JP5879508B2 - Resin coating apparatus and resin coating method - Google Patents

Description

  The present invention relates to a resin coating apparatus and a resin coating method 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.

  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.

JP 2007-66969 A

  However, 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. As described above, the conventional LED package manufacturing technology has a problem in that the emission characteristics of the LED package as a product vary due to variations in the emission wavelength of the individual LED elements, leading to a decrease in production yield. .

  Therefore, the present invention provides a resin coating apparatus and a resin coating that can make the light emission characteristics of the LED package uniform and improve the production yield even when the light emission wavelength of the individual LED elements varies in the LED package manufacturing system. It aims to provide a method.

The resin coating apparatus 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 covers the LED element mounted on the substrate. A resin coating apparatus for applying a resin, wherein the resin is made to emit light by controlling the resin application unit and a resin application unit that discharges the resin in a variable amount and applies the resin to any application target position. A coating control unit that executes a coating process for measurement that is applied to a light-transmissive member for measurement and a coating process that is applied to the LED element for actual production, and a light source unit that emits excitation light that excites the phosphor. A translucent member mounting portion on which the translucent member on which the resin is applied in trial in the measurement coating process is placed; and the excitation light emitted from the light source unit is transmitted to the translucent portion Coated by appropriate resin coating amount defined as the light emitting characteristics measuring unit for measuring the emission characteristics of the light emitted from the resin by irradiating the applied resin by previously measured and the measurement result of the emission characteristic measuring portion A coating amount derivation processing unit for deriving a proper resin coating amount of the resin to be applied to the LED element for actual production based on the light emission characteristics of the resin, and the coating control unit for determining the proper resin coating amount. A production execution processing unit that executes a production coating process for coating the LED element with a resin having an appropriate resin coating amount and records a performance record of the production coating process, and the coating control unit includes: The test application, the measurement of the light emission characteristics, and the derivation of the appropriate resin application amount of the resin are performed every time the production application process has passed a predetermined interval. To.

The resin coating method 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 covers the LED element mounted on the substrate. A resin application method for applying a resin, wherein the resin is applied to a translucent member as a light emission characteristic measurement test by a resin application part that discharges the resin in a variable amount, and the resin includes A translucent member placement step of placing the trial-applied translucent member on the translucent member placement portion, and excitation light emitted from a light source that emits excitation light that excites the phosphor. a light emitting characteristic measurement step of measuring the emission characteristics of the light emitted from the resin by irradiating the applied resin, the provisions by previously measured and the measurement result in the light emission characteristic measuring step A coating amount derivation step of deriving the appropriate resin coating amount of the resin to be coated on the LED element for the actual production based on the emission characteristics of the resin applied in appropriate resin coating amount of, being the derived By directing the appropriate resin application amount to the application control unit that controls the resin application unit, the production application process for applying the resin of the appropriate resin application amount to the LED element is executed and the execution results of the production application process are performed. The measurement application step, the light emission characteristic measurement step, and the application amount derivation step are executed each time a predetermined interval has passed in which the execution results of the production application process have been set in advance.

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 translucent member on which a resin is trial-applied for light emission characteristic measurement is used as the translucent member mounting portion. A measurement result obtained by measuring the light emission characteristics of the light emitted from the resin by emitting excitation light that excites the phosphor from the light source unit placed above and irradiating the resin applied to the translucent member from above; The deviation from the light emission characteristics of the resin applied at the appropriate resin application amount specified by measuring in advance is obtained, and the appropriate resin application amount of the resin to be applied to the LED element for actual production is derived based on this deviation. By performing the process to be performed every time the execution result of the production coating process in the production execution process passes a predetermined interval, a variation in emission wavelength of the individual LED elements or Even when the fabric condition is varied, with uniform emission characteristics of the LED package, thereby improving the production yield.

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 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 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 Explanatory drawing of correction | amendment execution conditions which perform emission color correction processing in 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%)). The appropriate resin coating amount of the resin 8 is also set to an appropriate value (uncomfortable expression) according to the phosphor concentration of the resin 8 to be 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. 11 ) 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. 11 ).

  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 discharging the resin 8 in a variable amount and applying it to any application target position. In addition to the pneumatic dispenser 33, various liquid discharge methods such as a plunger method using a mechanical cylinder and a screw pump method can be employed for the resin discharge mechanism 35.

