JP2015002186A - Resin coating device and resin coating method in led package manufacturing system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a resin coating device and a resin coating method in an LED package manufacturing system capable of increasing the production efficiency by reducing the time for properly correcting the resin coating amount and capable of preventing production of a defective product caused by using an improper correction value.SOLUTION: In a resin coating which is used for manufacturing an LED package, before measuring the luminescence characteristic, which is performed after test-coating a resin 8 to a concave portion of an emboss part of a translucent member 43 to measure the luminescence characteristic, an air blow step is carried out in which an air blow nozzle 33b blows a gas to uniform the surface of the resin 8 which is test-coated on the translucent member 43. With this, the surface of the test-coated resin 8 can be swiftly stabilized and the uniform coating thickness at the measurement portion is obtained.

Description

  The present invention relates to a resin coating apparatus and a resin coating method in an LED package manufacturing system 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 this patent document example, after mounting an LED element on the bottom surface of a concave mounting portion having a reflective surface formed on a side wall, YAG phosphor particles are placed in a mounting portion in which YAG phosphor particles are dispersed in the mounting portion. An LED package is configured by injecting dispersed silicone resin, 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.

  In the above-described prior art examples, there is 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. As a result, the number of defective products deviating from the acceptable quality range has been inevitably increased.

  In order to minimize such variations in the light emission characteristics, it is required to manage the resin coating amount correctly. Therefore, the light emission characteristics of light emitted by this resin are targeted for the resin that has been trial-applied for measuring the light emission characteristics. Measuring is done. In this method, an appropriate resin application amount of the resin to be applied to the LED element for actual production is derived based on a deviation obtained by comparing the light emission characteristic measured by the trial application with a predetermined light emission characteristic. Yes.

JP 2007-66969 A

  However, the following inconveniences have been pointed out due to the characteristics of the resin in the light emission characteristic measurement by the above-described trial application. That is, in order to obtain a correct measurement result in the light emission characteristic measurement, it is required that the shape of the trially applied resin is stable and the application thickness of the measurement target portion is converged to a predetermined value. However, since a resin having a high viscosity such as a silicone resin or an epoxy resin is used as the type of resin applied to the LED element, it takes a certain amount of time for the surface shape to stabilize sufficiently after being applied from the discharge nozzle. . The amount of coating correction is done on a trial and error basis, and usually it is necessary to repeat the light emission characteristic measurement multiple times. Therefore, it takes time to obtain an appropriate correction value for resin coating amount correction, which hinders production efficiency. And an increase in defective products due to application of resin using an inappropriate correction value.

  Therefore, the present invention shortens the time required to properly correct the resin coating amount to improve production efficiency, and can prevent the generation of defective products due to using an inappropriate correction value. An object is to provide a resin coating apparatus and a resin coating method in a package manufacturing system.

  The resin coating apparatus in the LED package manufacturing system of the present invention is used in an LED package manufacturing system for manufacturing an LED package in which an LED element mounted on a substrate is covered with a resin containing a phosphor, and the LED mounted on the substrate. A resin coating apparatus in an LED package manufacturing system that covers an element and coats the resin, the resin coating unit that discharges the resin in a variable amount and applies the resin to any application target position, and the resin coating unit. A control unit for controlling to perform a measurement application process for applying the resin to a light-transmitting member for light emission characteristic measurement and a production application process for applying to the LED element for actual production; and the phosphor. A light source unit that emits excitation light that excites the light, and a translucent member on which the resin is trial-coated in the measurement coating process Light-emitting characteristic measurement that measures the light-emitting characteristic of light emitted from the resin by irradiating the resin applied to the light-transmitting member with the excitation light emitted from the light-transmitting member mounting part. A gas spraying unit that blows a gas to level the surface shape of the trial-applied resin prior to the measurement of the light emission characteristics on the translucent member after resin application in the coating process for measurement, and the light emission By obtaining a deviation between the measurement result of the characteristic measurement unit and the light emission characteristic defined in advance, and correcting the application amount based on this deviation, an appropriate resin application amount for actual production to be applied to the LED element is obtained. Derived application amount derivation processing unit, and production execution processing unit for instructing the derived appropriate resin application amount to the application control unit and executing a production application process for applying the appropriate resin application amount of resin to the LED element When With was.

