JP2012222251A - Discharge device, discharging method and manufacturing method of led module - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a discharge device capable of enhancing the yield by minimizing variation in the characteristics of an object, and to provide a discharge method and a manufacturing method of an LED module.SOLUTION: The discharge device comprises nozzles 33, 35 which discharge a liquid material, a control unit 10 which controls the nozzles 33, 35 to discharge the liquid material, an optical characteristics measurement unit 36 which measures the optical characteristic values of an LED module 50 from which the liquid material is discharged, and a characteristics determination unit 11 which determines whether or not the difference between the optical characteristic values thus measured and a predetermined target value falls within a predetermined range. When a determination is made by the characteristics determination unit 11 that the difference does not fall within a predetermined range, the control unit 10 controls the nozzle 33 and/or 35 to discharge the liquid material again.

Description

  The present invention relates to a discharge device, a discharge method, and an LED module manufacturing method for discharging a liquid material onto an object.

  Conventionally, when a liquid material (or viscous material) is applied to an object called a workpiece, a nozzle (or needle) that discharges the liquid material is provided at the lower part of the syringe, and the syringe is supplied with pneumatic pressure from the dispenser. There is a pneumatic dispenser that applies a liquid material (or viscous material) to a workpiece by discharging the liquid material from a nozzle (see Patent Document 1).

  When manufacturing LED devices or LED modules used for lighting fixtures or LED products, a pneumatic dispenser or a sealing material for sealing an LED chip or a resin containing a phosphor is filled (potting). A potting device or the like is used.

JP-A-7-163926

  Conventionally, when a liquid material containing a phosphor is filled (potted) on a substrate on which an LED chip is mounted (for example, a surface-mounted COB, a device frame, a ceramic substrate, a package frame with a resin, or a shell type) The filling amount was confirmed visually, and the optical characteristics and electrical characteristics of the LED chip were measured after curing the filled liquid material.

However, since the liquid material supplied to the syringe contains various materials such as CiO ₂ , silicon, and hybrid resin in addition to the phosphor, a liquid material having a large specific gravity can be obtained depending on the specific gravity of each material. It gradually accumulates below the syringe, and a difference occurs in the phosphor concentration over time after the liquid material is supplied to the syringe. For this reason, even if the same amount of liquid material is ejected, there is a problem that the characteristics of the LED chip filled with the liquid material first and the characteristics of the LED chip filled with the liquid material finally vary, resulting in poor yield. It was.

  The present invention has been made in view of such circumstances, and an object of the present invention is to provide a discharge device, a discharge method, and an LED module manufacturing method capable of suppressing variation in characteristics of an object and improving yield.

  According to a first aspect of the present invention, there is provided a discharge device that discharges a liquid material onto an object, wherein a nozzle that discharges the liquid material, a control unit that controls the liquid material to be discharged from the nozzle, and the liquid material are discharged. A measuring unit that measures a characteristic value of the target object, and a determination unit that determines whether or not a difference between the characteristic value measured by the measuring unit and a predetermined target value is within a predetermined range. Is configured such that when the determination unit determines that the difference is not within a predetermined range, the liquid material is discharged again from the nozzle.

  According to a second aspect of the present invention, there is provided a discharge device according to the first aspect, further comprising a determining unit that determines a discharge amount of the liquid material to be discharged again according to the difference.

  According to a third aspect of the present invention, there is provided the discharge device according to the first or second aspect, wherein the adjustment unit that adjusts the distance between the tip of the nozzle and the object, and the amount of liquid material discharged from the nozzle onto the object. An interval between the tip of the nozzle and the object when the liquid material is discharged again according to the amount of the liquid material measured by the measurement unit. Is configured to be adjusted to be short / long.

  According to a fourth aspect of the present invention, there is provided a discharge device according to the first or second aspect, further comprising an adjustment unit that adjusts a distance between the tip of the nozzle and the object, and the adjustment unit determines the discharge amount determined by the determination unit. The distance between the tip of the nozzle and the object when the liquid material is discharged again is adjusted so as to be longer / shorter according to the amount of liquid.

  A discharge device according to a fifth aspect of the present invention is the discharge device according to any one of the first to fourth aspects, wherein the object is an LED module having an LED chip mounted on a substrate, and the liquid material contains a phosphor. The measuring unit is configured to measure an optical characteristic value including chromaticity coordinates of the LED chip on which the liquid material is potted.

  According to a sixth aspect of the present invention, in the fifth aspect of the invention, the measuring unit is configured to measure a spectral spectrum ratio of the LED chip.

