipe for connecting the first supply flow path and the first filling chamber provided in the coating apparatus, and a second connection flow path and the second filling chamber provided in the coating apparatus are connected. A second connection pipe, the first connection pipe may be provided in the first opening, and the second connection pipe may be provided in the second opening. With this configuration, when the cartridge is mounted on the coating apparatus, a flow path for feeding the phosphor dispersion liquid and the precursor solution from the filling chamber to the coating apparatus can be formed.

  In the above configuration, the first stirring member may be provided in the first filling chamber, and the second stirring member may be provided in the second filling chamber. With this configuration, since the phosphor dispersion liquid and the precursor solution in each filling chamber are stirred by the stirring member, precipitation and segregation of the phosphor particles in the phosphor dispersion liquid and the precursor composition in the precursor solution are prevented. be able to.

  Moreover, the said structure WHEREIN: The opening part for indoor pressurization for pressurizing from the outside may be formed in the 1st filling chamber and the 2nd filling chamber. With this configuration, the first filling chamber and the second filling chamber can be pressurized from the outside, so that the phosphor dispersion liquid and the precursor solution can be reliably and sufficiently fed from the filling chamber to the coating apparatus.

  In order to achieve the above object, the present invention provides a coating apparatus that includes a mounting portion for mounting the above-described cartridge and applies a phosphor dispersion film for forming a wavelength conversion portion to a light emitting surface of a light emitting device. A first supply channel for feeding the phosphor dispersion liquid filled in the first filling chamber; a second supply channel for feeding the precursor solution filled in the second filling chamber; A first spray nozzle for injecting a body dispersion liquid onto the light emitting device; and a second spray nozzle for injecting the precursor solution onto the light emitting device.

  According to the above configuration, the cartridge is mounted on the coating device that applies the phosphor dispersion film to the light emitting surface of the light emitting device, and the phosphor dispersion solution and the precursor solution are applied in pairs when the cartridge is replaced. Supplied to the device. Therefore, it is possible to suppress the concentration change that occurs when the phosphor dispersion liquid and the precursor solution are replenished to the coating apparatus. The coating apparatus can form a phosphor dispersion film in which the phosphor is uniformly dispersed in the light emitting device by using the phosphor dispersion liquid and the precursor solution supplied from the cartridge. Therefore, changes in chromaticity and variations when the light emitting device emits light can be suppressed.

  In the above configuration, the first supply channel is formed with a first supply port for supplying the phosphor dispersion liquid, and the second supply channel is supplied with the precursor solution. A mouth may be formed, and the first supply port and the second supply port may be opened vertically upward. With this configuration, the phosphor dispersion liquid and the precursor solution are fed vertically downward from the filling chamber to the supply channel. Therefore, it is possible to prevent dripping of the phosphor dispersion liquid and the precursor solution at the connection portion between the filling chamber and the supply flow path.

  Further, in the above configuration, a first supply pipe for connecting the first filling chamber and the first supply flow path, a second supply pipe for connecting the second filling chamber and the second supply flow path, The first supply pipe may be provided at the first supply port, and the second supply pipe may be provided at the second supply port. With this configuration, it is possible to form a flow path for feeding the phosphor dispersion liquid and the precursor solution from the filling chamber to the supply flow path when the cartridge is mounted on the coating apparatus.

  Further, in the above configuration, the phosphor dispersion liquid fed to the first spray nozzle is stored, the first storage tank for exhausting mixed air, and the precursor solution fed to the second spray nozzle. And a second storage tank for storing and exhausting the mixed air. With this configuration, even when air is mixed in the phosphor dispersion liquid or the precursor solution when the cartridge is replaced, the air mixed in the first storage tank or the second storage tank is discharged. can do. Therefore, air is not mixed into the phosphor dispersion liquid or the precursor solution ejected from the spray nozzle, and thus a uniform phosphor dispersion film can be formed on the light emitting device.

  Moreover, in the said structure, a 1st storage tank exists in the position below a perpendicular direction rather than the 1st connection part which connects a 1st filling chamber and a 1st supply flow path, and a 2nd storage tank is 2nd. You may exist in the position below a perpendicular direction rather than the 2nd connection part which connects a filling chamber and a 2nd supply flow path. With this configuration, it is possible to prevent the back flow of the phosphor dispersion liquid and the precursor solution temporarily stored in the first storage tank and the second storage tank, and further, in the first connection section and the second connection section. It is possible to prevent the phosphor dispersion liquid and the precursor solution from leaking outside.

  Moreover, the said structure WHEREIN: The opening part for pressurization in a tank for pressurizing from the outside may be formed in a 1st storage tank and a 2nd storage tank. With this configuration, the inside of the first storage tank and the second storage tank can be pressurized from the outside, so that the phosphor dispersion liquid and the precursor solution can be reliably and sufficiently fed from the storage tank to the spray nozzle.