  The resin coating method in the LED package manufacturing system of the present invention is a LED package manufacturing system for manufacturing an LED package in which an LED element mounted on a substrate is covered with a resin containing a phosphor, and a plurality of LEDs mounted on the substrate. A resin coating method in an LED package manufacturing system that covers an element and applies the resin. The LED package manufacturing system includes: a component mounting device that mounts a plurality of LED elements on the substrate; and a plurality of LED elements. Element characteristic information providing means for providing information obtained by separately measuring emission characteristics including emission wavelength in advance as element characteristic information, and appropriate resin application of the resin for obtaining an LED package having the prescribed emission characteristics Information corresponding to the quantity and the element characteristic information is provided as resin application information A map data associating the grease information providing means, the mounting position information indicating the position of the LED element mounted by the component mounting apparatus on the board, and the element characteristic information of the LED element is created for each board. Based on the map data creation means, the map data and the resin application information, the resin of the proper resin application amount for providing the regular light emission characteristics required for the finished product is applied to each LED element mounted on the substrate. A measurement application step of applying the resin to the light-transmitting member as a light emission characteristic measurement by a resin discharge unit that discharges the resin in a variable amount, and the resin is a test application A translucent member mounting step of mounting the translucent member on a translucent member mounting unit including a light source unit that emits excitation light that excites the phosphor, and the light source unit Irradiating the resin applied to the translucent member with the emitted excitation light from the light emission characteristic measuring step for measuring the light emission characteristic of the light emitted from the resin, and prior to the measurement of the light emission characteristic, after the resin application Obtain a deviation between the gas spraying step of blowing gas in order to level the surface shape of the trial-applied resin on the translucent member, and the measurement result in the light emission characteristic measurement step and a predetermined light emission characteristic. Based on the application amount derivation processing step of deriving the appropriate resin application amount for actual production to be applied to the LED element by correcting the appropriate resin application amount based on the calculated appropriate resin application amount A production execution step of causing the resin coating apparatus to execute a production coating process for coating the LED element with the appropriate amount of resin applied to the LED element.

  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 measurement coating in which a resin is trial-coated on a light-transmitting member as a light emission characteristic measurement by a resin discharge portion. Prior to the measurement of the light emission characteristics performed after the step, the test-applied resin is performed by performing a gas spraying process in which a gas is blown to level the surface shape of the test-applied resin on the light-transmitting member after the resin application. The shape of the coating can be quickly stabilized to converge the coating thickness of the measurement target part, reducing the time required to properly correct the resin coating amount, improving production efficiency, and improper correction values. It is possible to prevent the occurrence of defective products due to use.

The block diagram which shows the structure of the LED package manufacturing system of one embodiment of this invention Structure explanatory drawing of the LED package manufactured by the LED package manufacturing system of one embodiment of this invention Explanatory drawing of the supply form of LED element used in the LED package manufacturing system of one embodiment of this invention, and element characteristic information Explanatory drawing of the resin application | coating information used in the LED package manufacturing system of one embodiment of this invention Explanatory drawing of a structure and function of the component mounting apparatus in the LED package manufacturing system of one embodiment of this invention Explanatory drawing of the map data used in the LED package manufacturing system of one embodiment of this invention Explanatory drawing of a structure and function of the resin coating apparatus in the LED package manufacturing system of one embodiment of this invention Explanatory drawing of the light emission characteristic test | inspection function with which the resin coating apparatus was equipped in the LED package manufacturing system of one embodiment of this invention Explanatory drawing of the air blowing process after the trial application | coating of resin performed prior to the light emission characteristic measurement in the LED package manufacturing system of one embodiment of this invention The block diagram which shows the structure of the control system of the LED package manufacturing system of one embodiment of this invention Flowchart of LED package manufacturing by LED package manufacturing system of one embodiment of the present invention Flow chart of threshold data creation processing for non-defective product determination in LED package manufacturing system of one embodiment of the present invention Explanatory drawing of the threshold value data for good quality determination in the LED package manufacturing system of one embodiment of the present invention Chromaticity diagram for explaining threshold data for non-defective product determination in the LED package manufacturing system of one embodiment of the present invention The 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 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 Process explanatory drawing which shows the LED package manufacturing process by the LED package manufacturing system of one embodiment of this invention 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, the component mounting apparatus M1, the curing apparatus M2, the wire bonding apparatus M3, the resin coating apparatus M4, the curing apparatus M5, and the piece cutting apparatus M6 are connected by the LAN system 2. These devices are connected and controlled by the management computer 3 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.

