JP2014075544A - Led package manufacturing system and led package manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an LED package manufacturing system and an LED package manufacturing method capable of increasing the production yield and the productivity by controlling the light emission characteristics of LED packages to be uniform even when the emission wavelength from each piece of LED elements varies.SOLUTION: In a resin application used in manufacturing LED packages which include LED elements covered with a resin containing a fluorescent substance, the resin application is performed during performing test application of the resin as a light emission characteristic measurement by selecting a second mode in which resin application for actual production is performed in parallel or a first mode in which the resin application for actual production is not basically carried out. By performing a sampling inspection when the frequency of defective generation is high, the defective production rate can be reduced.

Description

  The present invention relates to an LED package manufacturing system and an LED package manufacturing method for manufacturing an LED package in which an LED element mounted on a substrate is covered with a resin containing a phosphor.

  In recent years, LEDs (light emitting diodes) having excellent characteristics of low power consumption and long life have been widely used as light sources for various lighting devices. Since the basic light emitted from the LED element is currently limited to three colors of red, green, and blue, in order to obtain white light suitable for general lighting applications, the above three basic lights are added. A method of obtaining white light by color mixing, a method of obtaining pseudo white light by combining a blue LED and a phosphor emitting yellow fluorescence having a complementary color relationship with blue are used. In recent years, the latter method has been widely used, and an illumination device using an LED package in which a blue LED and a YAG phosphor are combined has been used for a backlight of a liquid crystal panel (for example, a patent). Reference 1).

  In Patent Document 1, an LED element is mounted on the bottom surface of a concave mounting portion having a reflective surface formed on a side wall, and then YAG phosphor particles are dispersed in the mounting portion in which YAG phosphor particles are dispersed in the mounting portion. An LED package is configured by injecting a silicone resin, an epoxy resin, or the like to form a resin packaging portion. And, for the purpose of uniforming the height of the resin packaging part in the mounting part after the resin injection, a residual resin storage part for discharging and storing the surplus resin injected more than a specified amount from the mounting part is formed. An example is given. As a result, even when the discharge amount from the dispenser varies at the time of resin injection, a resin packaging portion having a certain resin amount and a specified height is formed on the LED element.

JP 2007-66969 A

  However, the above-described prior art has a problem that the light emission characteristics of the LED package as a product vary due to variations in light emission wavelengths of individual LED elements. In other words, the LED element has undergone a manufacturing process in which a plurality of elements are formed on the wafer at the same time, and due to various error factors in this manufacturing process, such as non-uniform composition during film formation on the wafer, the wafer state Inevitably, variations in emission wavelength occur in the LED elements divided into individual pieces. And in the above-mentioned example, since the height of the resin wrapping part covering the LED element is set uniformly, the variation in the emission wavelength in the individual LED element is directly reflected in the variation in the emission characteristic of the LED package as a product. Is done. As a result, the number of defective products that deviate from the acceptable quality range increases, and the production yield decreases.

  Therefore, according to the actual emission wavelength of the individual LED elements, for example, by adjusting the coating amount of the phosphor-containing resin, even if the emission wavelength of the individual LED elements varies, the emission characteristics of the LED package It is desirable to establish a technology that can make the temperature uniform.

  However, since the composition and properties of the phosphor-containing resin are not always stable, even if an appropriate resin coating amount is set in advance according to the actual emission wavelength of the LED element, It is inevitable that the concentration and resin viscosity of the resin fluctuate. For this reason, even if the resin is discharged from the coating device at a preset appropriate resin application amount, the resin application amount itself may vary from the preset appropriate value, or even if the resin application amount itself is appropriate Depending on the concentration change, the supply amount of the phosphor particles that should be supplied may vary. In order to eliminate such an inconvenience, it becomes necessary to inspect whether or not an appropriate supply amount of phosphor particles is supplied at a predetermined interval.

  As such an inspection, there is a method in which an object to be inspected is separately prepared, a resin is trial-applied to the object to be examined, and whether a desired amount of phosphor particles is supplied. However, when performing such trial application and inspection of the supply amount of the phosphor particles, the period between the start of the trial application and the correction of the supply amount based on the inspection result is appropriate. There is a need to stop the production line. As a result, production efficiency decreases.

  Therefore, according to the present invention, in the LED package manufacturing system and manufacturing method, even when the light emission wavelength of the individual LED elements varies, the light emission characteristics of the LED package can be made uniform and the production yield can be improved. An object of the present invention is to provide a resin coating apparatus and a resin coating method capable of improving production efficiency.

One aspect of the present invention is a system for manufacturing an LED package comprising a substrate, an LED element mounted on the substrate, and a resin layer containing a phosphor that covers the LED element,
A component mounting apparatus for mounting the LED element on the substrate;
A resin coating device that applies the resin to the LED elements mounted on the substrate to form the resin layer;
A sampling inspection unit for sampling and inspecting the LED elements coated with the resin by the resin coating device;
The resin coating device is
A resin application part having an application nozzle that discharges the resin in an arbitrary application target position by variably discharging the application amount;
By controlling the resin coating unit, a coating control unit that executes a coating process for measurement for applying the resin to a light-transmitting member for light emission characteristic measurement and a production coating process for coating the LED element for actual production. When,
A light source unit that emits excitation light for exciting the phosphor;
A translucent member mounting portion on which the translucent member on which the resin is trial-coated in the measurement coating process;
A light emission characteristic measurement unit that measures the light emission characteristic of light emitted by the resin by irradiating the resin applied to the light transmitting member with the excitation light emitted from the light source unit;
An application amount derivation processing unit for deriving an appropriate resin application amount of the resin to be applied to the LED element for actual production based on a measurement result of the light emission characteristic measurement unit and a predetermined light emission characteristic;
A production execution processing unit for causing the resin application unit to execute a production application process for applying the appropriate resin application amount to the LED element by commanding the appropriate resin application amount to the application control unit;
The application control unit
At least a part of the correction period from the start of the measurement coating process until the appropriate resin coating amount is derived by the coating amount deriving processing unit and a command from the production execution processing unit is issued based on the proper resin coating amount. In the first production mode in which the production coating process is not executed,
Selectively executing any one of the second production modes for executing the production coating process in the at least part of the period;
The sampling inspection unit selects one or more of the LED elements on which the production coating process has been performed in a predetermined period before the start of the measurement coating process, and performs a first sampling test on the selected LED elements. The present invention relates to an LED package manufacturing system comprising a sampling inspection control unit for instructing.

Another aspect of the present invention is a method of manufacturing an LED package comprising a substrate, an LED element mounted on the substrate, and a resin layer containing a phosphor that covers the LED element,
A production application step of applying the resin for actual production by a resin discharge unit that discharges the application amount variably;
A measurement application step of applying the resin to the translucent member as a light emission characteristic measurement by the resin discharge unit;
A translucent member mounting step of mounting the translucent member on which the resin has been trial-applied on a translucent member mounting unit including a light source unit that emits excitation light for exciting the phosphor;
A light emission characteristic measuring step of measuring the light emission characteristic of the light emitted by the resin by irradiating the resin applied to the translucent member with the excitation light emitted from the light source unit;
A coating amount derivation processing step for deriving an appropriate resin coating amount of the resin to be applied to the LED element for actual production based on the measurement result in the light emission characteristic measurement step and a predetermined light emission characteristic;
A production execution step of executing a production application process for applying the resin of the appropriate resin application amount to the LED element by commanding the derived appropriate resin application amount to an application control unit that controls the resin discharge unit;
The first production mode in which the production application step is not executed for at least a part of the correction period from the start of the measurement application step until the appropriate resin application amount is derived and a command based on the appropriate resin application amount is issued. And a selection step of selecting any mode of the second production mode for executing the production coating step in the at least part period;
Including a first inspection step of selecting one or more of the LED elements on which the production coating process has been performed in a predetermined period before the start of the measurement coating step and performing a first sampling inspection. The present invention relates to an LED package manufacturing method.

  According to the present invention, in a resin coating used for manufacturing an LED package in which an LED element is covered with a resin containing a phosphor, a light-transmitting member obtained by trial coating of a resin for measuring light emission characteristics is provided with a light source unit. A measurement result obtained by measuring the light emission characteristics of the light emitted from the resin by irradiating the resin applied to the light transmissive member with the excitation light emitted from the light source unit, which is placed on the light transmissive member placement unit, and a prescribed value. For example, when the deviation of the emission wavelength of the individual LED elements varies by obtaining, for example, a deviation from the emitted light emission characteristics and deriving an appropriate amount of resin to be applied to the LED element for actual production based on this deviation Even in this case, the light emission characteristics of the LED package can be made uniform, and the production yield can be improved.

  The first production mode in which the production application process is not executed in at least a part of the correction period from the start of the measurement application step until the appropriate resin application amount is derived and a command based on the appropriate resin application amount is issued. Either the (quality priority mode) or the second production mode (production priority mode) in which the production coating process is executed is selectively executed in at least a part of the period. This makes it possible to set the period during which LED package production is stopped to the minimum necessary length according to the actual production line conditions. As a result, production efficiency can be improved.

  Further, for example, when the measurement result is different from the desired light emission characteristic in the light emission characteristic measurement step, the LED element produced by executing the production coating process in a predetermined period before the start of the measurement coating process By selecting one or more and executing the first sampling inspection, further high quality can be ensured.

It is a block diagram which shows the structure of the LED package manufacturing system of one embodiment of this invention. It is a structure explanatory view of the LED package manufactured by the LED package manufacturing system of one embodiment of the present invention. It is explanatory drawing of the supply form and element characteristic information of the LED element used in the LED package manufacturing system of one embodiment of this invention. It is explanatory drawing of the resin application information used in the LED package manufacturing system of one embodiment of this invention. It is explanatory drawing of a structure and function of the component mounting apparatus in the LED package manufacturing system of one embodiment of this invention. It is explanatory drawing of the map data used in the LED package manufacturing system of one embodiment of this invention. It is explanatory drawing of a structure and function of the resin coating apparatus in the LED package manufacturing system of one embodiment of this invention.