  A discharge device according to a seventh aspect is the discharge device according to any one of the first to sixth aspects, wherein the first nozzle that discharges a liquid material containing a red phosphor and the liquid material that contains a yellow phosphor are discharged. The control unit is configured to discharge the liquid material from the second nozzle after discharging the liquid material from the first nozzle.

  According to an eighth aspect of the present invention, there is provided a discharge method using a discharge device that discharges a liquid material onto an object, wherein the step of controlling the liquid material to be discharged from a nozzle that discharges the liquid material and the liquid material are discharged Determining a characteristic value of the object; determining whether a difference between the measured characteristic value and a predetermined target value is within a predetermined range; and determining that the difference is not within the predetermined range. A step of controlling the liquid material to be discharged again from the nozzle.

  According to a ninth aspect of the present invention, there is provided a method for manufacturing an LED module, comprising: a step of potting the LED chip with a liquid material; and a characteristic value of the LED chip with the liquid material potted therein. The step of determining whether the difference between the measured characteristic value and the predetermined target value is within a predetermined range, and if the difference is not within the predetermined range, And potting again with a liquid material.

  In the first invention, the eighth invention, and the ninth invention, the characteristic value of the nozzle that discharges the liquid material, the control unit that controls the liquid material to be discharged from the nozzle, and the object to which the liquid material has been discharged. And a determination unit that determines whether or not a difference between the measured characteristic value and a predetermined target value is within a predetermined range. The object is, for example, an LED module in which an LED chip is mounted on a substrate, but is not limited thereto. If the object is an LED module (LED), the characteristic value is, for example, chromaticity coordinates (x, y), emission spectrum (spectral spectrum), luminous intensity, dominant wavelength, color temperature, etc. For electrical characteristics, for example, forward voltage, forward current, and the like. The liquid material is, for example, a resin (for example, epoxy resin) containing a phosphor of a predetermined color (for example, yellow, red), but is not limited to this, and the characteristic value is the amount of the liquid material. If it depends, it may be a resin that does not contain a phosphor. The predetermined range can be set to ± 0.005, for example, when the characteristic value is chromaticity coordinates.

  When the determination unit determines that the difference is not within the predetermined range, the control unit ejects the liquid material from the nozzle again. For example, if the chromaticity coordinates (x, y) of the LED chip filled (potted) with the first discharged liquid material has not reached the target value vicinity (predetermined range), the liquid material is filled again to approach the target value. (Potting). As a result, the characteristic value of the object can be brought close to the target value (within a predetermined range) before the liquid material is cured, so that variations in the characteristic of the object can be suppressed and the yield can be improved.

  In the second invention, the determining unit determines the discharge amount of the liquid material to be discharged again according to the difference. For example, the discharge amount is increased as the difference is larger. Since the difference from the target value is taken into consideration, the characteristic value of the object can be brought closer to the target value with fewer re-discharges than when the discharge amount of the liquid material to be discharged again is constant, and the discharge process can be performed. The time required can be shortened.

  In the third aspect of the invention, the adjustment unit that adjusts the distance between the tip of the nozzle and the object, and the measurement unit that measures the amount of the liquid material discharged from the nozzle to the object are provided. The adjustment unit has a drive unit that adjusts the position (height) of the nozzle. For example, the adjustment unit is not limited to the one that directly adjusts the distance between the tip of the nozzle and the object. It may be adjusted indirectly such as the distance from the surface of the mounting table on which the object is mounted to the tip of the nozzle. The measurement unit can use, for example, an optical displacement meter, and measures the amount of the discharged liquid material by measuring the distance from the measurement unit of the liquid material discharged before measurement to the surface.

  The adjustment unit adjusts the distance between the tip of the nozzle and the object to be shortened when the liquid material is discharged again according to the amount of the measured liquid material. That is, when the amount of liquid material discharged before measurement is large, it is assumed that the amount of liquid material discharged again in order to bring the characteristic value close to the target value, so that the tip of the nozzle and the object (for example, The distance between the liquid material discharged onto the object and the surface of the liquid material is reduced, so that the liquid material discharged from the nozzle can easily adhere to the surface of the liquid material already discharged, and the liquid discharged again due to the surface tension of the liquid material. The material can be easily placed on the object (easy to pot). In addition, when the amount of liquid material discharged before measurement is small, it is assumed that the amount of liquid material discharged again in order to bring the characteristic value close to the target value, so the tip of the nozzle and the object (for example, The liquid material discharged from the nozzle is made easier to adhere to the surface of the liquid material that has already been discharged, and the liquid material that is discharged again due to the surface tension of the liquid material. The material can be easily placed on the object (easy to pot).