  1 shows an example in which a production line is configured by arranging the components mounting device M1 to the piece cutting device M6 in series, but the LED package manufacturing system 1 does not necessarily have such a line configuration. However, as long as the information transmission described in the following description is appropriately performed, each process work may be 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 contained phosphor is mixed with yellow light to emit light, and is 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 for which the light emission characteristic measurement is completed in this way are sorted for each characteristic rank as shown in FIG. 3D, and are distributed into five types according to each characteristic rank. Attached individually to 13a. Thereby, the three types of LED sheets 13A, 13B in which the LED elements 5 corresponding to the Bin codes [1], [2], [3], [4], and [5] are adhered and held on the adhesive sheet 13a, respectively. 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, if the LED 8 is covered and the resin 8 is accurately applied 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 an appropriate amount of supplying phosphor particles. This ensures the normal emission wavelength required for the finished product after the resin is thermally cured.

  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%)). 3), and an appropriate resin coating amount of the resin 8 is used, and a numerical value corresponding to the phosphor concentration of the resin 8 to be used is used. 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] are applied. Resin 8 of VD0, VE0 (appropriate resin application amount 15 (1)) is applied. Similarly, when the resin having the phosphor concentration D2 is applied, the appropriate resin application amounts VF0, VG0, VH0 for the Bin codes [1], [2], [3], [4], and [5], respectively. , VJ0, VK0 (appropriate resin coating amount 15 (2)) of resin 8 is applied. In addition, 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. , VR0 (appropriate resin application amount 15 (3)) of resin 8 is applied. The appropriate resin coating amount is set for each of a plurality of different phosphor concentrations as described above, in order to ensure quality by applying the resin 8 having the optimum phosphor concentration according to the degree of variation in the emission wavelength. This is because it is more preferable.

  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). Further, the component mounting portion B is disposed on the side of the board transport mechanism 21, and 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 element 5 on the substrate 4 by the component mounting apparatus M1, any of the LED sheets 13A, 13B, 13C, 13D, and 13E is used in the element mounting program created in advance, that is, in the individual mounting operation by 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 for each board ID code 14a that identifies each board.

  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 mounted at the lower end and to be able to blow air with the air blow nozzle 33b. 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.

  Resin 8 is supplied to the resin discharge head 32 in a state of being stored in a syringe attached to the dispenser 33A, and the resin 8 in the dispenser 33A is discharged by applying air pressure into the dispenser 33A by the resin discharge mechanism 35A. 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 35A 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 discharging the resin 8 in a variable amount and applying it to any application target position. The resin discharge head 32 is provided with an air blow unit 33B having an air blow nozzle 33b with a nozzle port facing downward. By supplying air pressure to the air blow unit 33B by the air blowing mechanism 35B, the air blow nozzle 33b is provided. Air can be blown downward from 33b.

  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 amount of the phosphor particles to 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. And the resin application part C provided in the resin application apparatus M4 shown in the present embodiment is a measurement application process for applying the resin 8 to the translucent member 43 having the embossed part 43a for the above-mentioned light emission characteristic measurement, It has a function of executing together with a production coating process for coating the LED elements 5 mounted on the substrate 4 for actual production. 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, as the translucent member 43, an embossed type in which an embossed portion 43a corresponding to the concave shape of the LED package 50 is provided on the lower surface of a transparent resin tape material is used, and the embossed portion 43a includes: The resin 8 is applied by the discharge nozzle 33a.

  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, as shown in FIG. 8B, a prescribed application amount is applied to the concave portion 43b on the upper surface of the embossed portion 43a of the translucent member 43 supported on the lower surface side by the trial strike stage 45. The resin 8 is applied by discharge. 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.

  Here, the technical significance of air blowing by the air blow nozzle 33b will be described with reference to FIG. In the trial hitting stage 45, first, as shown in FIG. 9A, a predetermined amount of resin 8 is applied to the recess 43b of the embossed portion 43a by the discharge nozzle 33a. Next, as shown in FIG. 9B, air having a specified pressure and flow rate is blown to the recess 43b immediately after application by the air blow nozzle 33b. As a result, the resin 8 in the concave portion 43b, which has been in an upward convex shape immediately after application, is spread by air to form a concave portion 8a. Thereafter, the surface shape of the resin 8 in the recess 43b changes with the passage of time. As shown in FIG. 9C, the initial shape 8b having a large degree of recess, as shown in FIG. The degree is reduced to change to a stable shape 8c having a substantially planar shape near the center. Data such as suitable pressure and flow rate in air blowing is obtained in advance by individual trials and stored in the storage unit 81 as air blow data.