It is explanatory drawing of the light emission characteristic test | inspection function with which the resin coating apparatus in the LED package manufacturing system of one embodiment of this invention was equipped. It is a block diagram which shows the structure of the control system of the LED package manufacturing system of one embodiment of this invention. It is a flowchart of LED package manufacture by the LED package manufacturing system of one embodiment of this invention. It is a flowchart of the threshold value data creation process for good quality determination in the LED package manufacturing system of one embodiment of the present invention. It is explanatory drawing of the threshold value data for good quality determination in the LED package manufacturing system of one embodiment of this invention. It is a chromaticity diagram explaining threshold data for non-defective product determination in the LED package manufacturing system of one embodiment of the present invention. It is a flowchart of the resin application | coating operation process in the LED package manufacturing process by the LED package manufacturing system of one embodiment of this invention. It is a flowchart of the 1st sampling inspection. It is a time chart which shows the timing of the 1st sampling inspection in quality priority mode. It is a flowchart of the 2nd sampling inspection. It is a time chart which shows the timing of the 2nd sampling inspection in production priority mode.

It is explanatory drawing of the resin application | coating operation process in the LED package manufacturing process by the LED package manufacturing system of one embodiment of this invention. It is process explanatory drawing which shows the LED package manufacturing process by the LED package manufacturing system of one embodiment of this invention. It is process explanatory drawing which shows the LED package manufacturing process by the LED package manufacturing system of one embodiment of this invention.

  Next, embodiments of the present invention will be described with reference to the drawings. First, the configuration of the LED package manufacturing system 1 will be described with reference to FIG. The LED package manufacturing system 1 has a function of manufacturing an LED package in which an LED element mounted on a substrate is covered with a resin containing a phosphor. In the present embodiment, as shown in FIG. 1, each of a component mounting apparatus M1, a curing apparatus M2, a wire bonding apparatus M3, a resin coating apparatus M4, a curing apparatus M5, a piece cutting apparatus M6, and a sampling inspection unit M7. Are connected by the LAN system 2, and the management computer 3 controls these devices in an integrated manner.

  The component mounting apparatus M1 mounts the LED element 5 on the substrate 4 (see FIG. 2) serving as the base of the LED package by bonding with a resin adhesive. The curing device M2 cures the resin adhesive used for bonding at the time of mounting by heating the substrate 4 after the LED element 5 is mounted. The wire bonding apparatus M3 connects the electrode of the substrate 4 and the electrode of the LED element 5 with a bonding wire. The resin coating device M4 applies a resin containing a phosphor to each LED element 5 on the substrate 4 after wire bonding. The curing device M5 cures the resin applied so as to cover the LED elements 5 by heating the substrate 4 after the resin application. The piece cutting device M6 cuts the substrate 4 after the resin is cured into each individual LED element 5 and divides it into individual LED packages. Thereby, the LED package divided | segmented into the piece is completed.

  The sampling inspection unit M7 is a unit attached to the production line composed of the component mounting apparatus M1 to the piece cutting apparatus M6, and samples and inspects the LED elements 5 coated with the resin by the resin coating apparatus M4. The sampling inspection may be performed on each LED element 5 in a state where the resin is cured by the curing device M5 and the substrate is cut into individual substrates by the individual cutting device M6. Alternatively, without curing the resin by the curing device M5, the substrate 4 may be cut into individual substrates by the individual piece cutting device M6 while the resin is in an uncured state, and sampling inspection may be performed. Alternatively, a sampling inspection can be performed in a state where the resin is applied by the resin coating device M4 without curing the resin by the curing device M5 and cutting the substrate 4 by the piece cutting device M6.

  The sampling inspection unit M7 includes a sampling inspection control unit 52. The sampling inspection control unit 52 includes a calculation unit such as a CPU (Central Processing Unit) and a memory such as an auxiliary storage device that stores a predetermined algorithm for processing to be described later. A target board is specified, and a command is issued to execute a sampling inspection at a predetermined timing for the specified board. The command may be a command for a device included in the sampling inspection unit M7, or may be a command for other devices (for example, a light emission characteristic measuring unit 39 described later). Alternatively, the command is issued by displaying a message for instructing a specified substrate to be subjected to a sampling inspection at a predetermined timing on a display device such as a liquid crystal display device or by outputting it by voice. May be.

  Note that FIG. 1 is merely an example, and in particular, when the command is issued by the above-described message display, the sampling inspection unit M7 can be included in the resin coating apparatus M4. The function of the sampling inspection control unit 52 can be provided in the application control unit 36 and the storage unit 81. Further, FIG. 1 shows an example in which each of the component mounting device M1 to the piece cutting device M6 is arranged in series to constitute a production line, but the LED package production system 1 does not necessarily have such a line. It is not necessary to adopt the configuration, and as long as the information transmission described in the following description is appropriately performed, the configuration may be such that each process work is sequentially executed by each of the distributed devices. Also, a plasma processing apparatus that performs plasma treatment for electrode cleaning prior to wire bonding before and after the wire bonding apparatus M3, and a surface modification for improving resin adhesion before resin application after wire bonding. You may make it interpose the plasma processing apparatus which performs the plasma processing for the purpose of quality.

  Here, with reference to FIG. 2, FIG. 3, the board | substrate 4, the LED element 5, and the LED package 50 as a finished product used as the work object in the LED package manufacturing system 1 are demonstrated. As shown in FIG. 2A, the substrate 4 is a multiple-type substrate in which a plurality of individual substrates 4a serving as a base of one LED package 50 in a finished product are formed. Each individual substrate 4a includes Each LED mounting portion 4b on which the LED element 5 is mounted is formed. The LED element 5 is mounted in the LED mounting portion 4b for each individual substrate 4a, and then the resin 8 is applied to cover the LED element 5 in the LED mounting portion 4b. Is cut for each individual substrate 4a to complete the LED package 50 shown in FIG.

  The LED package 50 has a function of irradiating white light used as a light source of various lighting devices, and includes a phosphor that emits yellow fluorescence that is complementary to the blue LED element 5 and blue. By combining with the resin 8, pseudo white light is obtained. As shown in FIG. 2 (b), the individual substrate 4a is provided with a cavity-shaped reflecting portion 4c having, for example, a circular or elliptical annular bank that forms the LED mounting portion 4b. The N-type part electrode 6a and the P-type part electrode 6b of the LED element 5 mounted inside the reflection part 4c are connected to the wiring layers 4e and 4d formed on the upper surface of the individual substrate 4a by bonding wires 7, respectively. The The resin 8 covers the LED element 5 in this state and is applied to the inside of the reflecting portion 4c with a predetermined thickness. In the process in which the blue light emitted from the LED element 5 is irradiated through the resin 8, the resin 8 The phosphor contained in is mixed with yellow light to emit light and irradiated as white light.

  As shown in FIG. 3A, the LED element 5 is configured by stacking an N-type semiconductor 5b and a P-type semiconductor 5c on a sapphire substrate 5a, and further covering the surface of the P-type semiconductor 5c with a transparent electrode 5d. An N-type part electrode 6a and a P-type part electrode 6b for external connection are formed on the N-type semiconductor 5b and the P-type semiconductor 5c, respectively. As shown in FIG. 3B, the LED elements 5 are taken out from the LED wafer 10 that is stuck and held on the holding sheet 10a in a state where a plurality of LED elements 5 are formed in a lump and then divided into pieces. The LED element 5 is divided into individual pieces from the wafer state due to various error factors in the manufacturing process, for example, non-uniform composition during film formation on the wafer. It is inevitable that variations occur in the case. If such an LED element 5 is mounted on the substrate 4 as it is, the emission characteristics of the LED package 50 as a product will vary.

  In the present embodiment, in order to prevent such quality defects due to variations in light emission characteristics, the light emission characteristics of a plurality of LED elements 5 manufactured in the same manufacturing process are measured in advance, Element characteristic information corresponding to data indicating the light emission characteristics of the LED elements 5 is created, and an appropriate amount of the resin 8 corresponding to the light emission characteristics of each LED element 5 is applied in the application of the resin 8. . In order to apply an appropriate amount of the resin 8, resin application information to be described later is prepared in advance.

  First, element characteristic information will be described. As shown in FIG. 3C, the LED elements 5 taken out from the LED wafer 10 are individually identified by element IDs (in this case, the individual LED elements 5 with the serial number (i) in the LED wafer 10). Are given sequentially to the light emission characteristic measuring device 11. In addition, as element ID, if it is the information which can specify the LED element 5 separately, you may make it use the matrix coordinate which shows the arrangement | sequence of the LED element 5 in the other data format, for example, the LED wafer 10, as it is. By using the element ID of such a format, the LED element 5 can be supplied in the state of the LED wafer 10 in the component mounting apparatus M1 described later.

  In the light emission characteristic measuring device 11, electric power is actually supplied to each LED element 5 through a probe to emit light, and the light is spectrally analyzed to measure predetermined items such as a light emission wavelength and light emission intensity. For the LED element 5 to be measured, a standard distribution of emission wavelengths is prepared as reference data in advance, and the wavelength range corresponding to the standard range in the distribution is further divided into a plurality of wavelength ranges. The plurality of target LED elements 5 are ranked according to the emission wavelength. Here, Bin codes [1], [2], [3], [4], [5] are assigned in order from the low wavelength side corresponding to each of the ranks set by dividing the wavelength range into five. ] Is given. Then, element characteristic information 12 having a data structure in which the Bin code 12b is associated with the element ID 12a is created.