  According to the present invention, the supply body for supplying the coating liquid containing the phosphor to the coating device for coating the phosphor dispersion film on the light emitting surface of the light emitting device is filled with the phosphor dispersion liquid containing the phosphor. A cartridge in which a filling chamber and a second filling chamber filled with a precursor solution containing a translucent ceramic precursor composition are integrally provided can be obtained. Therefore, when the cartridge is replaced, the phosphor dispersion liquid and the precursor solution can be supplied in pairs to the coating apparatus. Therefore, it is possible to suppress the concentration change that occurs when the phosphor dispersion liquid and the precursor solution are replenished to the coating apparatus. The coating device can form a phosphor dispersion film in which the phosphor is uniformly dispersed in the light emitting device by using the phosphor dispersion liquid and the precursor solution supplied from the cartridge, so that the light emitting device emits light. Changes in chromaticity and variations can be suppressed.

1 is an overall view of a coating apparatus according to a first embodiment. It is a block diagram of the cartridge which concerns on 1st Embodiment. It is a block diagram which shows the modification of the cartridge which concerns on 1st Embodiment. It is a block diagram of the coating device which concerns on 1st Embodiment. It is a schematic sectional drawing of the light-emitting device before an application | coating process. It is a schematic sectional drawing of the light-emitting device after a baking process. It is a general view of the coating device which concerns on 2nd Embodiment. It is a block diagram of the cartridge which concerns on 2nd Embodiment. It is a block diagram of the coating device which concerns on 2nd Embodiment. It is a general view of the coating device which concerns on 3rd Embodiment.

Embodiments of the present invention will be described below with reference to the drawings.
<First Embodiment>

  FIG. 1 is a configuration diagram of a coating apparatus according to the first embodiment. As shown in FIG. 1, the cartridge 1 is mounted on a coating device 2 and supplies a coating solution 5 to the coating device 2. The coating device 2 is a device that applies a phosphor dispersion film for forming the wavelength conversion unit 35 (see FIG. 6) to the light emitting surface of the light emitting device 3. The coating apparatus 2 applies a phosphor dispersion liquid 5a containing phosphor particles having wavelength conversion characteristics to the light emitting surface of the light emitting apparatus 3, and then applies a precursor solution 5b containing a precursor composition of a translucent ceramic. It is applied to the light emitting surface of the light emitting device 3. By baking the coating film (phosphor dispersion film) formed in this way, the wavelength conversion unit 35 is formed in the light emitting device 3.

  The cartridge 1 and the coating device 2 are detachably mounted. The cartridge 1 supplies the coating solution 5 containing the phosphor to the coating device 2 that coats the phosphor dispersion film for forming the wavelength conversion unit 35 on the light emitting surface of the light emitting device 3. FIG. 2 is a configuration diagram of the cartridge according to the first embodiment. As shown in FIG. 2, the cartridge 1 includes a filling chamber 11, a connecting pipe 12, a stirring member 13, and a holding unit 14.

  The filling chamber 11 includes a first filling chamber 11a and a second filling chamber 11b. The first filling chamber 11 a and the second filling chamber 11 b are provided as a single unit with the cartridge 1. The first filling chamber 11a is filled with a phosphor dispersion liquid 5a containing a phosphor having wavelength conversion characteristics. The second filling chamber 11b is filled with a precursor solution 5b containing a light-transmitting ceramic precursor composition.

  In addition, an opening 111 for feeding the coating solution 5 is formed at the bottom of the filling chamber 11. In FIG. 2, a first opening 111a for sending the phosphor dispersion liquid 5a is formed in the first filling chamber 11a, and a second opening 111b for sending the precursor solution 5b is formed in the second filling chamber 11b. Is formed. An internal pressure of 0.01 to 0.5 MPa is applied in the first filling chamber 11a and the second filling chamber 11b. Therefore, when the cartridge 1 is mounted on the coating device 2, the phosphor dispersion liquid 5 a and the precursor solution 5 b are sent out from the opening 111 of the filling chamber 11 to the coating device 2 due to the internal pressure.

  In addition, an indoor pressurizing opening 112 for pressurizing from the outside may be formed in the first filling chamber 11a and the second filling chamber 11b. FIG. 3 is a configuration diagram illustrating a modified example of the cartridge according to the first embodiment. In FIG. 3, a first chamber pressurizing opening 112a for pressurizing from the outside is formed in the first filling chamber 11a, and a second chamber pressurizing opening 112b for pressurizing from the outside is formed in the second filling chamber 11b. Has been. Further, a pressurizing device (not shown) such as a compressor is connected to the first indoor pressurizing opening 112a and the second indoor pressurizing opening 112b. The inside of the first filling chamber 11a and the second filling chamber 11b is pressurized by this pressurizing device. Thereby, since the inside of the first filling chamber 11a and the second filling chamber 11b can be pressurized from the outside, the phosphor dispersion liquid 5a and the precursor solution 5b are reliably and sufficiently supplied from the filling chamber 11 to the coating apparatus 2. Can be sent.

  Next, the connection pipe 12 is a tubular member for connecting the filling chamber 11 and the supply flow path 21 provided in the coating apparatus 2, and is provided in the opening 111 of the filling chamber 11. When the cartridge 1 is mounted on the coating apparatus 2, the connecting pipe 12 is connected to the supply flow path 21 of the coating apparatus 2, and has a flow path for feeding the coating liquid 5 from the filling chamber 11 to the supply flow path 21. Form. The connecting pipe 12 has a structure in which the flow path is opened by connection with the supply flow path 21 of the coating apparatus 2.