  As a result, the resin thickness in the vicinity of the central portion to be measured for light emission characteristics in the applied resin 8 changes from the unstable thickness d1 in the initial shape 8b to the stable thickness d2 converged to a steady value in the stable shape 8c. Change. In trials conducted on a plurality of types of resins, the resin in the recesses 43b flows between the case where the resin is left alone after application and the case where air is blown immediately after application as in the present embodiment. Thus, it has been found that there is a large difference in the time until stabilization to a shape suitable for the measurement of light emission characteristics.

  For example, it is empirically demonstrated that the time required for stabilization can be shortened to about half of 60 seconds by blowing air under application conditions such as resin materials and embossed shapes that require about 120 seconds to stabilize under natural conditions. It has been confirmed. Therefore, the air blowing unit 33B and the air blowing mechanism 35B including the air blowing nozzle 33b are used for the resin 8 that has been trial-applied to the recess 43b of the translucent member 43 after the resin application before the measurement of the light emission characteristics in the measurement application process. It is a gas blowing part that blows air (gas) to level the surface shape.

  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 light transmissive member mounting portion 41, an LED package 50 * having a configuration in which the resin 8 in the LED package 50 is replaced with a transparent resin 80 containing no phosphor particles is used. In the LED package 50 *, the wiring layers 4e and 4d connected to the LED element 5 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. Thus, the LED element 5 emits blue light.

  Then, in the process in which the blue light is transmitted through the transparent resin 80 and then irradiated to the resin 8 that has been trial-applied in the concave portion 43b of the translucent member 43, the yellow light emitted from the phosphor in the resin 8 is excited and emitted. White light in which blue light is added and mixed 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. In this light emission characteristic measurement, in the present embodiment, it is possible to efficiently converge the thickness of the measurement target site to the appropriate thickness for high-precision light emission characteristic measurement by the air blowing effect as described above. It is possible to achieve both measurement accuracy and improved work efficiency.

  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 35A, and performs 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. 10).

  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. 10, 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 addition to programs and data necessary for control processing by the system control unit 60, the storage unit 61 stores element characteristic information 12, resin application information 14, and map data 18 and threshold data 81a as necessary. ing. 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 by rotating a single storage medium such as a CD 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 35A, the air blowing mechanism 35B, and the test hitting / measurement unit 40 that constitute the resin application part C, thereby transmitting the resin 8 for measuring the light emission characteristics. A process for performing a measurement coating process for trial coating on the member 43 and a production coating process for coating 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. 10, 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 coating 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. It may be configured.

  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. 11 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. 17A, 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). 17 (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 as shown in FIG. 17 (c), the resin adhesive 23 is thermally cured to become a resin adhesive 23 *. The LED 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. 17D, 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 in order to set a pass / fail judgment threshold value in production coating (see threshold value data 81a shown in FIG. 10). 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. 12, 13, and 14. FIG. In FIG. 12, first, a resin 8 containing a 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. 13 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 applying the resin 8 containing the phosphor with the genuine content are non-defective products. The non-defective product judgment range (threshold value) of the measured value for judgment is shown. In FIGS. 13A, 13B, and 13C, the phosphor concentration in the resin 8 is 5%. 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. 13 (a), when the phosphor concentration of the resin 8 is 5%, the Bin code 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 coordinate ZA0 (X _A0 , Y _A0 on the chromaticity table shown in FIG. ).

  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.

  13B and 13C show the emission characteristic measurement values and the non-defective product determination range (threshold value) when the phosphor concentrations of the resin 8 are 10% and 15%, respectively. 13 (b) and 13 (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 transported to the resin coating device M4 (ST7), and as shown in FIG. 18A, 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 value data 81a, and the resin application information 14, an operation of applying a specified amount of the resin 8 shown in FIG. 18B covering the LED element 5 is performed (ST8). Details of this resin application work processing will be described with reference to FIGS. First, at the start of the resin coating operation, the resin container is exchanged as necessary (ST21). That is, the dispenser 33 </ b> A attached to the resin discharge head 32 is replaced with one containing a phosphor 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. Is applied in the recess 43 b on the upper surface of the embossed portion 43 a of the translucent member 43. 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 35A, 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-described 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.