  That is, the element characteristic information 12 is information obtained by individually measuring the light emission characteristics including the light emission wavelengths of the plurality of LED elements 5 in advance. The element characteristic information 12 is prepared in advance by an LED element manufacturer or the like and is used for the LED package manufacturing system 1. Is transmitted. The element characteristic information 12 may be transmitted in a form recorded on a single storage medium, or may be transmitted to the management computer 3 via the LAN system 2. In any case, the transmitted element characteristic information 12 is stored in the management computer 3 and provided to the component mounting apparatus M1 as necessary.

  The plurality of LED elements 5 whose light emission characteristics have been measured in this way are sorted for each characteristic rank as shown in FIG. 3 (d), and are sorted into five types according to each characteristic rank. Attached individually to the sheet 13a. Thereby, five types of LED sheets 13A, 13B, in which the LED elements 5 corresponding to the Bin codes [1], [2], [3], [4], and [5] are bonded and held on the adhesive sheet 13a, 13C, 13D, and 13E are created, and when these LED elements 5 are mounted on the individual substrate 4a of the substrate 4, the LED elements 5 are already classified into LED sheets 13A, 13B, 13C, and 13D. , 13E in the form of the component mounting apparatus M1. At this time, the LED elements 5 corresponding to any of the Bin codes [1], [2], [3], [4], and [5] are held in the LED sheets 13A, 13B, 13C, 13D, and 13E, respectively. The element characteristic information 12 is provided from the management computer 3 in a form indicating whether or not it has been.

  Next, resin application information prepared in advance corresponding to the above-described element characteristic information 12 will be described with reference to FIG. In the LED package 50 configured to obtain white light by combining a blue LED and a YAG phosphor, the blue light emitted from the LED element 5 and the yellow light emitted from the phosphor excited by the blue light are emitted. Since mixing is performed, the amount of the phosphor particles in the concave LED mounting portion 4b on which the LED element 5 is mounted is an important factor in securing the normal light emission characteristics of the LED package 50 of the product.

  As described above, there are variations classified by the Bin codes [1], [2], [3], [4], and [5] in the emission wavelengths of the plurality of LED elements 5 that are simultaneously operated. Therefore, the appropriate amount of the phosphor particles in the resin 8 applied to cover the LED element 5 differs depending on the Bin codes [1], [2], [3], [4], and [5]. It will be a thing. In the resin application information 14 prepared in the present embodiment, as shown in FIG. 4, the appropriate resin application amount for each Bin classification of the resin 8 containing YAG-based phosphor particles in a silicone resin, an epoxy resin, or the like, It is defined in advance according to the Bin code section 17 in units of nl (nanoliter). That is, when the resin 8 is accurately applied so as to cover the LED element 5 by the appropriate resin application amount shown in the resin application information 14, the amount of the phosphor particles in the resin covering the LED element 5 is the appropriate amount of the phosphor particles supplied. Thus, the regular emission wavelength required for the finished product after the resin is thermally cured is ensured.

  Here, as shown in the phosphor concentration column 16, there are a plurality of phosphor concentrations indicating the concentration of the phosphor particles in the resin 8 (here, D1 (5%), D2 (10%), D3 (15%)). The appropriate resin application amount of the resin 8 is set to an appropriate numerical value according to the phosphor concentration of the resin 8 to be used and the variation in the emission wavelength of the LED element 5. That is, when the resin having the phosphor concentration D1 is applied, the appropriate resin application amounts VA0, VB0, VC0, and Bin codes [1], [2], [3], [4], and [5], respectively. Resin 8 of VD0, VE0 (appropriate resin coating amount 15 (1)) is applied. Similarly, when the resin having the phosphor concentration D2 is applied, the appropriate resin application amounts VF0, VG0, VH0 are respectively obtained for the bin codes [1], [2], [3], [4], and [5]. , VJ0, VK0 (appropriate resin coating amount 15 (2)) of resin 8 is applied. Further, when a resin having a phosphor concentration D3 is applied, the appropriate resin application amounts VL0, VM0, VN0, and VP0 for the bin codes [1], [2], [3], [4], and [5], respectively. , VR8 (appropriate resin coating amount 15 (3)) of resin 8 is applied. In this way, the appropriate resin coating amount is set for each of a plurality of different phosphor concentrations. The optimum phosphor concentration is selected according to the degree of variation in the emission wavelength (standard deviation), and the selected phosphor This is because it is more preferable to apply an appropriate amount of the resin 8 having a concentration in terms of ensuring quality.

  Next, the configuration and function of the component mounting apparatus M1 will be described with reference to FIG. As shown in the plan view of FIG. 5A, the component mounting apparatus M1 includes a substrate transport mechanism 21 that transports the work target substrate 4 supplied from the upstream side in the substrate transport direction (arrow a). The substrate transport mechanism 21 is provided with an adhesive application part A shown in section AA in FIG. 5B and a component mounting part B shown in section BB in FIG. It is installed. The adhesive application unit A is disposed on the side of the substrate transport mechanism 21 and supplies the resin adhesive 23 in the form of a coating film having a predetermined film thickness, and the substrate transport mechanism 21 and the adhesive supply unit 22. Is provided with an adhesive transfer mechanism 24 that is movable in the horizontal direction (arrow b). The component mounting part B is disposed on the side of the board transport mechanism 21 and has the parts supply mechanism 25 and the board transport mechanism 21 that hold the LED sheets 13A, 13B, 13C, 13D, and 13E shown in FIG. A component mounting mechanism 26 that is movable in the horizontal direction (arrow c) above the supply mechanism 25 is provided.

  As shown in FIG. 5B, the substrate 4 carried into the substrate transport mechanism 21 is positioned by the adhesive application portion A, and is bonded to the LED mounting portion 4b formed on each individual substrate 4a. The agent 23 is applied. That is, first, the adhesive transfer mechanism 24 is moved above the adhesive supply unit 22 so that the transfer pin 24a is brought into contact with the coating film of the resin adhesive 23 formed on the transfer surface 22a, and the resin adhesive 23 is adhered. Next, the adhesive transfer mechanism 24 is moved above the substrate 4 and the transfer pin 24a is lowered to the LED mounting portion 4b (arrow d), whereby the resin adhesive 23 attached to the transfer pin 24a is moved into the LED mounting portion 4b. Supplied by transfer to the element mounting position.

  Next, the substrate 4 after application of the adhesive is conveyed to the downstream side, positioned at the component mounting portion B as shown in FIG. 5 (c), and the LED elements are targeted for each LED mounting portion 4b after the adhesive is supplied. 5 is implemented. That is, first, the component mounting mechanism 26 is moved above the component supply mechanism 25, and the mounting nozzle 26a is lowered with respect to any of the LED sheets 13A, 13B, 13C, 13D, and 13E held by the component supply mechanism 25, and mounted. The LED element 5 is held and taken out by the nozzle 26a. Next, the component mounting mechanism 26 is moved above the LED mounting portion 4b of the substrate 4 to lower the mounting nozzle 26a (arrow e), whereby the LED element 5 held by the mounting nozzle 26a is bonded to the adhesive in the LED mounting portion 4b. It is mounted at the element mounting position where is applied.

  In mounting the LED elements 5 on the board 4 by the component mounting apparatus M1, any one of the LED sheets 13A, 13B, 13C, 13D, and 13E can be used in an individual mounting operation by the component mounting program 26, that is, the component mounting mechanism 26. The order in which the LED elements 5 are taken out and mounted on the plurality of individual boards 4a of the board 4 is set in advance, and the component mounting work is executed according to this element mounting program.

  When the component mounting work is executed, mounting position information 71a (see FIG. 9) indicating which of the plurality of individual boards 4a of the board 4 is mounted from the work execution history is extracted. Record. The mounting position information 71a and the LED element 5 mounted on each individual substrate 4a correspond to any characteristic rank (Bin code [1], [2], [3], [4], [5]). Data associated with the element characteristic information 12 indicating whether or not to be created is created as map data 18 shown in FIG. 6 by the map creation processing unit 74 (see FIG. 9).

  In FIG. 6, the individual positions of the plurality of individual substrates 4a of the substrate 4 are specified by combinations of matrix coordinates 19X and 19Y indicating the positions in the X direction and the Y direction, respectively. Then, by making the Bin code to which the LED element 5 mounted at the position belongs correspond to the individual cell of the matrix constituted by the matrix coordinates 19X and 19Y, the LED element 5 mounted by the component mounting apparatus M1 on the substrate 4 Map data 18 in which the mounting position information 71a indicating the position and the element characteristic information 12 about the LED element 5 are associated is created.

  That is, the component mounting apparatus M1 displays the map data 18 in which the mounting position information indicating the position of the LED element 5 mounted by the apparatus on the board 4 and the element characteristic information 12 on the LED element 5 are associated with the board 4 A map creation processing unit 74 is provided as map data creation means to be created every time. The created map data 18 is transmitted as feedforward data to the resin coating apparatus M4 described below via the LAN system 2.

  Next, the configuration and function of the resin coating apparatus M4 will be described with reference to FIGS. The resin coating device M4 has a function of coating the resin 8 so as to cover the plurality of LED elements 5 mounted on the substrate 4 by the component mounting device M1. As shown in the plan view of FIG. 7A, the resin coating apparatus M4 transfers the work target substrate 4 supplied from the upstream side to the substrate transport mechanism 31 that transports the substrate 4 in the substrate transport direction (arrow f). ) Is provided with a resin coating portion C shown in a CC cross section. The resin application part C is provided with a resin discharge head 32 configured to discharge the resin 8 from the discharge nozzle 33a attached to the lower end.

  As shown in FIG. 7B, the resin discharge head 32 is driven by the nozzle moving mechanism 34, and the nozzle moving mechanism 34 is controlled by the application control unit 36, whereby the horizontal direction (arrow g shown in FIG. 7A). ) Move and lift operations. The resin discharge head 32 is supplied with the resin 8 stored in a syringe attached to the dispenser 33, and the resin discharge mechanism 35 discharges the resin 8 in the dispenser 33 by applying air pressure into the dispenser 33. It is discharged through the nozzle 33 a and applied to the LED mounting portion 4 b formed on the substrate 4. At this time, by controlling the resin discharge mechanism 35 by the application control unit 36, the discharge amount of the resin 8 can be arbitrarily controlled. That is, the resin application part C has a function of applying the resin 8 to an arbitrary application target position by ejecting the resin 8 in a variable amount.