  In the fourth aspect of the invention, the adjusting unit is provided for adjusting the distance between the tip of the nozzle and the object. The adjustment unit has a drive unit that adjusts the position (height) of the nozzle. For example, the adjustment unit is not limited to the one that directly adjusts the distance between the tip of the nozzle and the object. The distance from the surface of the mounting table to be mounted to the tip of the nozzle may be adjusted indirectly. The adjustment unit adjusts the distance between the tip of the nozzle and the object when the liquid material is discharged again according to the amount of discharge determined by the determination unit.

  For example, when the determined discharge amount is large, the liquid material discharged from the nozzle has already been increased by increasing the distance between the tip of the nozzle and the object (for example, the surface of the liquid material discharged onto the object). The surface of the discharged liquid material can be easily attached, and the liquid material to be discharged again can be easily placed (potted easily) on the object due to the surface tension of the liquid material. In addition, when the determined discharge amount is small, the liquid material discharged from the nozzle has already been reduced by shortening the distance between the tip of the nozzle and the object (for example, the surface of the liquid material discharged onto the object). The surface of the discharged liquid material can be easily attached, and the liquid material to be discharged again can be easily placed (potted easily) on the object due to the surface tension of the liquid material.

  In the fifth invention, the object is an LED module in which an LED chip is mounted on a substrate, the liquid material contains a phosphor, and the measurement unit is an LED chip in which the liquid material is potted. Measure optical property values including chromaticity coordinates. When the amount of liquid material containing a phosphor is confirmed visually (potting amount, application amount or filling amount, etc.), the liquid material is cured, and then the optical property value is measured. In comparison, before the liquid material is cured, the liquid material can be repeatedly ejected as necessary until the optical characteristic value falls within a predetermined range with respect to the target value, thereby suppressing variations in the optical characteristics of the LED chip. Yield can be improved.

  In the sixth invention, the measurement unit measures the ratio of the spectral spectrum of the LED chip on which the liquid material is potted. The ratio of the spectral spectrum is, for example, the ratio of the peak wavelength and peak value of RGB, and in this case, the target value can also be the ratio of the peak wavelength and peak value of RGB. When the measured RGB peak wavelength or peak value ratio does not reach the target value vicinity (predetermined range), the liquid material is filled (potted) again to approach the target value. As a result, the liquid material is cured after visually confirming the discharge amount (potting amount, application amount or filling amount, etc.) of the liquid material containing the phosphor, and then the ratio of the spectral spectrum is determined. Compared to the case of measuring, before curing the liquid material, the liquid material can be repeatedly ejected as necessary until the spectral spectrum ratio falls within a predetermined range with respect to the target value. The variation in characteristics can be suppressed and the yield can be improved.

  In the seventh invention, a first nozzle that discharges a liquid material containing a red phosphor and a second nozzle that discharges a liquid material containing a yellow phosphor are provided. The controller discharges the liquid material from the second nozzle after discharging the liquid material from the first nozzle. For example, when the object is an LED module having a blue LED chip, a liquid material (for example, epoxy resin) containing a red phosphor is filled around the LED chip, and a liquid material containing a yellow phosphor on the upper side thereof (For example, epoxy resin) is filled.

  The red phosphor is excited by light emitted from the blue LED chip and has a light emission peak at a wavelength of 600 to 650 nm, for example, but the light emission peak is not limited thereto. In addition, an appropriate material can be used for the red phosphor. The yellow phosphor is excited by light emitted from the blue LED chip and has a light emission peak at a wavelength of 560 to 600 nm, for example, but the light emission peak is not limited thereto. Further, as the material of the yellow phosphor, an appropriate material can be used. By determining the discharge order of the liquid material so that the light emitted from the blue LED chip first passes through the resin containing the red phosphor and then passes through the resin containing the yellow phosphor, the yellow fluorescent light is determined. A situation in which yellow light generated in the body is absorbed by the red phosphor can be suppressed, and luminous efficiency can be improved.

  According to the present invention, it is possible to suppress a variation in characteristics of an object and improve a yield.

It is a schematic diagram which shows an example of a structure of the discharge apparatus of this Embodiment. It is explanatory drawing which shows an example of the determination method of discharge amount. It is explanatory drawing which shows an example which adjusts the height position of a nozzle. It is a flowchart which shows the process sequence by the discharge device of this Embodiment.