  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. That is, the light emission characteristics when the light emitted from the measurement light source unit 45 is irradiated onto the translucent member 43 on which the resin 8 has been trial-applied by the resin application unit C, and the light emission characteristics including the spectroscope 42 and the light emission characteristic measurement processing unit 39. By measuring by the characteristic measuring unit and comparing the measurement result with a preset threshold value, the suitability of the preset resin coating amount defined by the resin coating 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. 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.

  A detailed configuration of the trial hitting / measurement unit 40 will be described with reference to FIG. As shown in FIG. 8A, the translucent member 43 is wound and supplied on the supply reel 47 and fed along the upper surface of the trial hitting stage 40a, and then irradiated with the translucent member mounting portion 41. It is wound around a collection reel 48 driven by a take-up motor 49 via a portion 46. As a mechanism for collecting the translucent member 43, various methods such as a method of feeding the translucent member 43 into the collection box by a feeding mechanism in addition to the method of collecting the translucent member by winding it on the collection reel 48 are adopted. Can do.

  The irradiation unit 46 has a function of irradiating the translucent member 43 with measurement light emitted from the light source unit 45, and the measurement light emitted from the light source unit 45 is contained in a light shielding box 46a having a simple dark box function. A light focusing tool 46b guided by a fiber cable is provided. The light source unit 45 has a function of emitting excitation light that excites the phosphor contained in the resin 8. In the present embodiment, the light source unit 45 is disposed above the translucent member mounting unit 41 and transmits measurement light. The light member 43 is irradiated from above via the light focusing tool 46b.

  Here, as the translucent member 43, a flat sheet-like member made of transparent resin is used 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. The embossed type etc. which were made are used (refer FIG.8 (b)). In the process in which the translucent member 43 is sent over the test hitting / measurement unit 40, the resin 8 is trial-applied to the translucent member 43 by the resin ejection head 32. In this trial application, a prescribed amount of resin 8 is applied to the translucent member 43 by the discharge nozzle 33a, as shown in FIG. 8B, with respect to the translucent member 43 whose lower surface is supported by the trial hitting stage 40a. 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 40a 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 this way, the white light emitted from the light source unit 45 is irradiated from above through the light converging tool 46b onto the light transmitting member 43 guided into the light shielding box 46a after the resin 8 is trial-coated. The light transmitted through the resin 8 applied to the translucent member 43 is disposed below the translucent member mounting portion 41 via a light transmitting opening 41 a provided in the translucent member mounting portion 41. The light is received by the integrating sphere 44. FIG. 8C shows the structure of the translucent member mounting portion 41 and the integrating sphere 44. The translucent member mounting portion 41 has a structure in which an upper guide member 41 c having a function of guiding both end surfaces of the translucent member 43 is mounted on the upper surface of the lower support member 41 b that supports the lower surface of the translucent member 43. Yes.

  The translucent member placement section 41 guides the translucent member 43 during conveyance in the test hitting / measurement unit 40, and places the translucent member 43 on which the resin 8 has been trial-applied in the measurement coating process to hold the position. It has a function to do. The integrating sphere 44 has a function of collecting the transmitted light that has been irradiated from the light focusing tool 46 b (arrow h) and transmitted through the resin 8 and led to the spectroscope 42. That is, the integrating sphere 44 has a spherical spherical reflecting surface 44 c inside, and transmitted light (arrow i) incident from the opening 44 a located immediately below the light transmitting opening 41 a is the top of the integrating sphere 44. In the process of entering into the reflection space 44b from the opening 44a provided in the light source and repeating the total reflection (arrow j) by the spherical reflecting surface 44c, it is taken out as measurement light (arrow k) from the output part 44d and is sent by the spectroscope 42. Received light.

  In the above-described configuration, the white light emitted by the LED package used for the light source unit 45 is applied to the resin 8 that has been trial-applied to the translucent member 43. In this process, the blue light component contained in the white light excites the phosphor in the resin 8 to emit yellow light. White light obtained by adding and mixing yellow light and blue light is irradiated upward from the resin 8 and is received by the spectroscope 42 via the integrating sphere 44 described above.