  A test hitting / measurement unit 40 is disposed on the side of the substrate transport mechanism 31 so as to be positioned within the movement range of the resin discharge head 32. Prior to the actual production application operation for applying the resin 8 to the LED mounting portion 4b of the substrate 4, the test hitting / measurement unit 40 determines whether or not the application amount of the resin 8 is appropriate. It has a function of determining by measuring the light emission characteristics. In other words, the light emission characteristics when the light-transmitting member 43 on which the resin 8 has been trial-applied by the resin application part C is irradiated with light from the measurement light source part are measured by the light emission characteristic measurement part 39, and the measurement results are preset. By comparing with the threshold value, the suitability of the preset resin application amount defined by the resin application information 14 shown in FIG. 4 is determined.

  The composition and properties of the resin 8 containing the phosphor particles are not necessarily stable, and even if an appropriate resin application amount is set in advance in the resin application information 14, the concentration of the phosphor and the resin viscosity over time. Inevitable fluctuations. For this reason, even if the resin 8 is discharged with the discharge parameters corresponding to the preset appropriate resin application amount, the resin application amount itself varies from the preset appropriate value, or the resin application amount itself is appropriate. However, the supply amount of the phosphor particles that should be originally supplied varies depending on the concentration change.

  In order to eliminate such inconvenience, in the present embodiment, a test coating for inspecting whether or not an appropriate supply amount of phosphor particles is supplied at a predetermined interval is executed by the resin coating apparatus M4. In addition, by measuring the light emission characteristics of the test-applied resin, the supply amount of the phosphor particles is stabilized in accordance with the light emission characteristics that should originally exist. The resin coating unit C provided in the resin coating apparatus M4 shown in the present embodiment includes a measurement coating process for applying the resin 8 to the light-transmitting member 43 for the above-described light emission characteristic measurement, and a substrate for actual production. 4 has a function of executing a production coating process to be applied to the LED element 5 mounted in the state 4. Both the coating process for measurement and the coating process for production are executed when the coating control unit 36 controls the resin coating unit C.

  As shown in FIG. 8, the test hitting / measuring unit 40 has an external structure in which a cover portion 40b provided with an application slide window 40c that is slidable (arrow h) with respect to an elongated horizontal base portion 40a is disposed. The test strike stage 45 that supports the translucent member 43 from the lower surface side, the translucent member mounting portion 41 on which the translucent member 43 is placed, and the translucent member mounting portion 41 are disposed in the interior. A spectroscope 42 is provided. The translucent member mounting unit 41 includes a light source unit that emits excitation light that excites the phosphor. From the light source unit, the translucent member 43 on which the resin 8 is applied by trial in the measurement coating process. Excitation light is irradiated from the lower surface side.

  In the present embodiment, an LED element 5 sealed with a resin 8 that does not contain a phosphor is used as a light source part. Thereby, the light emission characteristic measurement of the resin 8 applied by trial can be performed by the light having the same characteristic as the excitation light emitted in the finished LED package 50, and a more reliable test result can be obtained. . Note that it is not always necessary to use the same LED element 5 as that used in the finished product. If the light source device emits blue light having a certain wavelength in the same manner as the LED element 5 (for example, a blue laser light source), It can be used as a light source unit for inspection.

  The translucent member 43 is wound and supplied on the supply reel 44 and fed along the upper surface of the test strike stage 45 (arrow i), and then the gap between the translucent member mounting portion 41 and the spectroscope 42 is reached. It is wound up on a collection reel 46 that is driven by a winding motor 47. Here, a flat sheet-like member made of a transparent resin is used as the translucent member 43 as a tape material having a predetermined width, or an embossed portion 43a corresponding to the concave shape of the LED package 50 is provided on the lower surface of the same tape material. Embossed type is used.

  In a state where the application sliding window 40c is slid and opened, the upper surface of the trial hitting stage 45 is exposed upward, and the resin discharge head 32 applies the resin 8 to the light transmitting member 43 placed on the upper surface. It becomes possible. In this trial application, the resin 8 having a specified application amount is applied to the light transmissive member 43 by the discharge nozzle 33a, as shown in FIG. This is done by discharging.

  FIGS. 8B and 8A show a state in which the preset appropriate discharge amount of the resin 8 defined by the resin application information 14 is applied to the translucent member 43 made of the tape material. FIGS. 8B and 8B show a state in which the resin 8 having a preset appropriate discharge amount is similarly applied to the embossed portion 43a of the embossed type translucent member 43 described above. In addition, as will be described later, the resin 8 applied in the test hitting stage 45 is a test application for empirically determining whether or not the phosphor supply amount is appropriate for the target LED element 5. Therefore, when the resin 8 is continuously applied to the plurality of points on the translucent member 43 by the same trial application operation by the resin discharge head 32, the correlation between the measured light emission characteristic value and the application amount is known. Based on the data, the application amount is varied in stages and applied.

  In FIG. 8C, the translucent member 43 on which the resin 8 has been trial-applied is moved by the trial hitting stage 45 so that the resin 8 is positioned above the translucent member mounting portion 41, and the cover portion 40b is further moved. It shows a state in which a darkroom for measuring the light emission characteristics is formed between the base 40a and the base 40a. For the translucent member mounting portion 41, an LED package 50A having a configuration in which the resin 8 in the LED package 50 is replaced with a transparent resin 80 that does not contain phosphor particles is used. The wiring layers 4e and 4d connected to the LED element 5 in the LED package 50A are connected to the power supply device 48. When the power supply device 48 is turned on, the LED element 5 is supplied with power for light emission. The LED element 5 emits blue light.

  Then, in the process in which the blue light passes through the transparent resin 80 and is then applied to the resin 8 that has been trial-applied to the translucent member 43, yellow light and blue light emitted by excitation of the phosphor in the resin 8 are added. White light mixed in color is irradiated upward from the resin 8. A spectroscope 42 is arranged above the trial hitting / measurement unit 40, and the white light emitted from the resin 8 is received by the spectroscope 42, and the received white light is analyzed by the light emission characteristic measuring unit 39. Luminescent properties are measured. Here, the light emission characteristics such as the color tone rank of white light and the luminous flux are inspected, and a deviation from the prescribed light emission characteristics is detected as the inspection result. That is, the light emission characteristic measuring unit 39 measures the light emission characteristic of the light emitted from the resin 8 by irradiating the resin 8 applied to the light transmitting member 43 with the excitation light emitted from the LED element 5 as the light source unit.

  The measurement result of the light emission characteristic measurement unit 39 is sent to the application amount derivation processing unit 38, and the application amount derivation processing unit 38 obtains a deviation between the measurement result of the light emission characteristic measurement unit 39 and the predetermined light emission characteristic. Based on the above, a process for deriving an appropriate resin application amount of the resin 8 to be applied to the LED element 5 for actual production is performed. The new appropriate discharge amount derived by the application amount derivation processing unit 38 is sent to the production execution processing unit 37, and the production execution processing unit 37 commands the newly derived appropriate resin application amount to the application control unit 36. Accordingly, the application control unit 36 controls the nozzle moving mechanism 34 and the resin discharge mechanism 35 to perform a production application process for applying an appropriate resin application amount of the resin 8 to the LED elements 5 mounted on the substrate 4. 32.

  In this production coating process, first, an appropriate amount of resin 8 specified by the resin coating information 14 is actually applied, and light emission characteristics are measured while the resin 8 is uncured. Then, based on the obtained measurement results, a non-defective range of emission characteristic measurement values when the emission characteristics are measured for the resin 8 applied in the production coating is set, and the non-defective range is determined for the quality determination in the production coating. It is used as a threshold value (see threshold value data 81a shown in FIG. 9).

  That is, in the resin coating method in the LED package manufacturing system shown in the present embodiment, the LED element 5 is used as the light source unit for measuring the light emission characteristics, and is preliminarily defined as a basis for setting a threshold value for quality determination in production coating. As the emission characteristics, the regular emission characteristics required for the finished product in which the resin 8 applied to the LED element 5 is cured are biased by the difference in emission characteristics due to the resin 8 being in an uncured state. Emission characteristics are used. Thereby, control of the resin application amount in the resin application process to the LED element 5 can be performed based on the normal light emission characteristics of the finished product.

  Next, the configuration of the control system of the LED package manufacturing system 1 will be described with reference to FIG. Here, among the components of each device constituting the LED package manufacturing system 1, in the management computer 3, the component mounting device M1, and the resin coating device M4, the element characteristic information 12, the resin coating information 14, the map data 18, and the above-mentioned The components related to the transmission / reception and update processing of the threshold data 81a are shown.

  In FIG. 9, the management computer 3 includes a system control unit 60, a storage unit 61, and a communication unit 62. The system control unit 60 controls the LED package manufacturing work by the LED package manufacturing system 1 in an integrated manner. In the storage unit 61, in addition to programs and data necessary for the control processing by the system control unit 60, element characteristic information 12, resin application information 14, mode information 51, and map data 18 and threshold data as necessary. 81a is stored. The communication unit 62 is connected to other devices via the LAN system 2 and exchanges control signals and data. The element characteristic information 12 and the resin application information 14 are transmitted from the outside via the LAN system 2 and the communication unit 62 or via a single storage medium such as a CD-ROM (C-ROM) and stored in the storage unit 61. .