  Hereinafter, the present invention will be described with reference to the drawings illustrating embodiments thereof. FIG. 1 is a schematic diagram illustrating an example of the configuration of the ejection device 100 according to the present embodiment. The ejection device 100 according to the present embodiment is a device that ejects a liquid material onto an object. Hereinafter, an LED module in which an LED chip (for example, a blue LED chip) is mounted on a substrate will be described as an example of the object. However, the object is not limited to this. As the liquid material, for example, a phosphor containing a phosphor and an epoxy resin or a mixture of an epoxy resin and a silicon resin can be used as a sealing resin for sealing the LED chip. It is not limited to this. Further, the term “ejection” includes meanings such as ejection, application, filling, and potting of a liquid material.

  As shown in FIG. 1, the discharge device 100 includes a mounting table 20 on which a plurality of LED modules 50 each having an LED chip mounted on a substrate are mounted. The mounting table 20 is provided with a wiring pattern for supplying power to each LED module 50, and the power supply unit 14 is connected to the mounting table 20.

  The power supply unit 14 has, for example, a constant voltage circuit or a constant current circuit, and can individually supply a predetermined current or a predetermined voltage to each LED module 50 under the control of the control unit 10 described later. .

  The electrical characteristic measurement unit 15 has a function as a measurement unit that measures the characteristic value of the object, measures the forward voltage and forward current of each LED module 50, and outputs the measurement values to the control unit 10.

  The apparatus main body 40 is disposed above the mounting table 20, and the apparatus main body 40 is two-dimensionally moved in the horizontal direction with respect to the mounting table 20 as shown by the arrow in FIG. Can do. By moving the apparatus main body 40 in the horizontal direction, the tip portions 331 and 351 of nozzles 33 and 35 described later, the probe 361 of the optical characteristic measuring unit 36, and the light receiving unit 371 of the measuring unit 37 are arranged above each LED module 50. can do. In addition, it can replace with the structure which drives the apparatus main body 40 in a horizontal direction (lateral direction), and can also be set as the structure which drives the mounting base 20 in a horizontal direction.

  In the apparatus main body 40, a nozzle 33 is suspended and a syringe 32 is fixed. A nozzle 35 is suspended from the apparatus main body 40 and a syringe 34 is fixed. A pressure pipe 38 is connected to the syringe 32, and a predetermined amount of liquid material is discharged from the nozzle 33 by pressurizing the liquid surface of the liquid material in the syringe 32 with pressurized air from a pressure source (not shown). The In addition, a pressure pipe 39 is connected to the syringe 34, and a predetermined amount of liquid material is supplied from the nozzle 35 by pressurizing the liquid surface of the liquid material in the syringe 34 with pressurized air from a pressure source (not shown). Discharged. The discharge amount of the liquid material is controlled by the control unit 10.

  For example, the syringe 32 stores a liquid material containing a red phosphor, and the syringe 34 stores a liquid material containing a yellow phosphor, for example. In addition, the kind of fluorescent substance is not limited to red and yellow, Moreover, the liquid material which does not contain fluorescent substance can also be used. Moreover, although it is the structure provided with the two syringes 32 and 34 in the example of FIG. 1, the number of syringes is not limited to two, One or three or more may be sufficient.

  A measuring unit 37 that measures the amount of the liquid material discharged from the nozzle to the object is fixed to the apparatus main body 40. As the measuring unit 37, for example, an optical displacement meter including a spectroscopic unit, a fiber, a light receiving unit 371, and the like can be used. The measurement unit 37 irradiates the surface of the LED module 50 with light having a predetermined wavelength (for example, infrared wavelength), and an interference wave between reflected light from the LED module 50 and reference reflected light reflected inside the measurement unit 37. And the distance (interval) from the internal reflection surface to the surface of the LED module 50 can be measured.

  When the LED chip is filled with a liquid material, the distance to the surface of the liquid material can be measured, so it is necessary to determine the amount of the discharged liquid material according to the short and long distance. Can do. Note that another measuring device can be used instead of the optical displacement meter as long as the amount of the discharged liquid material can be measured.

  The measuring unit 37 outputs the measured distance (or discharge amount) to the control unit 10.

  The optical property measurement unit 36 has a function as a measurement unit that measures the characteristic value of the object. The optical characteristic measurement unit 36 includes a probe 361, receives light from the LED module 50, measures the optical characteristic value of the LED module 50, and outputs the measurement result to the control unit 10. Examples of the optical characteristics include chromaticity coordinates (x, y), emission spectrum (spectral spectrum), luminous intensity, dominant wavelength, and color temperature of the LED module 50.