  As shown in FIG. 1 and FIG. 2, the connection pipe 12 includes the first connection pipe 12 a for connecting the first supply flow path 21 a included in the coating apparatus 2 and the first filling chamber 11 a, and the coating apparatus 2. And a second connecting pipe 12b for connecting the second supply channel 21b and the second filling chamber 11b. The first connecting pipe 12a is provided in the first opening 111a, and the second connecting pipe 12b is provided in the second opening 111b. The phosphor dispersion liquid 5a is fed from the first filling chamber 11a to the first supply channel 21a through the first connection pipe 12a. The precursor solution 5b is fed from the second filling chamber 11b to the second supply channel 21b through the second connection pipe 12b. Thereby, when the cartridge 1 is mounted on the coating apparatus 2, a flow path for feeding the phosphor dispersion liquid 5 a and the precursor solution 5 b from the filling chamber 11 to the coating apparatus 2 can be formed.

  Further, the stirring member 13 is rotatably provided in the filling chamber 11. In FIG. 2, a first stirring member 13a for stirring the phosphor dispersion liquid 5a is provided in the first filling chamber 11a, and a second stirring member 13b for stirring the precursor solution 5b is provided in the second filling chamber 11b. ing. Further, the stirring member 13 is rotated by the driving force applied by the stirring device 131 and stirs the coating liquid 5 in the filling chamber 11. Thereby, since the phosphor dispersion liquid 5a and the precursor solution 5b in the filling chamber 11 are stirred by the stirring member 13, the phosphor particles in the phosphor dispersion liquid 5a and the precursor composition in the precursor solution 5b Precipitation and segregation can be prevented. The stirring member 13 is not particularly limited, and examples thereof include a stirring rod having a stirring propeller and a magnetic stirrer.

  The holding unit 14 is a member for detachably mounting the cartridge 1 on the coating device 2 and includes a chuck unit 141. The chuck portion 141 is a holding member for holding the cartridge 1 to the coating device 2 in a detachable manner. As shown in FIG. 1, the chuck portion 141 engages with an engagement portion 26 provided in the coating apparatus 2. The cartridge 1 is mounted on the coating device 2 by the chuck portion 141 being engaged with the engaging portion 26 and the connection pipe 12 being connected to the supply flow path 21.

  Next, the phosphor dispersion liquid 5a will be described. The phosphor dispersion liquid 5a is a dispersion liquid in which phosphor particles having wavelength conversion characteristics, swellable particles, and inorganic fine particles are dispersed in a mixed solvent composed of pure water and an organic solvent.

  The phosphor is excited by a predetermined wavelength (excitation wavelength) and emits fluorescence having a wavelength different from the excitation wavelength. In this embodiment, a YAG (yttrium, aluminum, garnet) phosphor that converts blue light (wavelength 420 nm to 485 nm) into yellow light (wavelength 550 nm to 650 nm) is used. In addition, the kind of fluorescent substance is not limited to this, For example, other fluorescent substances, such as a non-garnet-type fluorescent substance which does not contain Ce, can also be used. Further, phosphor particles having a volume average particle diameter of 1 μm or more and 50 μm or less were used.

  As the swellable particles, a layered silicate mineral having a smectite structure rich in swellability was used. The mineral here refers to a solid substance having a certain chemical composition and crystal structure, which is a natural or synthetic inorganic substance. When such swellable particles are dispersed in a mixed solvent, a card house structure in which water in the mixed solvent enters and swells between layers of the smectite structure is obtained, so that the effect of greatly increasing the viscosity of the mixed liquid is obtained. . In addition, the kind of swellable particle | grain is not limited to this. For example, as the layered silicate mineral, a swellable clay mineral having a mica structure, a kaolinite structure, a smectite structure, or the like can be used. In addition, fluoride particles such as magnesium fluoride, aluminum fluoride, and calcium fluoride may be used as the swellable particles.

  As the inorganic particles, oxide fine particles such as silicon oxide, titanium oxide and zinc oxide, fluoride fine particles such as magnesium fluoride, and the like were used. In addition, in consideration of compatibility with the solvent, a material obtained by treating the surface of the inorganic particles with a silane coupling agent or a titanium coupling agent may be used as appropriate. As the particle size of the inorganic particles, a primary particle size having a central particle size of 0.001 μm or more and 1 μm or less was used.

  As a solvent for the phosphor dispersion liquid 5a, a mixed solution of pure water and IPA (isopropyl alcohol) was used. In addition, it is not limited to this, You may use another organic solvent instead of IPA. Any organic solvent having excellent compatibility with water may be used. For example, alcohols such as methanol, ethanol, propanol, and butanol can be used. Moreover, when a high boiling point organic solvent is used, the pot life of the mixed solution is not shortened, and the handleability is excellent.

  Next, the precursor solution 5b will be described. The precursor solution 5b is a solution in which a precursor composition of translucent ceramic is mixed in an organic solvent. In addition to these, the above-mentioned layered silicate mineral and inorganic particles may be mixed in the precursor solution 5b.