  The component mounting apparatus M1 includes a mounting control unit 70, a storage unit 71, a communication unit 72, a mechanism driving unit 73, and a map creation processing unit 74. The mounting control unit 70 controls each unit described below based on various programs and data stored in the storage unit 71 in order to execute a component mounting operation by the component mounting apparatus M1. The storage unit 71 stores mounting position information 71 a and element characteristic information 12 in addition to programs and data necessary for control processing by the mounting control unit 70. The mounting position information 71 a is created from execution history data of mounting operation control by the mounting control unit 70. The element characteristic information 12 is transmitted from the management computer 3 via the LAN system 2. The communication unit 72 is connected to other devices via the LAN system 2 and exchanges control signals and data.

  The mechanism driving unit 73 is controlled by the mounting control unit 70 to drive the component supply mechanism 25 and the component mounting mechanism 26. As a result, the LED elements 5 are mounted on the individual substrates 4 a of the substrate 4. The map creation processing unit 74 (map data creation means) includes mounting position information 71a indicating the position of the LED element 5 on the substrate 4 stored in the storage unit 71 and mounted by the component mounting apparatus M1, and an element for the LED element 5 A process of creating the map data 18 associated with the characteristic information 12 for each substrate 4 is performed. That is, the map data creating means is provided in the component mounting apparatus M1, and the map data 18 is transmitted from the component mounting apparatus M1 to the resin coating apparatus M4. The map data 18 may be transmitted from the component mounting apparatus M1 to the resin coating apparatus M4 via the management computer 3. In this case, the map data 18 is also stored in the storage unit 61 of the management computer 3 as shown in FIG.

  The resin coating apparatus M4 includes a coating control unit 36, a storage unit 81, a communication unit 82, a production execution processing unit 37, a coating amount derivation processing unit 38, and a light emission characteristic measuring unit 39. The application control unit 36 controls the nozzle moving mechanism 34, the resin discharge mechanism 35, and the test hitting / measurement unit 40 constituting the resin application unit C, so that the resin 8 is applied to the translucent member 43 for light emission characteristic measurement. The measurement coating process to be performed and the production coating process to be applied to the LED element 5 for actual production are performed.

  The storage unit 81 stores the resin application information 14, the map data 18, the threshold data 81a, and the actual production application amount 81b, in addition to the programs and data necessary for the control processing by the application control unit 36. The resin application information 14 is transmitted from the management computer 3 via the LAN system 2, and the map data 18 is similarly transmitted from the component mounting apparatus M1 via the LAN system 2. The communication unit 82 is connected to other devices via the LAN system 2 and exchanges control signals and data.

  The light emission characteristic measurement unit 39 performs a process of measuring the light emission characteristic of the light emitted from the resin by irradiating the resin 8 applied to the translucent member 43 with the excitation light emitted from the LED element 5 serving as the light source unit. . The application amount derivation processing unit 38 obtains a deviation between the measurement result of the light emission characteristic measurement unit 39 and the predetermined light emission characteristic, and based on this deviation, the appropriateness of the resin 8 to be applied to the LED element 5 for actual production is obtained. An arithmetic process for deriving the resin coating amount is performed. Then, the production execution processing unit 37 instructs the application control unit 36 to specify the appropriate resin application amount derived by the application amount derivation processing unit 38, thereby applying the appropriate resin application amount of resin to the LED element 5. Execute the process.

  In the configuration shown in FIG. 9, the processing function other than the function for executing the operation operation unique to each apparatus, for example, the function of the map creation processing unit 74 provided in the component mounting apparatus M1, and the resin coating apparatus M4 are provided. The function of the applied amount derivation processing unit 38 is not necessarily attached to the apparatus. For example, the functions of the map creation processing unit 74 and the application amount derivation processing unit 38 are covered by the arithmetic processing function of the system control unit 60 of the management computer 3 and necessary signal exchange is performed via the LAN system 2. You may comprise.

  In the configuration of the LED package manufacturing system 1 described above, the component mounting apparatus M1 and the resin coating apparatus M4 are both connected to the LAN system 2. Then, the management computer 3 and the LAN system 2 in which the element characteristic information 12 is stored in the storage unit 61 uses the information obtained by separately measuring the emission characteristics including the emission wavelengths of the plurality of LED elements 5 in advance as the element characteristic information. 12 is element characteristic information providing means provided to the component mounting apparatus M1. Similarly, the management computer 3 and the LAN system 2 in which the resin application information 14 is stored in the storage unit 61, the appropriate resin application amount of the resin 8 and the element characteristic information for obtaining the LED package 50 having the prescribed light emission characteristics, This is resin information providing means for providing information corresponding to the information as resin coating information to the resin coating apparatus M4.

  That is, the element characteristic information providing means for providing the element characteristic information 12 to the component mounting apparatus M1 and the resin information providing means for providing the resin coating information 14 to the resin coating apparatus M4 are the storage unit 61 of the management computer 3 which is an external storage means. The element characteristic information and the resin application information read out are transmitted to the component mounting apparatus M1 and the resin application apparatus M4 via the LAN system 2, respectively.

  Next, the LED package manufacturing process executed by the LED package manufacturing system 1 will be described along the flow of FIG. 10 with reference to the drawings. First, element characteristic information 12 and resin application information 14 are acquired (ST1). That is, the proper resin application amount of the resin 8 for obtaining the LED package 50 having the element characteristic information 12 obtained by individually measuring the emission characteristics including the emission wavelengths of the plurality of LED elements 5 in advance and the prescribed emission characteristics. The resin application information 14 in which the element characteristic information 12 is associated is acquired from an external device via the LAN system 2 or via a storage medium.

  Thereafter, the board 4 to be mounted is carried into the component mounting apparatus M1 (ST2). Then, as shown in FIG. 16A, the resin adhesive 23 is supplied to the element mounting position in the LED mounting portion 4b by raising and lowering the transfer pin 24a of the adhesive transfer mechanism 24 (arrow j). 16 (b), the LED element 5 held by the mounting nozzle 26a of the component mounting mechanism 26 is lowered (arrow k) and mounted in the LED mounting portion 4b of the substrate 4 via the resin adhesive 23 ( ST3). Then, the map creation processing unit 74 creates map data 18 that associates the mounting position information 71a with the element characteristic information 12 of each LED element 5 for the board 4 from the execution data of the component mounting work (ST4). ). Next, the map data 18 is transmitted from the component mounting apparatus M1 to the resin coating apparatus M4, and the resin coating information 14 is transmitted from the management computer 3 to the resin coating apparatus M4 (ST5). Thereby, it will be in the state which can perform the resin application | coating operation | work by the resin application | coating apparatus M4.

  Next, the substrate 4 after component mounting is sent to the curing device M2, where it is heated, whereby the resin adhesive 23 is thermally cured to become a resin adhesive 23A as shown in FIG. The element 5 is fixed to the individual substrate 4a. Next, the substrate 4 after resin curing is sent to the wire bonding apparatus M3, and as shown in FIG. 16D, the wiring layers 4e and 4d of the individual substrate 4a are respectively connected to the N-type portion electrodes 6a and P of the LED element 5. The mold part electrode 6 b is connected to the bonding wire 7.

  Next, threshold data creation processing for non-defective product determination is executed (ST6). This process is executed to set a pass / fail judgment threshold value (see threshold value data 81a shown in FIG. 9) in production coating. Bin codes [1], [2], [3 ], [4], and [5] are repeatedly executed for each of the production coatings. Details of the threshold data creation processing will be described with reference to FIGS. In FIG. 11, first, a resin 8 containing the phosphor specified in the resin application information 14 at a genuine concentration is prepared (ST11). Then, after setting the resin 8 on the resin discharge head 32, the resin discharge head 32 is moved to the test hitting stage 45 of the test hitting / measurement unit 40, and the resin 8 is applied to the specified application amount (appropriate resin application) indicated in the resin application information 14. The amount is applied to the translucent member 43 (ST12). Next, the resin 8 applied to the translucent member 43 is moved onto the translucent member mounting portion 41, the LED element 5 is caused to emit light, and the light emission characteristic when the resin 8 is uncured is measured by the light emission characteristic measurement unit 39. (ST13). Then, based on the light emission characteristic measurement value 39a which is a measurement result of the light emission characteristic measured by the light emission characteristic measurement unit 39, a non-defective product determination range of the measurement value for determining the light emission characteristic is determined to be non-defective (ST14). The non-defective product determination range is stored as threshold data 81a in the storage unit 81 and is also transferred to the management computer 3 and stored in the storage unit 61 (ST15).

  FIG. 12 shows that the threshold data created in this way, that is, the measured emission characteristics and emission characteristics obtained in the uncured state of the resin 8 after application of the resin 8 containing a phosphor with a genuine content is a non-defective product. The non-defective product judgment range (threshold value) of the measured value for judgment is shown. 12A, 12B, and 12C, the phosphor concentration in the resin 8 is 5%, respectively. The threshold values corresponding to the Bin codes [1], [2], [3], [4], and [5] in the case of 10% and 15% are shown.

  For example, as shown in FIG. 12 (a), when the phosphor concentration of the resin 8 is 5%, each of the Bin codes 12b corresponds to the application amount indicated by the appropriate resin application amount 15 (1). The light emission characteristic measurement unit 39 measured the light emission characteristics of the light emitted from the resin 8 by irradiating the blue light of the LED element 5 onto the resin 8 applied at the respective application amounts. It is shown in 1). Then, threshold data 81a (1) is set based on the respective emission characteristic measurement values 39a (1). For example, the measurement result of measuring the light emission characteristics of the resin 8 applied with the appropriate resin application amount VA0 corresponding to the Bin code [1] is the chromaticity coordinates ZA0 (XA0, YA0) on the chromaticity table shown in FIG. Represented by With this chromaticity coordinate ZA0 as the center, a predetermined range (for example, ± 10%) for the X coordinate and Y coordinate on the chromaticity table is set as a non-defective product determination range (threshold value). Similarly, for the appropriate resin coating amounts corresponding to the other Bin codes [2] to [5], a non-defective product determination range (threshold value) is set based on the light emission characteristic measurement result (chromaticity table shown in FIG. 13). (See chromaticity coordinates ZB0-ZE0 above). Here, the predetermined range set as the threshold is appropriately set according to the accuracy level of the light emission characteristics required for the LED package 50 as a product.