  Thereafter, as shown in FIG. 8B, air blowing is performed by the air blow nozzle 33b on the recess 43b after the resin application (ST23). That is, prior to the measurement of the light emission characteristics, air, which is a gas, is blown to the concave portion 43b of the translucent member 43 after resin application in order to level the surface shape of the test-applied resin 8 (gas spraying process). Thereby, the surface shape of the resin 8 in the recessed part 43b is leveled, and it will be in the state suitable for light emission characteristic measurement. Next, by sending the translucent member 43 in the test hitting / measurement unit 40, the resin 8 is trial-applied in the recess 43b, and further, the translucent member 43 after air is blown to the resin 8 is sent to excite the phosphor. It mounts on the translucent member mounting part 41 provided with the LED element 5 as a light source part which light-emits the excitation light to perform (translucent member mounting process).

  Then, the resin state is determined by irradiating the resin 8 applied to the translucent member 43 with the excitation light emitted from the LED element 5 (ST24). In this resin state determination, light emission characteristic measurement is performed in which the application thickness of the resin 8 applied to the translucent member 43 is executed in the next step, that is, the light emitted by the resin 8 is received by the spectroscope 42 and the light emission characteristic measurement unit 39 is received. This is performed for the purpose of empirically confirming whether or not the elapsed time after the resin application that defines the measurement timing is set appropriately when performing the light emission characteristic measurement.

  Here, the emission characteristic measurement is performed a plurality of times while changing the elapsed time after resin application, and the elapsed time after resin application is determined from the obtained measurement results that the variation in the measured value has converged within the allowable range. Confirm empirically. Thus, after it is determined that the resin state is good, the light emission characteristic measurement for finally detecting the light emission characteristic used in executing the production coating is performed (light emission characteristic measurement step) (ST25). ).

As a result, as shown in FIG. 16B, a light emission characteristic measurement value represented by the chromaticity coordinate Z (see FIG. 14) is obtained. This measurement result is not necessarily based on the above-mentioned error in the coating amount and the change in the concentration of the phosphor particles in the resin 8, and so on, and the standard color at the time of applying the appropriate resin shown in FIG. It does not coincide with the degree coordinates ZA0 to ZE0. For this reason, the deviation (ΔX _A) 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. , ΔY _A ) to (ΔX _E , ΔY _E ) are determined to determine whether correction is necessary to obtain desired light emission characteristics.

Here, it is determined whether or not the measurement result is within the threshold (ST26), and as shown in FIG. 16C, the deviation obtained in (ST23) is compared with the threshold. Thus, it is determined whether the deviations (ΔX _A , ΔY _A ) to (ΔX _E , ΔY _E ) are within ± 10% of 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 (ST27). That is, the deviation between the measurement result in the light emission characteristic measurement process and the predetermined light emission characteristic is obtained, and as shown in FIG. 16 (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. Based on the corrected appropriate resin coating amount (VA2 to VE2), the processes of (ST22), (ST23), (ST24), (ST25), (ST26), and (ST27) are repeatedly executed, and (ST26) By confirming that the deviation between the measurement result and the predetermined light emission characteristic is within the threshold value, the appropriate resin application 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.

  After that, the process moves to the next step, and discarding is executed (ST28). 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 33A and the resin discharge mechanism 35A are stabilized. In this way, when the appropriate resin coating amount that gives the desired light emission characteristics is determined, the production coating is executed (ST29). That is, when the production execution processing unit 37 instructs the application control unit 36 that controls the resin discharge mechanism 35A, 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 coatings by the dispenser 33A is counted, and it is monitored whether or not the number of coatings has passed a predetermined number of times (ST30). 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 (ST29) is repeated while maintaining the same actual production coating amount 81b. If the predetermined number of times has been confirmed in (ST30), 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 same measurement of light emission characteristics is performed thereafter. And the coating amount correction process based on the measurement result is repeatedly executed.

  When the resin application for one substrate 4 is thus completed, the substrate 4 is sent to the curing device M5, and the resin 8 is cured by heating 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 8 *, 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.