  The received white light is analyzed by the light emission characteristic measurement processing unit 39 to measure the light emission characteristics as shown in FIG. 7B. 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. The integrating sphere 44, the spectroscope 42, and the light emission characteristic measurement processing unit 39 emit excitation light emitted from the light source unit 45 onto the resin 8 coated with the light transmitting member 43 (here, white light emitted from the white LED). ) From above, the light emitted from the resin 8 is received from below the translucent member 43, and a light emission characteristic measuring unit for measuring the light emission characteristic of the light emitted from the resin 8 is configured. In the present embodiment, the light emission characteristic measuring unit is configured by disposing the integrating sphere 44 below the translucent member 43, and configured to receive light emitted from the resin 8 through the opening 44a of the integrating sphere 44. Has been.

  By configuring the light emission characteristic measuring unit as described above, the following effects can be obtained. That is, in the application shape of the resin 8 to be applied to the translucent member 43 shown in FIG. 8B, the lower surface side is always in contact with the upper surface of the translucent member 43 or the bottom surface of the embossed portion 43a. The lower surface of 8 is always at a reference height defined by the translucent member 43. Therefore, the height difference between the lower surface of the resin 8 and the opening 44a of the integrating sphere 44 is always kept constant. On the other hand, the upper surface of the resin 8 is not necessarily realized to have the same liquid surface shape and height due to disturbances such as application conditions by the discharge nozzle 33a, and between the upper surface of the resin 8 and the light focusing tool 46b. The interval of will vary.

  Here, considering the degree of stability when the irradiation light irradiated on the upper surface of the resin 8 is compared with the transmitted light from the lower surface of the resin 8, the irradiation light irradiated on the resin 8 is the light focusing tool 46b. Therefore, the degree of focusing is high, and the influence of the variation in the distance between the upper surface of the resin 8 and the light focusing tool 46b on the light transmission can be ignored. On the other hand, the transmitted light that has passed through the resin 8 is excitation light in which the phosphor is excited inside the resin 8, so that the degree of scattering is high, and the distance between the lower surface of the resin 8 and the opening 44 a varies. Has an influence on the degree of light being taken in by the integrating sphere 44.

  In the test hitting / measuring unit 40 shown in the present embodiment, the light emitted from the resin 8 is transmitted by irradiating the resin 8 with the excitation light emitted from the light source unit 45 as described above. Since the configuration in which light is received by the integrating sphere 44 from below the optical member 43 is employed, it is possible to determine stable light emission characteristics. Further, by using the integrating sphere 44, it is not necessary to separately provide a dark room structure in the light receiving portion, so that the apparatus can be made compact and the equipment cost can be reduced.

  As shown in FIG. 7B, the measurement result of the light emission characteristic measurement processing unit 39 is sent to the application amount derivation processing unit 38, and the application amount derivation processing unit 38 defines the measurement result of the light emission characteristic measurement processing unit 39 in advance. A deviation from the emitted light emission characteristic is obtained, and 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 based on the deviation. 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. 11).

  That is, in the resin coating method in the LED package manufacturing system shown in the present embodiment, a white LED is used as the light source unit 45 for measuring the light emission characteristics, and is prescribed in advance 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.

  In the present embodiment, the LED package 50 that emits white light is used as the light source unit 45. 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. . It is not always necessary to use the same LED package 50 as that used for the finished product. For light emission characteristics measurement, a light source device that can stably emit blue light having a constant wavelength (for example, a blue LED that emits blue light or a blue laser light source) is used as a light source unit for inspection. be able to. However, by using the LED package 50 that emits white light using a blue LED, there is an advantage that a light source device with stable quality can be selected at low cost. Here, blue light having a predetermined wavelength may be extracted using a band-pass filter.

  Instead of the test hit / measure unit 40 having the above-described configuration, a test hit / measure unit 140 having the configuration shown in FIGS. 9 and 10 may be used. That is, as shown in FIGS. 9 and 10, the test hitting / measuring unit 140 has an external structure in which a cover portion 140b is disposed above an elongated horizontal base portion 140a. The cover part 140b is provided with an opening part 140c, and the opening part 140c can be freely opened and closed by a sliding slide window 140d for application (arrow l). Inside the trial hitting / measurement unit 140, a trial hitting stage 145a for supporting the translucent member 43 from the lower surface side, a translucent member mounting portion 141 on which the translucent member 43 is placed, and a translucent member mounting portion 141. A spectroscope 42 is provided above.