  12B and 12C show the emission characteristic measurement values and the non-defective product determination range (threshold value) when the phosphor concentration of the resin 8 is 10% and 15%, respectively. 12 (b) and 12 (c), the appropriate resin application amount 15 (2) and the appropriate resin application amount 15 (3) indicate the appropriate resin application amounts when the phosphor concentrations are 10% and 15%, respectively. The emission characteristic measurement value 39a (2) and the emission characteristic measurement value 39a (3) are emission specific measurement values when the phosphor concentrations are 10% and 15%, respectively, and threshold data 81a ( 2) The threshold value data 81a (3) indicates a non-defective product determination range (threshold value) in each case. The threshold data created in this way is selectively used according to the Bin code 12b to which the target LED element 5 belongs in the production application work. Note that the threshold data creation process shown in (ST6) is executed as an off-line operation by a single inspection apparatus provided separately from the LED package manufacturing system 1, and is stored in the management computer 3 as threshold data 81a in advance. It is also possible to transmit the received data to the resin coating apparatus M4 via the LAN system 2.

  Thereafter, the substrate 4 after wire bonding is transferred to the resin coating device M4 (ST7), and as shown in FIG. 17A, the resin is discharged from the discharge nozzle 33a into the LED mounting portion 4b surrounded by the reflecting portion 4c. 8 is discharged. Here, based on the map data 18, the threshold data 81a, and the resin application information 14, an operation of applying a specified amount of the resin 8 shown in FIG. 17B so as to cover the LED element 5 is performed (ST8). ).

  Next, the substrate 4 is sent to the curing device M5, and the resin 8 is cured by being heated by the curing device M5 (ST9). As a result, as shown in FIG. 17C, the resin 8 applied so as to cover the LED element 5 is thermally cured to become the resin 8A, and is fixed in the LED mounting portion 4b. Next, the substrate 4 after the resin curing is sent to the individual piece cutting device M6, where the substrate 4 is cut into individual piece substrates 4a, and as shown in FIG. (ST10). Thereby, the LED package 50 is completed.

  For example, the individual LED package 50 is subjected to a sampling inspection (first sampling inspection, second sampling inspection) by the sampling inspection unit M7 (ST16). Note that the sampling inspection in ST16 is not necessarily started after ST10 is completed, and can be executed in parallel with the processing in ST1 to ST10. Further, not all the sampling inspection processes are executed by the sampling inspection unit M7. For example, using a device other than the sampling inspection unit M7 such as the light emission characteristic measuring device 11, some processes of the sampling inspection are performed. Can be executed.

  Details of the resin application work process and the sampling inspection will be described with reference to FIGS. In the present embodiment, mode information 51 is held in the storage unit 61 of the management computer 3. The mode information 51 is information set by the user, and the user sets either “quality priority mode” or “production priority mode”. “Quality priority mode” (first production mode) is a production mode in which production is not executed until the appropriate amount of applied resin is determined. “Production priority mode” (second production mode) This is a production mode in which production is executed in parallel with derivation.

  The system control unit 60 of the management computer 3 reads the mode information 51 from the storage unit 61 at the start of the resin coating work process or at a predetermined time during the resin coating work process (such as ST32 described later), and the system operation mode Is set to “quality priority mode” or “production priority mode”, and the resin application work process is executed according to the determination result.

  Furthermore, the system control unit 60 of the management computer 3 performs a first sampling inspection on the substrate 4 on which the resin 8 is applied by the resin application work process in order to improve the yield. Specifically, the first sampling inspection and the second sampling inspection described later are executed by the sampling inspection unit M7 in accordance with instructions from the system control unit 60. Hereinafter, the “quality priority mode” will be described first.

  In the “quality priority mode”, first, when the resin coating operation is started, the resin container is exchanged as necessary (ST21). That is, the dispenser 33 attached to the resin discharge head 32 is replaced with one containing a resin 8 having a phosphor concentration selected according to the characteristics of the LED element 5.

  Next, the resin application part C applies the resin 8 to the translucent member 43 for light emission characteristic measurement (application process for measurement) (ST22). That is, the resin 8 having an appropriate resin coating amount (VA0 to VE0) for each of the Bin cords 12b defined in FIG. 4 is formed on the light transmitting member 43 drawn out to the trial strike stage 45 by the trial strike / measurement unit 40. Apply. At this time, even if the discharge operation parameter corresponding to the appropriate resin application amount (VA0 to VE0) is commanded to the resin discharge mechanism 35, the actual resin application amount discharged from the discharge nozzle 33a and applied to the translucent member 43 is resin. The proper resin coating amount does not necessarily become the above-mentioned appropriate resin coating amount due to the change in the property of 8 over time, and the actual resin coating amount becomes VA1 to VE1 somewhat different from VA0 to VE0, as shown in FIG.

  Next, the light-transmitting member 43 is sent in the trial hitting / measurement unit 40, whereby the light-transmitting member 43 on which the resin 8 has been applied by trial is sent, and the LED element 5 is provided as a light source unit that emits excitation light that excites the phosphor. It is mounted on the translucent member mounting portion 41 (translucent member mounting step). Then, by irradiating the resin 8 applied to the translucent member 43 with the excitation light emitted from the LED element 5, the light emitted by the resin 8 is received by the spectroscope 42, and this light is measured by the light emission characteristic measuring unit 39. Emission characteristic measurement is performed (luminescence characteristic measurement step) (ST23).

  Thereby, as shown in FIG. 15B, a measured value of the light emission characteristic represented by the chromaticity coordinate Z (see FIG. 13) is obtained. This measurement result is not necessarily based on the above-described error in the coating amount and the change in the concentration of the phosphor particles in the resin 8, and the like, ie, the standard color at the time of proper resin coating shown in FIG. It does not coincide with the degree coordinates ZA0 to ZE0. For this reason, the deviation (ΔXA,) indicating the separation in the X and Y coordinates between the obtained chromaticity coordinates ZA1 to ZE1 and the standard chromaticity coordinates ZA0 to ZE0 at the time of proper resin application shown in FIG. [Delta] YA) to ([Delta] XE, [Delta] YE) are obtained, and the necessity of correction for obtaining desired light emission characteristics is determined.

  Here, it is determined whether or not the measurement result is within the threshold value (ST24), and as shown in FIG. 15C, the deviation obtained in (ST23) is compared with the threshold value. Thus, it is determined whether the deviations (ΔXA, ΔYA) to (ΔXE, ΔYE) are within a range of ± 10% with respect to ZA0 to ZE0. Here, if the deviation is within the threshold value, the discharge operation parameters corresponding to the preset appropriate resin application amounts VA0 to VE0 are maintained as they are. On the other hand, when the deviation exceeds the threshold value, the application amount is corrected (ST25). That is, the deviation between the measurement result in the light emission characteristic measurement step and the predetermined light emission characteristic is obtained, and as shown in FIG. 15 (d), the actual production to be applied to the LED element 5 based on the obtained deviation. The process of deriving the new appropriate resin application amount (VA2 to VE2) is executed by the application amount deriving processing unit 38 (application amount deriving process step).

  Here, the corrected appropriate resin application amounts (VA2 to VE2) are updated values obtained by adding correction amounts corresponding to the respective deviations to the preset appropriate resin application amounts VA0 to VE0. The relationship between the deviation and the correction amount is recorded in the resin application information 14 as known accompanying data in advance. Then, based on the corrected appropriate resin coating amount (VA2 to VE2), the processes of (ST22), (ST23), (ST24), and (ST25) are repeatedly executed, and the measurement result is defined in advance in (ST24). When it is confirmed that the deviation from the light emission characteristic is within the threshold value, the proper resin coating amount for actual production is determined. That is, in the above-described resin coating method, the appropriate resin coating amount is definitely derived by repeatedly executing the measurement coating step, the translucent member placement step, the light emission characteristic measurement step, and the coating amount derivation step. Yes. The determined proper resin application amount is stored in the storage unit 81 as the actual production application amount 81b. Note that a period during which the steps (ST22) to (ST25) are executed is referred to as a correction period.

  After that, the process moves to the next step, and discarding is executed (ST26). Here, by discharging a predetermined amount of the resin 8 from the discharge nozzle 33a, the resin flow state in the resin discharge path is improved, and the operations of the dispenser 33 and the resin discharge mechanism 35 are stabilized. Note that the processing of (ST27), (ST28), (ST29), and (ST30) indicated by the broken line frame in FIG. 14 is the same as the processing content shown in (ST22), (ST23), (ST24), and (ST25). It is executed when it is necessary to carefully check that the desired light emission characteristics are completely secured, and is not necessarily an essential execution item.

  In this way, when the appropriate resin coating amount that gives the desired light emission characteristics is determined, the production coating is executed (ST31). That is, when the production execution processing unit 37 instructs the application control unit 36 that controls the resin discharge mechanism 35, the appropriate resin application amount derived by the application amount derivation processing unit 38 and stored as the actual production application amount 81b. Then, a production coating process is performed in which the appropriate amount of resin 8 is applied to the LED element 5 mounted on the substrate 4 (production execution step).

  In the process of repeatedly executing the production coating process, the number of times of application by the dispenser 33 is counted, and in order to correct the application amount at a predetermined interval, has the predetermined number of times passed in advance? Whether or not is monitored (ST32). That is, until the predetermined number of times is reached, it is determined that there is little change in the properties of the resin 8 and the phosphor concentration, and the production coating execution (ST31) is repeated while maintaining the same actual production coating amount 81b. If the predetermined number of times has been confirmed in (ST32), it is determined that there is a possibility that the property of the resin 8 or the phosphor concentration has changed, and the process returns to (ST22). And the coating amount correction process based on the measurement result is repeatedly executed. Note that the interval monitored in ST32 may be set based on the number of substrates 4 on which application has been performed since the previous correction of the application amount or the elapsed time since the previous correction of the application amount. Alternatively, one lot (manufacturing lot) can be set as an application amount correction interval.