  The adjustment unit 31 includes a drive mechanism such as a cylinder, and adjusts the distance between the tip portions 331 and 351 of the nozzles 33 and 35 and the LED module 50 that is the object by moving the apparatus main body 40 up and down. In addition, the adjustment part 31 is not limited to what adjusts the space | interval of the front-end | tip parts 331 and 351 of the nozzles 33 and 35 and a target object directly, From the surface of the mounting base 20 which mounts a target object. It may be adjusted indirectly such as the distance to the tip portions 331 and 351 of the nozzles 33 and 35.

  The control unit 10 includes a characteristic determination unit 11, a discharge amount determination unit 12, an interval adjustment unit 13, and the like. The control unit 10 has a function as a control unit that controls to discharge the liquid material from the nozzles 33 and 35.

  The characteristic determination unit 11 has a function as a determination unit that determines whether or not the difference between the characteristic value measured by the measurement unit and the predetermined target value is within a predetermined range. For example, the characteristic determination unit 11 determines whether or not the difference between the characteristic value measured by the optical characteristic measurement unit 36 and a predetermined target value is within a predetermined range. When the characteristic value is chromaticity coordinates (x, y), the predetermined range can be set to a range of ± 0.005 with respect to the target value, for example. In addition, even if it is other than chromaticity coordinates, a target value and a predetermined range can be determined as appropriate.

  When the characteristic determination unit 11 determines that the difference is not within the predetermined range, the control unit 10 ejects the liquid material from the nozzle 33 and / or the nozzle 35 again. For example, when the chromaticity coordinates (x, y) of the LED module 50 filled (potted) with the first discharged liquid material has not reached the target value vicinity (predetermined range), the liquid material is again used to approach the target value. Fill (potting). As a result, the characteristic value of the object can be brought close to the target value (within a predetermined range) before the liquid material is cured, so that variations in the characteristic of the object can be suppressed and the yield can be improved.

  The discharge amount determination unit 12 has a function as a determination unit that determines the discharge amount of the liquid material to be discharged again according to the difference. The discharge amount determination unit 12 determines the discharge amount of the liquid material to be discharged again according to the difference. For example, the discharge amount is increased as the difference is larger.

  FIG. 2 is an explanatory diagram showing an example of a method for determining the discharge amount. The example of FIG. 2 shows the case where the optical characteristic is chromaticity coordinates, but the case of other optical characteristics can be determined in the same manner. As shown in FIG. 2, the discharge amount R of the red liquid material (the liquid material containing the red phosphor) and the yellow liquid material (containing the yellow phosphor) are previously associated with the difference between the chromaticity coordinates x and y. The discharge amount Y of the liquid material is determined, and the discharge amount of each liquid material is obtained according to the calculated difference. The table illustrated in FIG. 2 is not limited to the method of predetermining the table, and the discharge amount is calculated every time the difference is obtained using an expression for calculating the discharge amount according to the difference. You may do it.

  Since the difference between the characteristic value and the target value is taken into consideration, the characteristic value of the object can be brought closer to the target value with a smaller number of re-discharges than when the discharge amount of the liquid material to be discharged again is constant, The time required for the discharge process can be shortened.

  The optical characteristics are not limited to the color temperature, and other characteristics can be measured. For example, the discharge amount R of a red liquid material (a liquid material containing a red phosphor) in association with a difference between a target value and a ratio of a spectral wavelength RGB (red, green, blue) peak wavelength or peak value, etc. A discharge amount Y of a yellow liquid material (a liquid material containing a yellow phosphor) is determined, and the discharge amount of each liquid material can be obtained according to the calculated difference.