  The precursor composition of translucent ceramic utilized metal alkoxide. It is not limited to this, You may use organometallic compounds, such as metal acetylacetonate and metal carboxylate. As the metal alkoxide, a polysiloxane in which an organosiloxane compound is linked in a chain or a ring is used. In addition, a single molecule such as tetraethoxysilane may be used. The type of metal is not limited as long as a translucent ceramic body can be formed, but from the viewpoint of the stability of the formed ceramic body and the ease of manufacturing, one containing silicon is preferable. Moreover, you may contain multiple types of metal.

  IPA was used as the solvent for the precursor solution 5b. In addition, it is not limited to this, You may use another organic solvent. For example, when water is added, alcohols such as methanol, ethanol, propanol, and butanol having excellent compatibility with water can be used.

  The phosphor dispersion liquid 5a and the precursor solution 5b are set to a concentration and a filling amount according to the ratio between the consumption rate of the phosphor dispersion liquid 5a and the consumption rate of the precursor solution 5b in the coating apparatus 2. That is, the dispersion concentration of the phosphor particles, the swellable particles, and the inorganic fine particles in the phosphor dispersion liquid 5a, the mixing ratio of pure water and the organic solvent in the mixed solvent, and the filling amount in the first filling chamber 11a are as follows. 2 is set according to the ratio of the consumption rate of the phosphor dispersion 5a and the consumption rate of the precursor solution 5b. Further, the concentration of the precursor composition of the translucent ceramic in the precursor solution 5b and the filling amount into the second filling chamber 11b are the consumption rate of the phosphor dispersion liquid 5a and the consumption rate of the precursor solution 5b in the coating apparatus 2. It is set according to the ratio. Thereby, the density | concentration and filling amount of the phosphor dispersion liquid 5a and the precursor solution 5b with which each filling chamber 11 is filled can be set so that the phosphor dispersion liquid 5a and the precursor solution 5b can be used up simultaneously. . Therefore, the phosphor dispersion liquid 5a and the precursor solution 5b can be used efficiently without excess or deficiency.

  Next, the coating apparatus 2 will be described. FIG. 4 is a configuration diagram of the coating apparatus according to the first embodiment. As shown in FIG. 4, the coating apparatus 2 includes a supply flow path 21, a storage tank 22, a storage tank stirring member 23, a delivery flow path 24, a spray nozzle 25, and an engagement portion 26. .

  The supply channel 21 is connected to the filling chamber 11 of the cartridge 1 when the cartridge 1 is mounted on the coating device 2, and is a channel for feeding the coating solution 5 supplied from the filling chamber 11 to the storage tank 22. is there. As shown in FIG. 4, the supply flow path 21 includes a first supply flow path 21a for feeding the phosphor dispersion liquid 5a filled in the first filling chamber 11a and a precursor filled in the second filling chamber 11b. And a second supply channel 21b for feeding the solution 5b.

  The first supply channel 21a is provided with a first supply port 211a to which the phosphor dispersion liquid 5a is supplied, and the second supply channel 21b is supplied with the precursor solution 5b. A supply port 211b is formed. The first supply port 211a and the second supply port 211b are opened vertically upward. Thereby, the phosphor dispersion liquid 5a and the precursor solution 5b are fed from the filling chamber 11 to the supply channel 21 vertically downward. Therefore, dripping of the phosphor dispersion liquid 5a and the precursor solution 5b at the connection portion between the filling chamber 11 and the supply channel 21 can be prevented.

  When the cartridge 1 is mounted on the coating apparatus 2, the first filling tube 11a is inserted into the first supply port 211a, whereby the first filling chamber 11a and the first supply flow path 21a are connected. The phosphor dispersion liquid 5a is fed to the first storage tank 22a through the first supply channel 21a. Similarly, when the cartridge 1 is mounted on the coating device 2, the second connecting tube 12b is inserted into the second supply port 211b, whereby the second filling chamber 11b and the second supply channel 21b are connected. . The precursor solution 5b is sent to the second storage tank 22b through the second supply channel 21b. In the present embodiment, when connecting the filling chamber 11 and the supply flow path 21, the connection pipe 12 is inserted into the supply port 211 of the supply flow path 21. May be applied.

  The storage tank 22 temporarily stores the coating liquid 5 fed from the supply channel 21. A supply flow path 21 is connected to the lower part of the storage tank 22, and a delivery flow path 24 is connected to the bottom thereof. In FIG. 4, the storage tank 22 stores the phosphor dispersion liquid 5a and exhausts the mixed air, and the second storage tank 22b stores the precursor solution 5b and exhausts the mixed air. And. As a result, even when air is mixed in the phosphor dispersion liquid 5a or the precursor solution 5b when the cartridge 1 is replaced or the like, it is mixed during the period stored in the first storage tank 22a or the second storage tank 22b. Air can be discharged. Therefore, air is not mixed into the phosphor dispersion liquid 5a and the precursor solution 5b ejected from the spray nozzle 25, so that a uniform phosphor dispersion film can be formed on the light emitting device 3.