  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 unit C that discharges the resin 8 in a variable amount and applies the resin 8 to an arbitrary coating target position, and the resin coating unit C. A coating control unit 36 that executes a coating process for measurement to be applied to the translucent member 43 and a production coating process to be applied to the LED element for actual production, and a light source unit that emits excitation light that excites 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 measurement application process is placed, and the excitation light emitted from the light source unit on the translucent member 43. The light emission characteristic measuring unit 39 that measures the light emission characteristic of the light emitted from the resin 8 by irradiation, and the deviation between the measurement result of the light emission characteristic measuring unit 39 and the predetermined light emission characteristic is obtained, and an appropriate value is determined based on this deviation. Resin application amount By correcting, by instructing the application control unit 36 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, 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 for manufacturing the LED package 50 in which the LED element 5 is covered with a resin containing a phosphor, the light transmissive member 43 obtained by trial coating of the resin 8 for light emission characteristic measurement 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 translucent member 43 with the excitation light emitted from the light source unit, placed on the translucent member placement unit 41 and A deviation from the prescribed light emission characteristics can be obtained, and an appropriate resin application 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, prior to the measurement of the light emission characteristics performed after the measurement application, a gas spraying step of blowing a gas to equalize the surface shape of the resin 8 that has been trial-applied to the recess 43b of the translucent member 43 after the resin application is performed. By executing, it is possible to quickly stabilize the shape of the test-applied resin 8 and converge the application thickness of the measurement target portion. Accordingly, it is possible to improve the production efficiency by shortening the time for properly correcting the resin coating amount, and to prevent the generation of defective products due to using an inappropriate correction value.

  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 is a 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 resin coating apparatus and the resin coating method in the LED package manufacturing system according to the present invention result in shortening the time for properly correcting the resin coating amount to improve production efficiency and using an inappropriate correction value. Therefore, the present invention can be used in the field of manufacturing an LED package having an LED element 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 33A Dispenser 33a Discharge Nozzle 33B Air Blow Unit 33b Air Blow Nozzle 40 Test Strike / Measurement Unit 41 Translucent Member Placement Unit 42 Spectroscope 43 Translucent Member 45 Trial strike stage 50 LED package

Claims (2)

A resin coating apparatus that is used in an LED package manufacturing system for manufacturing an LED package in which an LED element mounted on a substrate is covered with a resin containing a phosphor, and that coats the resin covering the LED element mounted on the substrate. There,
A resin application part that discharges the resin in a variable amount and applies it to any application target position;
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;
In the measurement coating process, a gas spraying unit that blows gas to level the surface shape of the test-applied resin prior to the measurement of the light emission characteristics on the translucent member after resin coating,
Appropriate resin application for actual production to be applied to the LED element by obtaining a deviation between the measurement result of the light emission characteristic measuring unit and a predetermined light emission characteristic and correcting the application amount based on this deviation A coating amount derivation processing unit for deriving the amount;
A production execution processing unit for instructing the derived appropriate resin application amount to the application control unit and executing a production application process for applying the resin of the appropriate resin application amount to the LED element; Resin coating device in LED package manufacturing system. In an LED package manufacturing system for manufacturing an LED package formed by covering LED elements mounted on a substrate with a resin containing a phosphor, the LED package manufacturing system for applying the resin to cover a plurality of LED elements mounted on the substrate A resin coating method in which
The LED package manufacturing system includes a component mounting apparatus for mounting a plurality of the LED elements on the substrate, and information obtained by separately measuring light emission characteristics including light emission wavelengths of the plurality of LED elements in advance. Resin information providing information as a resin application information corresponding to the element characteristic information providing means provided as the above, and an appropriate resin application amount of the resin for obtaining an LED package having a prescribed light emission characteristic and the element characteristic information Map data for creating, for each board, map data associating providing means and mounting position information indicating the position of the LED element mounted on the board by the component mounting apparatus with the element characteristic information on the LED element Based on the creation means, the map data, and the resin coating information, it has regular emission characteristics required for the finished product. The appropriate resin coating amount of the resin for, and a resin coating device for applying to each LED element mounted on the substrate,
An application process for measurement in which the resin is applied to the translucent member as a light emission characteristic measurement by a resin discharge unit that discharges the resin in a variable amount.
A translucent member placement step of placing the translucent member on which the resin has been trial-applied on a translucent member placement portion having a light source that emits excitation light that excites 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;
Prior to the measurement of the light emission characteristics, a gas blowing step of blowing a gas to level the surface shape of the resin applied to the light-transmitting member after the resin application,
Appropriate for actual production to be applied to the LED element by obtaining a deviation between the measurement result in the light emission characteristic measuring step and a predetermined light emission characteristic and correcting the appropriate resin application amount based on the deviation. A coating amount derivation process for deriving a resin coating amount;
And a production execution step for causing the resin coating apparatus to perform a production coating process for coating the LED element with the resin having the proper resin coating amount based on the derived appropriate resin coating amount. Resin application method in the system.

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