  The ratio of the spectral spectrum is, for example, the ratio of the peak wavelength and peak value of RGB, for example, the ratio of the peak wavelength or peak value of another color based on the peak wavelength or peak value of the blue wavelength is used. be able to. In this case, the target value can also be the ratio of the peak wavelength and peak value of RGB. For example, when measuring the ratio of the spectral spectrum, the target value can also be the ratio of the peak wavelength and peak value of RGB (red, green, blue), for example. When the measured RGB (red, green, blue) peak wavelength or peak value ratio does not reach the vicinity of the target value (predetermined range), the liquid material is filled (potted) again to approach the target value. Thereby, after confirming the discharge amount (potting amount, application amount or filling amount, etc.) of the liquid material containing the phosphor visually as in the conventional case, the liquid material is cured, and then the spectral spectrum is measured. Compared to the case, before the liquid material is cured, the liquid material can be repeatedly ejected as necessary until the spectral spectrum falls within a predetermined range with respect to the target value. Suppression yield can be improved. In addition to the peak values of RGB (red, green, blue), the minimum value between the blue wavelength and the green wavelength and the wavelength, the minimum value between the green wavelength and the red wavelength, and the wavelength are the peak value and the peak. It may be included in the wavelength. In this case, a spectral spectrum ratio based on any of RGB peak values can be used. For example, any one of RGB, for example, with reference to the peak value of the blue wavelength, the peak value of the green wavelength and the red wavelength, the minimum value between the blue wavelength and the green wavelength, and the minimum value between the green wavelength and the red wavelength And a value converted with a predetermined reference value can be used as the ratio of the spectral spectrum.

  The space | interval adjustment part 13 has a function as an adjustment part which adjusts the space | interval of the front-end | tip parts 331 and 351 of the nozzles 33 and 35 and the LED module 50 which is a target object. The interval adjusting unit 13 shortens the interval between the tip portions 331 and 351 of the nozzles 33 and 35 and the LED module 50 when the liquid material is discharged again according to the amount of the liquid material measured by the measuring unit 37. Adjust as necessary.

  FIG. 3 is an explanatory diagram showing an example of adjusting the height position of the nozzle. In the example of FIG. 3, the LED module 50 includes an LED chip 51 mounted on a substrate 54, and a red liquid material 52 containing a red phosphor and a yellow liquid material 53 containing a yellow phosphor so as to cover the LED chip 51. The state of being discharged (potted) is shown.

  As a result of measuring the optical characteristics, when the liquid material is discharged again, as shown in FIG. 3A, when the amount of the liquid material discharged again to bring the characteristic value close to the target value is small, for example, When a large amount of liquid material has already been discharged, the nozzle 33 is discharged by shortening the distance between the tip 331 of the nozzle 33 and the LED module 50 (for example, the surface of the liquid material discharged to the LED module 30). The liquid material 60 to be discharged can be easily attached to the surface of the liquid material 53 that has already been discharged, and the liquid material to be discharged again can be easily placed (potted easily) on the object due to the surface tension of the liquid material. Note that the distance d1 between the tip 331 of the nozzle 33 and the mounting surface of the mounting table can be substituted for the distance between the tip 331 of the nozzle 33 and the LED module 50.

  Further, as shown in FIG. 3B, when the amount of liquid material ejected again to bring the characteristic value close to the target value is large, for example, when the amount of liquid material ejected is small, the tip of the nozzle 33 By increasing the distance between the portion 331 and the LED module 50 (for example, the surface of the liquid material discharged to the LED module 50), the liquid material 60 discharged from the nozzle 33 is attached to the surface of the liquid material 53 that has already been discharged. The liquid material to be ejected again due to the surface tension of the liquid material can be easily placed on the object (easy to pot). Note that the distance d2 between the tip 331 of the nozzle 33 and the mounting surface of the mounting table can be substituted for the length of the distance between the tip 331 of the nozzle 33 and the LED module 50. In the example of FIG. 3, d2> d1.

  In addition, when the discharge amount determined by the discharge amount determination unit 12 is small, the interval adjustment unit 13 and the tip portion 331 of the nozzle 33 and the LED module 50 (for example, the LED module) as illustrated in FIG. 50), the liquid material 60 discharged from the nozzle 33 is easily attached to the surface of the liquid material 53 that has already been discharged, and is discharged again due to the surface tension of the liquid material. The liquid material to be made can be easily placed on the object (easy to pot).

  In addition, when the discharge amount determined by the discharge amount determination unit 12 is large, the interval adjustment unit 13 and the tip portion 331 of the nozzle 33 and the LED module 50 (for example, an LED module), as shown in FIG. The liquid material 60 discharged from the nozzle 33 can be easily attached to the surface of the liquid material 53 that has already been discharged, and discharged again due to the surface tension of the liquid material. The liquid material to be made can be easily placed on the object (easy to pot).

  Further, as described above, the target is the LED module 50 in which the LED chip 51 is mounted on the substrate 54, the liquid material contains a phosphor, and the optical property measuring unit 36 is potted with the liquid material. The optical characteristic value including the chromaticity coordinates of the LED chip 51 is measured. When the amount of liquid material containing a phosphor is confirmed visually (potting amount, application amount or filling amount, etc.), the liquid material is cured, and then the optical property value is measured. In comparison, before the liquid material is cured, the liquid material can be repeatedly ejected as necessary until the optical characteristic value falls within a predetermined range with respect to the target value. Suppression yield can be improved.