  For example, when the cartridge 1 is mounted on the coating device 2, air may enter the supply channel 21 and air may be mixed into the phosphor dispersion liquid 5a or the precursor solution 5b. The air mixed in the phosphor dispersion liquid 5a is released from the liquid surface 221a of the phosphor dispersion liquid 5a to the space 222a above it during the period in which the phosphor dispersion liquid 5a is stored in the first storage tank 22a. Separated from the phosphor dispersion 5a. Similarly, the air mixed in the precursor solution 5b is released from the liquid surface 221b of the precursor solution 5b to the space 222b above the precursor solution 5b during the period in which the precursor solution 5b is stored in the first storage tank 22b. Separated from the precursor solution 5b. Therefore, since air does not enter the air phosphor dispersion 5a and the precursor solution 5b applied to the light emitting device 3, the phosphor dispersion 5a and the precursor solution 5b are more uniformly applied to the light emitting device 3. be able to.

  Moreover, as shown in FIG.1 and FIG.4, the 1st storage tank 22a is located in the downward direction of a perpendicular direction rather than the 1st connection part which connects the 1st filling chamber 11a and the 1st supply flow path 21a, The 2nd storage tank 22b is located in the vertical direction lower side rather than the 2nd connection part which connects the 2nd filling chamber 11b and the 2nd supply flow path 21b. For example, the first storage tank 22a is at a position lower than the first connection pipe 12a and the first supply port 211a (that is, the position on the lower side in the vertical direction), and the second storage tank 22b is the second connection pipe 12b and the second supply pipe 211a. 2 It is in a position lower than the supply port 211b (that is, a position on the lower side in the vertical direction). Thereby, the back flow of the phosphor dispersion liquid 5a and the precursor solution 5b temporarily stored in the first storage tank 22a and the second storage tank 22b can be prevented, and further, the first connection part and the second connection can be prevented. This prevents the phosphor dispersion liquid 5a and the precursor solution 5b from leaking outside.

  The storage tank 22 has an in-tank pressurization opening 223 for pressurizing the inside of the tank from the outside. As shown in FIG. 4, the first tank pressurization opening 223a is formed in the first storage tank 22a, and the second tank pressurization opening 223b is formed in the second storage tank 22b. Further, a pressurizing device (not shown) such as a compressor is connected to the pressurizing openings 223 in the tank, and the inside of the first storage tank 22a and the second storage tank 22b is pressurized by the pressurization apparatus. Is done. Thereby, since the inside of the 1st storage tank 22a and the 2nd storage tank 22b can be pressurized from the exterior, the phosphor dispersion liquid 5a and the precursor solution 5b are reliably and fully supplied from the storage tank 22 to the spray nozzle 25. can do.

  A storage tank agitating member 23 is rotatably provided in the storage tank 22. As shown in FIG. 4, a first storage tank stirring member 23a for stirring the phosphor dispersion liquid 5a is provided in the first storage tank 22a, and the precursor solution 5b is stored in the second storage tank 22b. A second storage tank stirring member 23b for stirring is provided. The storage tank stirring member 23 is rotated by a driving force applied by a stirring device (not shown) to stir the coating liquid 5 in the storage tank 22. Thereby, precipitation and segregation of the phosphor particles and the ceramic precursor composition during the period in which the phosphor dispersion liquid 5a and the precursor solution 5b are stored in the storage tank 22 can be prevented. The storage tank stirring member 23 is not particularly limited, and examples thereof include a stirring rod having a stirring propeller and a magnetic stirrer.

  The delivery channel 24 is a channel for connecting the storage tank 22 and the spray nozzle 25 to feed the phosphor dispersion liquid 5a and the precursor solution 5b from the storage tank 22 to the spray nozzle 25. In FIG. 4, the delivery channel 24 is composed of a first delivery channel 24a and a second delivery channel 24b. One end of the first delivery channel 24a is connected to the bottom of the first storage tank 22a, and the other end is connected to the first spray nozzle 25a. Then, the phosphor dispersion liquid 5a is fed from the first storage tank 22a to the first spray nozzle 25a through the first delivery channel 24a. Further, one end of the second delivery channel 24b is connected to the bottom of the second storage tank 22b, and the other end is connected to the spray nozzle 25b. Then, the precursor solution 5b is fed from the second storage tank 22b to the second spray nozzle 25b through the second delivery channel 24b.

  The spray nozzle 25 is a spray unit that sprays the coating liquid 5 fed from the delivery channel 24 toward the light emitting device 3. The spray nozzle 25 is formed with a compressed gas introduction port 251 and an injection port 252. Further, the injection port 252 is formed on a surface facing the light emitting device 3. The compressed gas introduction port 251 is connected to a pressurizing device (not shown) such as a compressor, and the compressed gas is introduced from the pressurizing device. The compressed gas is applied to the light emitting device 3 by entraining the application liquid 5 and injecting the application liquid 5 from the injection port 252.

  In FIG. 4, the spray nozzle 25 includes a first spray nozzle 25a and a second spray nozzle 25b. The first spray nozzle 25a is formed with a first compressed gas introduction port 251a and a first injection port 252a. The second spray nozzle 25b is formed with a second compressed gas inlet 251b and a second injection port 252b. When the coating device 2 coats the phosphor dispersion film on the light emitting surface of the light emitting device 3, first, in the first spray nozzle 25a, the compressed gas entrains the phosphor dispersion 5a and is ejected from the first ejection port 252a. Thus, the phosphor dispersion liquid 5 a is applied to the light emitting device 3. Thereafter, in the second spray nozzle 25b, the compressed gas entrains the precursor solution 5b and is injected from the second injection port 252b, whereby the precursor solution 5b is applied to the light emitting device 3. In FIG. 4, the spray nozzle 25 ejects the coating liquid 5 from the vertically lower side to the light emitting device 3 that is the object to be processed. However, the spray nozzle 25 may be ejected from the upper vertical direction.