  Next, the first sampling inspection will be described. After the predetermined number of times has been confirmed in ST32, the steps (ST22) to (ST24) are performed, and in the determination process of the measurement result in ST24, when the deviation is not within the threshold value (NG in ST24). Performs the first sampling inspection of ST35 in parallel with the execution of the procedure after ST25 described above. However, the first sampling inspection in ST35 does not need to be executed even if it is NG in ST24 until the next predetermined number of times is confirmed in ST32.

  In the first sampling inspection (ST35), as shown in FIG. 14C, when the predetermined number of times has been confirmed in ST32 immediately before becoming NG in ST24 (T3), and in advance in ST32 before that. After the passage of the number of times is confirmed (T1), when it becomes OK in ST24 (T2) (hereinafter referred to as the previous interval), a predetermined number of sheets are selected from the substrates 4 on which the production coating of ST31 has been executed. The substrate 4 is selected and the inspection lot is specified (see ST41, FIG. 14B). The inspection lot may be all the substrates 4 on which the production coating of ST31 has been executed in the previous interval, or may be the predetermined number NA of substrates 4 on which the production coating of ST31 has been executed immediately before T3. Hereinafter, a case where a predetermined number NA of substrates 4 on which production coating of ST31 has been executed immediately before T3 is used as an inspection lot will be described.

  Next, as shown in FIG. 14B, a predetermined number n1 of samples are obtained from the inspection lot (ST42). The sample selection method is not particularly limited. For example, the predetermined number n1 of individual substrates 4a randomly selected from the one substrate 4 that has been most recently subjected to production coating in ST31 can be selected. n1 samples can be obtained. Alternatively, a predetermined number n1 of samples can be obtained by randomly selecting one or more individual substrates 4a for each of the substrates 4 having the predetermined number NA. In this case, n1 ≧ NA.

  Next, all samples are tested (ST43). The test method is not particularly limited. For example, the test can be performed as follows. The sample LED elements 5 are actually caused to emit light one by one, and the phosphor in the resin 8 is excited to emit white light. The white light is received by a spectroscope similar to the spectroscope 42 and analyzed by a light emission characteristic measurement unit similar to the light emission characteristic measurement unit 39, thereby measuring the light emission characteristics. The deviation between the measurement result and the reference value is obtained, and if the deviation is within the allowable range, the sample is determined as “good”. On the other hand, if the deviation is outside the allowable range, the sample is determined as “defective”.

  When the LED element 5 is caused to emit light for the test, the resin is cured by the curing device M5, and the substrate 4 is separated into pieces by the piece cutting device M6. Also good. Alternatively, the substrate may be separated into pieces by the piece cutting device M6 without curing the resin with the curing device M5, and the LED element 5 may be energized to emit light while the resin is uncured. Further, when the LED element 5 can be energized without dividing the substrate into pieces, the LED element 5 may be energized to emit light while the resin is applied by the resin coating device M4.

  Next, it is determined whether the number of samples (Nc1) determined to be defective exceeds the acceptance determination number C1 (ST44), and if it exceeds (Yes in ST44), the inspection lot is rejected. It determines with a thing, and transfers to an anti-failure treatment (ST45). In the anti-failure treatment, the inspection interval (for example, the predetermined number of times of application of ST32) is reduced over a predetermined period (for example, 2 to 3 hours), for example, assuming that the frequency of occurrence of defects may be increased. Thereby, the defect occurrence rate can be lowered. On the other hand, if the number of samples determined to be defective (Nc1) is less than or equal to the acceptance determination number C1 (No in ST44), the inspection lot is determined to be acceptable and the first sampling inspection (ST35). Exit.

  Next, the production priority mode (second production mode) will be described. When the mode information 51 of the storage unit 61 is set to the “production priority mode”, when the passage of a predetermined interval is confirmed in ST32 described above, the process proceeds to the correction / production parallel execution process (ST34). In the production priority mode, the first sampling inspection can be executed at the same timing as the quality priority mode (see FIG. 14E).

  In the correction / production parallel execution process, first, the trial application of ST22 is executed. Next, the production coating of ST31 is executed, and the emission characteristic measurement of ST23 is performed in parallel. Thereafter, similarly to ST24, it is determined whether or not the deviation is within a threshold value. If the deviation is within the threshold value, the procedure of (ST25) to (ST30) in FIG. 14 is skipped as it is, the number of times of application (the count number of the interval) is reset, and then the procedure of (ST31) and (ST32) repeat. In addition, while performing the procedure of the above-mentioned light emission characteristic measurement (ST23) and measurement result determination (ST24), the production coating can be repeatedly executed as long as time permits.

  On the other hand, when the deviation exceeds the threshold value (NG in ST24), the coating amount correction in ST25 is performed. Also in this case, while performing the steps (ST23) to (ST25), the production coating of ST31 can be repeatedly executed in the same manner as described above. Alternatively, in the case of NG in ST24, after that point, the production application of ST31 may be temporarily stopped until the deviation is determined to be within the threshold value in ST24. Here, when the coating amount correction of ST25 is completed, the measurement coating step of ST22 is executed again with the corrected coating amount after the completion of the production coating performed at that time. During this time, the production application may be stopped. Thereafter, as described above, the production application in ST31 and the application amount correction procedures in (ST23) to (ST25) are executed in parallel until it is determined in ST24 that the deviation is within the threshold value. it can.

  However, when there are a plurality of resin discharge heads 32, for example, only one or more of the resin discharge heads 32 are used to perform the trial application of ST22, and in parallel, the remaining resin discharge heads 32 are used. May be used to perform the production application of ST31. In this case, the resin discharge head 32 used for the trial application in ST22 can be sequentially replaced every time the interval determined in ST32 elapses.

  Next, the second sampling inspection will be described. As described above, in the production priority mode, the production coating process of ST31 is executed even during the correction period. At this time, as shown in FIG. 14E, when it becomes NG in ST24, it becomes necessary to determine whether the substrate 14 on which the production coating process has been performed during the current correction period is good or bad. Therefore, when NG in ST24 during the correction / production parallel execution process in ST34, the process proceeds to the second sampling inspection (see FIG. 14D). At this time, the first sampling inspection can be executed in parallel with the second sampling inspection.

  In the second sampling inspection, first, as shown in FIG. 14E, when the predetermined number of times have been confirmed in ST32 immediately before becoming NG in ST24 (T3), the substrate on which the production coating of ST31 has been executed is performed. A predetermined number of substrates 4 are selected from 4 and an inspection lot is specified (see ST51, FIG. 14D). For example, the inspection lot may be configured by selecting a predetermined number of substrates 4 from all the substrates 4 on which the production coating of ST31 has been executed after T3, or all of which the production coating of ST31 has been executed after T3. The substrate 4 can also be used. Hereinafter, a case where all the substrates 4 on which the production coating of ST31 has been executed after T3 is set as an inspection lot will be described.

  Next, a predetermined number n2 of samples are obtained from the inspection lot (ST52). The method for selecting samples is not particularly limited. For example, a predetermined number n2 of individual substrates 4a randomly selected from the one substrate 4 that has been most recently applied for production in ST31 allows a predetermined number to be selected. n2 samples can be obtained. Alternatively, a predetermined number n2 of samples can be obtained by randomly selecting a predetermined number n2 of individual substrates 4a from all the substrates 4 in the inspection lot.

  Next, all samples are tested (ST53). The test method is not particularly limited. For example, the test can be performed as follows. The sample LED elements 5 are actually caused to emit light one by one, and the phosphor in the resin 8 is excited to emit white light. The white light is received by a spectroscope similar to the spectroscope 42 and analyzed by a light emission characteristic measurement unit similar to the light emission characteristic measurement unit 39, thereby measuring the light emission characteristics. The deviation between the measurement result and the reference value is obtained, and if the deviation is within the allowable range, the sample is determined as “good”. On the other hand, if the deviation is outside the allowable range, the sample is determined as “defective”. A specific mode for causing the LED element 5 to emit light for the test is the same as in the first sampling inspection.

  Next, it is determined whether the number of samples (Nc2) determined to be defective exceeds the acceptance determination number C2 (ST54), and if it exceeds (Yes in ST54), the inspection lot is rejected. It determines with a thing, and transfers to an anti-failure treatment (ST55). The contents of the ST55 anti-failure treatment can be the same as the ST45 anti-failure treatment. Alternatively, in the anti-failure treatment of ST55, the substrate 4 on which production coating has been performed in parallel with the procedures of (ST23) to (ST25) can be disposed of. On the other hand, if the number of samples determined to be defective (Nc2) is equal to or smaller than the acceptance determination number C2 (No in ST54), the inspection lot is determined to be acceptable and the second sampling inspection is terminated. .

  As described above, in the quality priority mode (first production mode), the appropriate resin application amount is derived by the application amount derivation processing unit 38 from the start of the measurement application process, and the production execution process based on the appropriate resin application amount is performed. The production coating process is not executed in all periods including at least a part of the “correction period” until the command from the unit 37 is issued. On the other hand, in the “production priority mode” (second production mode), the production coating process can be executed even during at least a part of the period. Here, as described above, the “at least a partial period” can be a period obtained by removing the measurement application process (trial application in ST22) from the “correction period”.