  Moreover, the 1st nozzle 33 which discharges the liquid material containing red fluorescent substance, and the 2nd nozzle 35 which discharges the liquid material containing yellow fluorescent substance are provided. The control unit 10 discharges the liquid material from the second nozzle 35 after discharging the liquid material from the first nozzle 33. For example, when the target is the LED module 50 having the blue LED chip 51, as shown in FIG. 3, the LED chip 51 is filled with a red liquid material 52 (for example, epoxy resin) containing a red phosphor. Then, a yellow liquid material 53 (for example, epoxy resin) containing a yellow phosphor is filled on the upper side.

  The red phosphor is excited by light emitted from the blue LED chip 51 and has a light emission peak at a wavelength of 600 to 650 nm, for example, but the light emission peak is not limited thereto. In addition, an appropriate material can be used for the red phosphor.

  The yellow phosphor is excited by light emitted from the blue LED chip 51 and has, for example, a light emission peak at a wavelength of 560 to 600 nm. However, the light emission peak is not limited to this. Further, as the material of the yellow phosphor, an appropriate material can be used.

  When the red liquid material is filled on the upper side of the yellow liquid material, the yellow light emitted from the yellow phosphor is absorbed by the red phosphor, so that the light extraction efficiency from the LED chip 51 is lowered. On the other hand, the red liquid material so that the light emitted from the blue LED chip 51 first passes through the red liquid material containing the red phosphor and then passes through the yellow liquid material containing the yellow phosphor. By filling the upper side of the yellow liquid material, it is possible to suppress the situation where yellow light generated by the yellow phosphor is absorbed by the red phosphor, and to improve the light emission efficiency.

  FIG. 4 is a flowchart showing a processing procedure performed by the ejection device 100 according to the present embodiment. The control unit 10 arranges the nozzle above the LED module 50 (S11) and discharges the liquid material (S12). In this case, in order to discharge the red liquid material, the control unit 10 first moves the nozzle 33 above the LED module 50 to discharge the red liquid material, and then discharges the yellow liquid material. It moves above 50 and discharges yellow liquid material.

  The control unit 10 measures the amount of the discharged liquid material with the measuring unit 37 (S13), and measures the optical characteristic value (for example, chromaticity coordinates) of the LED module 50 (S14). The control unit 10 determines whether or not the difference between the measured characteristic value and the target value is within a predetermined range (for example, ± 0.005 in the case of chromaticity coordinates) (S15).

  When the difference is not within the predetermined range (NO in S15), the control unit 10 determines the discharge amount of the liquid material according to the difference (S16). In this case, the liquid material discharged again is either the red liquid material or the yellow liquid material, or both.

  The control unit 10 adjusts the height of the nozzle when discharging the liquid material again (S17), and repeats the processing after step S12. The height of the nozzle (for example, the distance between the tip of the nozzle and the LED module) may be determined according to the amount of liquid material to be discharged again, or according to the amount (measured value) of the discharged liquid material. You may ask for it. Moreover, both can also be considered.

  If the difference is within the predetermined range (YES in S15), the control unit 10 determines whether there is another LED module (S18), and if there is another LED module (YES in S18), step S11. The subsequent processing is repeated, and if there is no other LED module (NO in S18), the processing is terminated.

  Moreover, the LED module in which the LED chip is mounted on the substrate can be manufactured by the processing procedure illustrated in FIG. More specifically, for example, a step of potting an LED chip with a liquid material, a step of measuring a characteristic value of the LED chip on which the liquid material is potted, and a difference between the measured characteristic value and a predetermined target value is within a predetermined range. If it is determined that the difference is not within the predetermined range, an LED module can be manufactured by performing a step of potting the LED chip again with a liquid material.

  In this embodiment, the optical material is not measured after the liquid material ejected onto the object is cured, but the optical property is measured in the course of the liquid material ejection process, and the liquid material is again measured according to the measurement result. Since the discharge amount is finally adjusted for each object, environmental changes such as ambient temperature or humidity, liquid material changes with time (concentration change, clay) It is not necessary to prepare a large number of control data for controlling the discharge amount in consideration of various factors such as a change in In addition, it is possible to quickly cope with changes in environmental conditions and changes with time of the liquid material. In the conventional method, the chromaticity coordinates of the LED module have a variation of 0.03 in the x coordinate and 0.06 in the y coordinate. According to this embodiment, the chromaticity coordinate ( The variation of x, y) can be within 0.005, and the yield can be improved and the manufacturing cost can be reduced.