  The engaging portion 26 is a member for mounting the cartridge 1 on the coating device 2. The engaging part 26 engages with the chuck part 141 and holds the cartridge 1 in the coating device 2 so as to be detachable.

  Next, the light emitting device 3 to which the phosphor dispersion liquid 5a and the precursor solution 5b are applied by the coating device 2 will be described. FIG. 5 is a schematic cross-sectional view of the light emitting device before the coating process. As shown in FIG. 5, the light emitting device 3 a before coating includes a substrate 31, a metal part 32, a light emitting element 33, and a protruding electrode 34.

  The substrate 31 has a concave cross-sectional shape in the thickness direction. The metal part 32 is provided in a recess (bottom part) of the substrate 31, and the light emitting element 33 is disposed on the metal part 32. The light emitting element 33 is provided with a protruding electrode 34 on the surface facing the metal portion 32. The metal part 32 and the light emitting element 33 are connected via a protruding electrode 34 (flip chip type). In the present embodiment, a blue LED element is used as the light emitting element 33. The blue LED element is formed, for example, by laminating an n-GaN-based cladding layer, an InGaN light-emitting layer, a p-GaN-based cladding layer, and a transparent electrode on a sapphire substrate.

  In the light emitting device 3, the phosphor dispersion liquid 5a is applied by the first spray nozzle 25a of the coating device 2, and then the precursor solution 5b is applied by the second spray nozzle 25b. Thereafter, the light emitting device 3 is transferred to a firing furnace and fired at a temperature set to such an extent that the light emitting element 33 is not damaged, for example, 100 to 300 ° C. As a result, the light emitting device 3 in which the wavelength conversion unit 35 is formed is obtained.

  FIG. 6 is a schematic cross-sectional view of the light emitting device after the firing treatment. As shown in FIG. 6, in the light emitting device 3 after firing, the wavelength conversion unit 35 is formed in the recess of the substrate 31 so as to seal the periphery of the light emitting element 33. In the wavelength converter 35, the light emitted from the light emitting element 33 is converted into light having a predetermined wavelength and emitted. In other words, the phosphor particles included in the wavelength conversion unit 35 are excited by light having a predetermined wavelength emitted from the light emitting element 33 and emit fluorescence having a wavelength different from the wavelength of the light.

  As described above, the cartridge 1 according to the present embodiment supplies the coating liquid 5 containing the phosphor to the coating device 2 that coats the phosphor dispersion film for forming the wavelength conversion unit 35 on the light emitting surface of the light emitting device 3. The cartridge is filled with a first filling chamber 11a filled with a phosphor dispersion liquid 5a containing a phosphor having wavelength conversion characteristics, and a precursor solution 5b containing a light-transmitting ceramic precursor composition. And a second filling chamber 11b.

  In this case, the phosphor dispersion liquid 5a containing the phosphor is used as the supply body for supplying the coating liquid 5 containing the phosphor to the coating device 2 that applies the phosphor dispersion film to the light emitting surface of the light emitting device 3. The first filling chamber 11a filled and the second filling chamber 11b filled with the precursor solution 5b containing the translucent ceramic precursor composition may be a cartridge 1 provided as a single unit. it can. Therefore, when the cartridge 1 is replaced, the phosphor dispersion liquid 5a and the precursor solution 5b can be supplied to the coating device 2 in pairs. Accordingly, it is possible to suppress the concentration change that occurs when the phosphor dispersion liquid 5a and the precursor solution 5b are replenished to the coating apparatus 2. The coating device 2 can form a phosphor dispersion film in which the phosphor is uniformly dispersed in the light emitting device 3 by using the phosphor dispersion liquid 5a and the precursor solution 5b supplied from the cartridge 1. Changes in chromaticity and variations when the light emitting device 3 emits light can be suppressed.

  Further, the coating apparatus 2 according to the present embodiment includes an engaging portion 26 (mounting portion) for mounting the cartridge 1, and a phosphor dispersion film for forming the wavelength converting portion 35 is used as the light emitting surface of the light emitting device 3. A first supply channel 21a for feeding the phosphor dispersion liquid 5a filled in the first filling chamber 11a and a precursor solution 5b filled in the second filling chamber 11b. A second supply channel 21b for feeding, a first spray nozzle 25 for injecting the phosphor dispersion liquid 5a to the light emitting device 3, and a second spray nozzle 25b for injecting the precursor solution 5b to the light emitting device 3 are provided.

  In this way, the cartridge 1 is mounted on the coating device 2 that applies the phosphor dispersion film to the light emitting surface of the light emitting device 3, and when the cartridge 1 is replaced, the phosphor dispersion 5a and the precursor solution 5b are changed. A pair is supplied to the coating apparatus 2. Accordingly, it is possible to suppress the concentration change that occurs when the phosphor dispersion liquid 5a and the precursor solution 5b are replenished to the coating apparatus 2. The coating device 2 can form a phosphor dispersion film in which the phosphor is uniformly dispersed in the light emitting device 3 using the phosphor dispersion 5a and the precursor solution 5b supplied from the cartridge 1. Therefore, changes in chromaticity and variations when the light emitting device 3 emits light can be suppressed.