  The translucent member mounting unit 141 includes a light source device that emits excitation light that excites the phosphor as in the case of the light source unit 45 illustrated in FIG. 8. The member 43 is irradiated with excitation light from the lower surface side of the light source device. The translucent member 43 is wound and supplied on the supply reel 47 in the same manner as in the example shown in FIG. 8, and is fed along the upper surface of the test strike stage 145a (arrow m), and then the translucent member mounting portion. It is wound up on a collection reel 48 driven by a winding motor 49 via between 141 and the spectroscope 42.

  In a state in which the application sliding window 140d is slid and opened, the upper surface of the test strike stage 145a is exposed upward, and the resin discharge head 32 applies the resin 8 to the light transmitting member 43 placed on the upper surface. Is possible. In this trial application, as shown in FIG. 8B, the resin 8 having a prescribed application amount is applied to the translucent member 43 by the discharge nozzle 33a with respect to the translucent member 43 whose lower surface is supported by the test strike stage 145a. This is done by discharging.

  In FIG. 10B, the translucent member 43 on which the resin 8 has been trial-applied is moved by the trial hitting stage 145a so that the resin 8 is positioned above the translucent member mounting portion 141, and the cover portion 140b is further moved. A state in which a darkroom for measuring light emission characteristics is formed between the base 140a and the base 140a is shown. An LED package 50 that emits white light is used as the light source device for the translucent member mounting portion 141. In the LED package 50, the wiring layers 4e and 4d connected to the LED element 5 are connected to the power supply device 142. When the power supply device 142 is turned on, the LED element 5 is supplied with power for light emission. The LED package 50 emits white light.

  Then, in the process in which the white light passes through the resin 8 and is irradiated to the resin 8 that has been trial-applied to the translucent member 43, the yellow light emitted from the phosphor in the resin 8 is excited by the blue light contained in the white light. White light in which light and blue light are added and mixed is irradiated upward from the resin 8. A spectroscope 42 is disposed above the trial hitting / measurement unit 140, 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 measurement processing unit 39. The emission characteristics 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 measurement processing unit 39 measures the light emission characteristic of the light emitted by 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 part. . Then, the measurement result of the light emission characteristic measurement processing unit 39 is sent to the coating amount derivation processing unit 38, and the same processing as in the example shown in FIG. 7 is executed.

  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. 11, 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 via a single storage medium such as a CD ROM, USB memory storage, SD card, and stored in the storage unit 61. Is done.

  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 measurement processing 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. Here, the application control unit 36 is provided with a light emission color correction processing unit 36a as an accompanying function. The light emission color correction processing unit 36a performs a light emission color correction process, that is, a series of work processes (trial application, measurement of light emission characteristics, and resin for the purpose of determining an appropriate resin coating amount for obtaining specified light emission characteristics. Derivation of the appropriate resin coating amount). This processing is executed by the light emission color correction processing unit 36a controlling the resin coating unit C, the light emission characteristic measurement processing unit 39, and the coating amount derivation processing unit 38.

  In addition to programs and data necessary for control processing by the application control unit 36, the storage unit 81 includes resin application information 14, map data 18, threshold data 81a, actual production application amount 81b, and correction execution condition data 83. Remember. 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 correction execution condition data 83 stores conditions for executing the light emission color correction process described above, for example, data on execution specified such as an execution interval and execution timing (see FIG. 20).

  The light emission characteristic measurement processing unit 39 performs a process of measuring the light emission characteristic of light emitted from the resin by irradiating the resin 8 applied to the light transmitting member 43 with the excitation light emitted from the light source unit 45. The application amount derivation processing unit 38 obtains a deviation between the measurement result of the light emission characteristic measurement processing unit 39 and a predetermined light emission characteristic, and based on this deviation, the resin 8 to be applied to the LED element 5 for actual production. An arithmetic process for deriving an appropriate resin application 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. The process is executed, and the performance of the production coating process is recorded in real time.