  In the above-described embodiment, the pneumatic dispenser has been described as an example. However, the dispenser is not limited to the pneumatic dispenser, and there are factors such as changes in environmental conditions and changes in liquid material over time. Any liquid ejecting apparatus, coating apparatus, potting apparatus, and these methods can be applied.

  Further, the present embodiment is not limited to the size of the object (work), and the present embodiment can be applied to objects of various sizes. In addition, by combining the function of measuring electrical characteristics and optical characteristics, the function of discharging liquid material, and the function of coating, multi-functionality can be realized, and costs can be reduced by reducing processes.

  In the above embodiment, the case where the phosphor is contained in the sealing resin (liquid material) for sealing the LED chip has been described. However, the variation in the characteristic value varies depending on the concentration of the phosphor and the like. It is not limited. This embodiment can be used in various applications such as application of liquid material, filling, masking, coating, molding, etc., for example, potting of IC substrates, lens formation of LED modules, and coating of bonding portions of substrates.

DESCRIPTION OF SYMBOLS 10 Control unit 11 Characteristic determination part 12 Discharge amount determination part 13 Space | interval adjustment part 14 Power supply part 15 Electrical property measurement part 20 Mounting stand 31 Adjustment part 32, 34 Syringe 33, 35 Nozzle 331, 351 Tip part 36 Optical characteristic measurement part 361 Probe 37 Measuring unit 371 Light receiving unit 38, 39 Pressure piping 40 Device main body 50 LED module (object)

Claims (9)

In a discharge device for discharging a liquid material onto an object,
A nozzle for discharging a liquid material;
A control unit for controlling the liquid material to be discharged from the nozzle;
A measurement unit for measuring the characteristic value of the object from which the liquid material is discharged;
A determination unit that determines whether or not a difference between the characteristic value measured by the measurement unit and a predetermined target value is within a predetermined range;
The controller is
An ejection apparatus configured to eject liquid material from the nozzle again when the determination unit determines that the difference is not within a predetermined range.   The ejection apparatus according to claim 1, further comprising a determination unit that determines an ejection amount of the liquid material to be ejected again according to the difference. An adjustment unit for adjusting the distance between the tip of the nozzle and the object;
A measuring unit that measures the amount of liquid material discharged from the nozzle onto the object,
The adjustment unit is
According to the amount of the liquid material measured by the measuring unit, the distance between the tip of the nozzle and the object when the liquid material is discharged again is adjusted to be short / long. The ejection device according to claim 1 or 2, wherein the ejection device is provided. An adjustment unit for adjusting the distance between the tip of the nozzle and the object;
The adjustment unit
The distance between the tip of the nozzle and the object when the liquid material is discharged again is adjusted to be long / short according to the amount of discharge determined by the determination unit. The discharge device according to claim 1, wherein the discharge device is a discharge device. The object is
An LED module in which an LED chip is mounted on a substrate,
The liquid material is
Contains phosphor,
The measuring unit is
The ejection device according to any one of claims 1 to 4, wherein an optical characteristic value including chromaticity coordinates of an LED chip on which the liquid material is potted is measured. The measuring unit is
The ejection device according to claim 5, wherein the discharge device is configured to measure a spectral spectrum ratio of the LED chip. A first nozzle that discharges a liquid material containing a red phosphor;
A second nozzle for discharging a liquid material containing a yellow phosphor,
The controller is
The discharge according to any one of claims 1 to 6, wherein the liquid material is discharged from the second nozzle after the liquid material is discharged from the first nozzle. apparatus. In a discharge method by a discharge device that discharges a liquid material to an object,
Controlling to discharge the liquid material from a nozzle that discharges the liquid material;
Measuring the characteristic value of the object to which the liquid material has been discharged;
Determining whether the difference between the measured characteristic value and the predetermined target value is within a predetermined range;
And a step of controlling the liquid material to be discharged again from the nozzle when it is determined that the difference is not within a predetermined range. In the manufacturing method of the LED module in which the LED chip is mounted on the substrate,
Potting the LED chip with a liquid material;
Measuring a characteristic value of the LED chip potted with a liquid material;
Determining whether the difference between the measured characteristic value and the predetermined target value is within a predetermined range;
And potting the LED chip again with a liquid material if it is determined that the difference is not within a predetermined range.

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