  As described above, the LED package manufacturing system 1 shown in the embodiment described above separately measures the component mounting apparatus M1 for mounting the plurality of LED elements 5 on the substrate 4 and the emission wavelengths of the plurality of LED elements 5 in advance. The element characteristic information providing means for providing the obtained information as element characteristic information 12 is associated with the appropriate resin application amount of the resin 8 for obtaining the LED package 50 having the prescribed light emission characteristic and the element characteristic information 12. Resin information providing means for providing the information as resin coating information 14, mounting position information 71a indicating the position of the LED element 5 mounted on the substrate 4 by the component mounting apparatus M1, and element characteristic information 12 on the LED element 5; , Based on the map data creation means for creating the map data 18 for each substrate 4, the map data 18 and the resin application information 14, The appropriate resin coating amount of the resin 8 for having a constant emission characteristics, has a configuration that includes a resin coating device M4 to be applied to each LED element mounted on the substrate 4.

  Then, the resin coating apparatus M4 controls the resin coating portion C for discharging the coating amount of the resin 8 and coating the resin coating portion C to an arbitrary position to be coated, and the resin coating portion C. A coating control unit 36 for executing a measurement coating process for trial application to the translucent member 43 and a production coating process for coating the LED element for actual production, and a light source unit for emitting excitation light for exciting the phosphor. The translucent member mounting portion 41 on which the translucent member 43 on which the resin 8 has been trial-applied in the application measurement process is placed, and the resin 8 in which excitation light emitted from the light source unit is applied to the translucent member 43. The light emission characteristic measurement unit 39 that measures the light emission characteristic of the light emitted by the resin 8 by irradiating the light, and the deviation between the measurement result of the light emission characteristic measurement unit 39 and the predetermined light emission characteristic is obtained, and based on this deviation Appropriate resin coating amount By correcting the application amount derivation processing unit 38 for deriving the appropriate resin application amount for actual production to be applied to the LED element 5, and by instructing the application control unit 36 on the derived appropriate resin application amount, It has a configuration including a production execution processing unit 37 that executes a production application process for applying the appropriate resin application amount of resin to the LED element 5.

  With the above-described configuration, in the resin coating used to manufacture the LED package 50 in which the LED element 5 is covered with a resin containing a phosphor, the light-transmitting member 43 obtained by trial application of the resin 8 for light emission characteristic measurement is used for the light source portion. The measurement result which measured the light emission characteristic of the light which this resin emits by placing on the translucent member mounting part 41 provided and irradiating the resin applied to the translucent member 43 with the excitation light emitted from the light source part And a predetermined emission amount of the resin to be applied to the LED element for actual production can be derived based on the deviation. Thereby, even when the light emission wavelengths of the individual LED elements 5 vary, the light emission characteristics of the LED package 50 can be made uniform and the production yield can be improved.

  Furthermore, since either the “production priority mode” or the “quality priority mode” is selected, the selected mode is set in the mode information 51, and production can be performed based on the selected mode. Thus, it is possible to execute production while maintaining a balance between the two requirements of improvement in yield and improvement in production efficiency. For example, when the composition and properties of the phosphor-containing resin are stable and the variation in the resin coating amount itself is small, correction of the coating amount is often not actually required. Therefore, in such a case, by setting the “production priority mode”, the production execution process is executed except when the measurement application process of ST22 is executed. It is also possible to satisfy both the demands for improving production efficiency. On the other hand, when the situation is not as described above, by setting the “quality priority mode” in the mode information 51, the yield can be improved while obtaining the maximum production efficiency.

  Then, by performing the first sampling inspection when it is determined as NG in ST24 of the resin application work process flow of FIG. 14A, whether or not the determination result is due to an increase in the frequency of occurrence of defects. Can be confirmed. When it can be confirmed that the frequency of occurrence of defects is increased, the occurrence of defective products can be suppressed by, for example, more frequently correcting the application amount. Thereby, the yield can be improved and the quality of the product can be guaranteed. In addition, by performing the second sampling inspection during production in the production priority mode, it is possible to inspect the substrate 4 that may have a high defective product rate without omission, so that the defective product rate can be more reliably confirmed. As well as product quality.

  In the LED package manufacturing system 1 having the above-described configuration, the management computer 3 and the component mounting device M1 to the piece cutting device M6 are connected by the LAN system 2, but the LAN system 2 is indispensable. It is not a configuration requirement. That is, there are storage means for storing the element characteristic information 12 and the resin application information 14 that are prepared in advance and transmitted from the outside for each LED package 50, and from these storage means, the element characteristics are sent to the component mounting apparatus M1. If there is a data providing means capable of providing the information 12 and the resin coating information 14 and the map data 18 to the resin coating apparatus M4 as needed, the LED package manufacturing system 1 shown in the present embodiment will be described. Function can be realized.

  The LED package manufacturing system of the present invention has the effect that even if the light emission wavelength of individual LED elements varies, the light emission characteristics of the LED package can be made uniform and the production yield can be improved. The present invention can be used in the field of manufacturing an LED package in which the element is covered with a resin containing a phosphor.

DESCRIPTION OF SYMBOLS 1 LED package manufacturing system 2 LAN system 4 Board | substrate 4a Single piece board 4b LED mounting part 4c Reflection part 5 LED element 8 Resin 12 Element characteristic information 13A, 13B, 13C, 13D, 13E LED sheet 14 Resin application information 18 Map data 23 Resin Adhesive 24 Adhesive transfer mechanism 25 Component supply mechanism 26 Component mounting mechanism 32 Resin discharge head 33 Dispenser 33a Discharge nozzle 40 Test hitting / measurement unit 41 Translucent member mounting portion 42 Spectroscope 43 Translucent member 45 Test hitting stage 50 LED Package 51 mode information

Claims (8)

A system for manufacturing an LED package comprising a substrate, an LED element mounted on the substrate, and a resin layer containing a phosphor covering the LED element,
A component mounting apparatus for mounting the LED element on the substrate;
A resin coating device that applies the resin to the LED elements mounted on the substrate to form the resin layer;
A sampling inspection unit for sampling and inspecting the LED elements coated with the resin by the resin coating device;
The resin coating device is
A resin application part having an application nozzle that discharges the resin in an arbitrary application target position by variably discharging the application amount;
By controlling the resin coating unit, a coating control unit that executes a coating process for measurement for applying the resin to a light-transmitting member for light emission characteristic measurement and a production coating process for coating the LED element for actual production. When,
A light source unit that emits excitation light for exciting the phosphor;
A translucent member mounting portion on which the translucent member on which the resin is trial-coated in the measurement coating process;
A light emission characteristic measurement unit that measures the light emission characteristic of light emitted by the resin by irradiating the resin applied to the light transmitting member with the excitation light emitted from the light source unit;
An application amount derivation processing unit for deriving an appropriate resin application amount of the resin to be applied to the LED element for actual production based on a measurement result of the light emission characteristic measurement unit and a predetermined light emission characteristic;
A production execution processing unit for causing the resin application unit to execute a production application process for applying the appropriate resin application amount to the LED element by commanding the appropriate resin application amount to the application control unit;
The application control unit
At least a part of the correction period from the start of the measurement coating process until the appropriate resin coating amount is derived by the coating amount deriving processing unit and a command from the production execution processing unit is issued based on the proper resin coating amount. In the first production mode in which the production coating process is not executed,
Selectively executing any one of the second production modes for executing the production coating process in the at least part of the period;
The sampling inspection unit selects one or more of the LED elements on which the production coating process has been performed in a predetermined period before the start of the measurement coating process, and performs a first sampling test on the selected LED elements. An LED package manufacturing system comprising a sampling inspection control unit for instructing The sampling inspection control unit
2. The LED package manufacturing system according to claim 1, wherein execution of the first sampling inspection is instructed only when the appropriate resin application amount is changed. The sampling inspection control unit further includes:
In the second production mode, one or more LED elements that have been subjected to the production coating process in the at least a part of the period are selected, and an instruction to execute a second sampling inspection on the selected LED elements is given. The LED package manufacturing system according to claim 1 or 2, wherein The sampling inspection control unit
4. The LED package manufacturing system according to claim 3, wherein execution of the second sampling inspection is instructed only when the appropriate resin application amount is changed.   5. The LED package manufacturing system according to claim 1, wherein the at least a part of the period is a period excluding the correction period during the coating process for measurement. A method of manufacturing an LED package comprising a substrate, an LED element mounted on the substrate, and a resin layer containing a phosphor covering the LED element,
A production application step of applying the resin for actual production by a resin discharge unit that discharges the application amount variably;
A measurement application step of applying the resin to the translucent member as a light emission characteristic measurement by the resin discharge unit;
A translucent member mounting step of mounting the translucent member on which the resin has been trial-applied on a translucent member mounting unit including a light source unit that emits excitation light for exciting the phosphor;
A light emission characteristic measuring step of measuring the light emission characteristic of the light emitted by the resin by irradiating the resin applied to the translucent member with the excitation light emitted from the light source unit;
A coating amount derivation processing step for deriving an appropriate resin coating amount of the resin to be applied to the LED element for actual production based on the measurement result in the light emission characteristic measurement step and a predetermined light emission characteristic;
A production execution step of executing a production application process for applying the resin of the appropriate resin application amount to the LED element by commanding the derived appropriate resin application amount to an application control unit that controls the resin discharge unit;
The first production mode in which the production application step is not executed for at least a part of the correction period from the start of the measurement application step until the appropriate resin application amount is derived and a command based on the appropriate resin application amount is issued. And a selection step of selecting any mode of the second production mode for executing the production coating step in the at least part period;
Including a first inspection step of selecting one or more of the LED elements on which the production coating process has been performed in a predetermined period before the start of the measurement coating step and performing a first sampling inspection. LED package manufacturing method.   When the second production mode is selected, one or more of the LED elements on which the production coating process has been executed in the at least part of the period is selected, and a second sampling inspection is executed. The LED package manufacturing method according to claim 6.   The LED package manufacturing method according to claim 6 or 7, wherein the at least a part of the period is a period excluding execution of the measurement application step in the correction period.

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