  Here, as the execution results, any one of the number of the substrates 4 on which the resin 8 is applied by the resin application part C, the number of times the resin 8 is applied by the dispenser 33 of the resin application part C, or the continuous execution time of the production application process is selected. Used. In the present embodiment, the application control unit 36 including the light emission color correction processing unit 36a performs test application and light emission every time the recorded production application execution result passes a predetermined interval. A light emission color correction process including measurement of characteristics and derivation of an appropriate resin application amount of the resin is executed. Note that the application control unit 36 may record the execution results of the production application process.

  In the configuration shown in FIG. 11, processing functions other than the function for executing work operations unique to each apparatus, for example, the function of the map creation processing unit 74 provided in the component mounting apparatus M1, and provided in the resin coating apparatus M4. 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. 12 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). 18A, 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 n). As shown in FIG. 18B, the LED element 5 held by the mounting nozzle 26a of the component mounting mechanism 26 is lowered (arrow o) 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 coating operation | work by the resin 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. 18 (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. 18 (d), 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. 11). 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. 13, 14, and 15. FIG. In FIG. 13, 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 40 a 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 characteristics in an uncured state of the resin 8 are measured by the light emission characteristic measuring section having the above-described configuration. Measure (ST13). Then, based on the light emission characteristic measurement value 39a which is the measurement result of the light emission characteristic measured by the light emission characteristic measurement unit, a non-defective product determination range of the measurement value for determining the light emission characteristic to be non-defective is set (ST14). The non-defective product determination range is stored as threshold data 81a in the storage unit 81, transferred to the management computer 3, and stored in the storage unit 61 (ST15).

  FIG. 14 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. 14A, 14B, and 14C, 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. 14A, when the phosphor concentration of the resin 8 is 5%, each of the Bin codes 12b corresponds to the application amount shown in each of the appropriate resin application amounts 15 (1). In addition, the measurement result obtained by measuring the light emission characteristics of the light emitted from the resin 8 by irradiating the resin 8 coated with the respective coating amounts with the blue light of the LED element 5 is the light emission characteristic measured value 39a (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 application 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 results (chromaticity table shown in FIG. 15). (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.

  14B and 14C 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. 14B and 14C, 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. 19A, 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 prescribed amount of the resin 8 shown in FIG. 19B 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 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 translucent member 43 drawn out to the trial placement stage 40a by the trial placement / 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, by transmitting the translucent member 43 in the test hitting / measurement unit 40, the translucent member 43 on which the resin 8 has been trial-applied is sent and placed on the translucent member mounting portion 41 (translucent member mounting step). . And the excitation light which excites a fluorescent substance is light-emitted from the light source part 45 arrange | positioned above the translucent member mounting part 41 (excitation light emission process). Then, by irradiating the resin 8 applied to the translucent member 43 from above with the excitation light, the light emitted by the resin 8 is received by the spectroscope 42 from below the translucent member 43 via the integrating sphere 44, The light emission characteristic measurement processing unit 39 measures the light emission characteristic (light emission characteristic measurement step) (ST23).

As a result, as shown in FIG. 17B, a light emission characteristic measurement value represented by the chromaticity coordinate Z (see FIG. 15) 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 so on, and the standard color at the time of application of 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 value (ST24), and as shown in FIG. 17C, the deviation obtained in (ST23) is compared with the threshold value. 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 (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. 17 (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, an appropriate resin is obtained by repeatedly performing a light emission color correction process including a measurement coating process, a translucent member placement process, an excitation light emission process, a light emission characteristic measurement process and a coating amount derivation process. The application amount is deterministically derived. 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 (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. 16 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. The production application process for applying the appropriate amount of resin 8 to the LED element 5 mounted on the substrate 4 is executed, and the execution result of the production application process is recorded (production execution process). In the process of repeatedly executing the production coating process, the light emission color correction processing unit 36a performs the resin coating unit C and the light emission characteristic measurement process based on the correction execution condition data 83 set in advance and stored in the storage unit 81. By controlling the unit 39 and the coating amount derivation processing unit 38, the light emission color correction process described above is repeatedly executed.