In the first embodiment, the connection pipe 12 connects the filling chamber 11 and the supply flow path 21, but the present invention is not limited to this, and other connection forms may be applied.
Second Embodiment

  FIG. 7 is an overall view of a coating apparatus according to the second embodiment. In the second embodiment, the cartridge 1B is detachably attached to the coating device 2B. The second embodiment has the same configuration as that of the first embodiment except that the configuration for connecting the filling chamber 11 and the supply flow path 21 is different.

  FIG. 8 is a configuration diagram of a cartridge according to the second embodiment. The cartridge 1B has the same configuration as the cartridge 1 of the first embodiment except that the connection pipe 12 is not provided in the opening 111.

  FIG. 9 is a configuration diagram of a coating apparatus according to the second embodiment. The coating apparatus 2B has the same configuration as the coating apparatus 2 of the first embodiment, except that it further includes a supply pipe 27 connected to the filling chamber 11 of the cartridge 1B.

  The supply pipe 27 is a tubular member for connecting the filling chamber 11 and the supply flow path 21, and is provided at the supply port 211 of the supply flow path 21. When the cartridge 1B is mounted on the coating apparatus 2B, the supply pipe 27 is connected to the filling chamber 11, and a flow path for feeding the phosphor dispersion liquid 5a and the precursor solution 5b from the filling chamber 11 to the supply flow path 21. Form. The opening 111 of the cartridge 1B has a structure in which the flow path is opened when the supply pipe 27 is connected.

  As shown in FIGS. 7 and 9, the supply pipe 27 includes a first supply pipe 27a for connecting the first filling chamber 11a and the first supply flow path 21a, a second filling chamber 11b, and a second supply flow. It is comprised with the 2nd supply pipe | tube 27b for connecting the path | route 21b. Further, as shown in FIG. 9, the first supply pipe 27a is provided in the first supply port 211a, and the second supply pipe 27b is provided in the second supply port 211b. When the cartridge 1B is mounted on the coating apparatus 2B, the first supply tube 27a is inserted into the first opening 111a, thereby connecting the first filling chamber 11a and the first supply channel 21a. Similarly, when the cartridge 1B is mounted on the coating apparatus 2B, the second filling chamber 11b and the second supply channel 21b are connected by inserting the second supply pipe 27b into the second opening 111b. . The phosphor dispersion liquid 5a is fed from the first filling chamber 11a to the first supply channel 21a through the supply pipe 27a. The precursor solution 5b is fed from the second filling chamber 11b to the second supply channel 21b through the second supply pipe 27b. Thereby, when the cartridge 1 is mounted on the coating apparatus 2, a flow path for feeding the phosphor dispersion liquid 5 a and the precursor solution 5 b from the filling chamber 11 to the supply flow path 21 can be formed.

In the first embodiment, the connection pipe 12 connects the filling chamber 11 and the supply flow path 21, but the present invention is not limited to this, and other connection forms may be applied.
<Third Embodiment>

  In addition, the filling chamber 11 and the supply flow path 21 may be connected by connecting the connection pipe 12 provided in the opening 111 and the supply pipe 27 provided in the supply port 211 in a butted state. Good. FIG. 10 is an overall view of a coating apparatus according to the third embodiment. In the third embodiment, the cartridge 1C is detachably attached to the coating device 2C. The third embodiment has the same configuration as that of the first and second embodiments, except that the configuration for connecting the filling chamber 11 and the supply flow path 21 is different.

  The cartridge 1 </ b> C has the same configuration as that of the first embodiment (see FIG. 2), and a connection pipe 12 is provided in an opening 111 formed in the filling chamber 11. Further, the coating device 2C has the same configuration as that of the second embodiment (see FIG. 9), and a supply pipe 27 is provided in a supply port 211 formed in the supply flow path 21.

As shown in FIG. 10, when the cartridge 1C is mounted on the coating device 2C, the first dispersion tube 5a is connected to the first supply tube 27a so that the phosphor dispersion liquid 5a is the first. A flow path for feeding from the filling chamber 11a to the first supply flow path 21a is formed. Similarly, when the cartridge 1C is mounted on the coating apparatus 2C, the second connecting pipe 12b and the second supply pipe 27b are connected so as to face each other, whereby the precursor solution 5b is removed from the second filling chamber 11b. 2 A flow path for feeding to the supply flow path 21b is formed. At this time, the connection pipe 12 may be inserted into the supply pipe 27, or the connection pipe 12 and the supply pipe 27 may be joined together using a connecting member.
<Experimental example>

  Next, experimental results actually performed using the coating apparatus 2 of the first to third embodiments will be described. In these experiments, a phosphor dispersion film containing a YAG phosphor that converts blue light into yellow light (wavelength 550 nm to 650 nm) was applied to the light emitting surface of an LED light emitting device equipped with a blue LED element. And the change and variation of the light emission chromaticity of the light-emitting device 3 which formed the wavelength conversion part 35 by baking were confirmed visually. Table 1 shows the results of these experiments. In Experimental Examples 1 to 3, after the phosphor dispersion liquid 5a and the precursor solution 5b are replenished to the coating apparatus 2 at once by exchanging the cartridge 1 in the first to third embodiments, the phosphor dispersion film The result of forming is shown. Further, the comparative experimental example shows a result of forming a phosphor dispersion film after replenishing only the precursor solution 5b to the coating apparatus 2 of the first embodiment.

  As shown in Table 1, in Experimental Examples 1 to 3, it was confirmed that changes in chromaticity and variations when the light emitting device 3 was caused to emit light were reduced. On the other hand, in the comparative experimental example, it was confirmed that the chromaticity greatly changes or varies even with visual observation.

  The present invention has been described based on the embodiments. This embodiment is an exemplification, and it is understood by those skilled in the art that various modifications can be made to each of the constituent elements and combinations of the processes and are within the scope of the present invention.

  INDUSTRIAL APPLICABILITY The present invention can be used in a manufacturing apparatus for forming a wavelength conversion unit including a phosphor that converts the wavelength of light emitted from a light emitting element on the light emitting surface of the light emitting device having the light emitting element.

DESCRIPTION OF SYMBOLS 1, 1A, 1B, 1C Cartridge 11 Filling chamber 111 Opening part 112 Indoor pressurization opening part 12 Connection pipe 13 Stirring member 131 Stirring apparatus 14 Holding part 141 Chuck part 2, 2B, 2C Coating apparatus 21 Supply flow path 211 Supply port 22 Reservoir 221a, 221b Liquid level 222a, 222b Space 223 Opening for pressurizing in chamber interior 23 Stirring member for reservoir 24 Delivery channel 25 Spray nozzle 251 Compressed gas inlet 252 Injection port 26 Engagement part (mounting part)
27 Supply tube 3 Light emitting device 31 Substrate 32 Metal part 33 Light emitting element 34 Projection electrode 35 Wavelength conversion part 5 Coating liquid 5a Phosphor dispersion liquid 5b Precursor solution

Claims (12)

A cartridge for supplying a coating solution containing a phosphor to a coating device that coats a phosphor dispersion film for forming a wavelength conversion unit on a light emitting surface of a light emitting device,
A first filling chamber filled with a phosphor dispersion liquid containing a phosphor having wavelength conversion characteristics;
A second filling chamber filled with a precursor solution containing a translucent ceramic precursor composition;
A cartridge comprising:   The phosphor dispersion liquid and the precursor solution are set to a concentration and a filling amount according to a ratio between a consumption rate of the phosphor dispersion liquid and a consumption rate of the precursor solution in the coating apparatus. The cartridge according to claim 1. A first opening for delivering the phosphor dispersion is formed in the first filling chamber;
The cartridge according to claim 1, wherein a second opening for delivering the precursor solution is formed in the second filling chamber. A first connection pipe for connecting the first supply flow path and the first filling chamber provided in the coating apparatus;
A second connection pipe for connecting the second supply flow path and the second filling chamber provided in the coating apparatus;
Further comprising
A first connecting pipe is provided in the first opening;
The cartridge according to claim 3, wherein the second connection pipe is provided in the second opening. A first stirring member is provided in the first filling chamber;
The cartridge according to any one of claims 1 to 4, wherein a second stirring member is provided in the second filling chamber.   The cartridge according to any one of claims 1 to 5, wherein an indoor pressurizing opening for pressurizing from the outside is formed in the first filling chamber and the second filling chamber. A coating device comprising a mounting portion for mounting the cartridge according to any one of claims 1 to 6, and applying a phosphor dispersion film for forming a wavelength conversion portion to a light emitting surface of a light emitting device. ,
A first supply channel for feeding the phosphor dispersion liquid filled in the first filling chamber;
A second supply flow path for feeding the precursor solution filled in the second filling chamber;
A first spray nozzle for injecting the phosphor dispersion liquid onto the light emitting device;
And a second spray nozzle that sprays the precursor solution onto the light emitting device. In the first supply channel, a first supply port to which the phosphor dispersion liquid is supplied is formed,
In the second supply channel, a second supply port to which the precursor solution is supplied is formed,
The coating apparatus according to claim 7, wherein the first supply port and the second supply port open vertically upward. A first supply pipe for connecting the first filling chamber and the first supply flow path;
A second supply pipe for connecting the second filling chamber and the second supply flow path;
Further comprising
The first supply pipe is provided at the first supply port,
The coating apparatus according to claim 8, wherein the second supply pipe is provided in the second supply port. A first storage tank for storing the phosphor dispersion liquid fed to the first spray nozzle and exhausting mixed air;
A second storage tank for storing the precursor solution fed to the second spray nozzle and exhausting the mixed air;
The coating apparatus according to any one of claims 7 to 9, further comprising: The first storage tank is located at a lower position in the vertical direction than the first connection portion connecting the first filling chamber and the first supply flow path;
The coating apparatus according to claim 10, wherein the second storage tank is located at a lower position in the vertical direction than the second connection portion that connects the second filling chamber and the second supply channel.   The coating apparatus according to claim 10 or 11, wherein an opening for pressurization inside the tank for pressurizing from the outside is formed in the first storage tank and the second storage tank.

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