  That is, in the present embodiment, the emission color correction processing is executed prior to the start of the production application work, and the appropriate resin application amount is set, but the emission characteristics of the product in the actual production process depend on various factors. fluctuate. For example, the phosphor concentration in the resin 8 tends to change over time due to fluctuation factors such as sedimentation of phosphor particles in the resin, and the viscosity of the resin 8 is not necessarily constant. Further, regarding the resin discharge characteristics of the dispenser 33 to which the resin 8 is applied, even if the same discharge parameter is commanded, variations in the discharge amount are unavoidable due to the clogged state of the discharge nozzle 33a, inherent nozzle device differences, and the like. Therefore, in the process of repeatedly performing the production coating process, it is desirable to monitor the light emission characteristics of the product at an appropriate interval timing and execute the light emission color correction process to correct the appropriate resin coating amount as necessary.

  In the present embodiment, the execution timing of the light emission color correction process is determined based on the execution performance of the production coating process recorded by the production execution processing unit 37 and the correction execution condition data 83 stored in the storage unit 81. The Here, as shown in FIG. 20A, in the correction execution condition data 83, the execution performance standard 84 and the application execution condition standard 85 are divided into two standards to determine the execution timing of the emission color correction process. ing.

  In the execution result standard 84, a predefined execution result, that is, a work duration 84a indicating a series of durations from the start of work in the resin coating apparatus M4, and a number of boards indicating the number of substrates 4 produced in the series of works. 84b, the number of times of application operation 84c indicating the number of times the dispenser 33 has applied the resin 8 by applying the resin 8 in the application work is used as a specific numerical parameter indicating the execution performance. These numerical parameters recorded in real time correspond to predetermined intervals that are set in advance, that is, the interval time for the operation duration 84a, the interval number for the substrate number 84b, and the number of intervals for the coating operation count 84c. Every time elapses, the emission color correction process is executed. For these specified intervals, the emission color correction processing may always be executed at the same interval using a preset fixed value, and the product state transition is performed by the emission characteristic processing function provided in the resin coating apparatus M4. The tendency may be determined, and the specified interval may be dynamically optimally set according to the apparatus state.

  In the application execution condition standard 85, operations / events that are presumed to be related to variations in the amount of resin application that causes the light emission characteristics to fluctuate are defined in advance, and these operations / events are executed. It is considered that the application execution condition for the substrate 4 by the dispenser 33 has been changed. Examples of such operations / events in the work include a resin replenishment 85a for replacing the syringe containing the resin 8 in the dispenser 33, a nozzle replacement 85b for cleaning or replacing the discharge nozzle 33a of the dispenser 33, and the dispenser 33. The air pressure adjustment 85c for changing the air pressure for resin discharge supplied to the is listed. When an execution operation input to that effect is made during execution of such an operation / event, the application control unit 36 determines that the application execution condition in the production application process has been changed, and executes the emission color correction process for each change. Let

  FIG. 20B shows the timing of the emission color correction process executed based on such correction execution condition data 83. Here, a method is shown in which the above-mentioned specified interval is set using the light emission characteristic processing function of the resin coating apparatus M4. That is, in the graph of FIG. 20B, the horizontal axis represents the operation duration as a numerical parameter indicating the performance of execution, and the vertical axis represents the measured light emission characteristic value. The Δ mark shown at the bottom of the graph indicates the correction execution timing at which the emission color correction process is executed.

  After the production coating process is started, the light emission characteristics of the product are measured at an appropriately set monitoring pitch. Then, the elapsed time until the timing when the value of the measurement result reaches the threshold limit (upper limit or lower limit) set as the non-defective product determination range is determined as the reference interval T1, and the emission color correction processing is performed at this timing. Is executed. If the operation / event such as resin replenishment 85a, nozzle replacement 85b,... Corresponding to the change of the application execution condition is executed after the production application process is started, the application control unit 36 sets the application execution condition. The light emission color correction process is executed for each change.

  The intervals T2 and T3 that define the execution timing of the next light emission color correction process may be set to the same value following the interval T1, but in order to eliminate the loss time due to the execution of the light emission color correction process as much as possible. The intervals T2 and T3 may be set to be longer than the interval T1 by a time increment determined by a predetermined algorithm. Here, the example in which the operation duration 84a is used as a numerical parameter indicating the execution result has been described, but the interval is similarly set even when the number of substrates 84b and the number of application operations 84c are used as numerical parameters indicating the execution result. . In this case, the interval is based on the number of sheets and the number of times.

  That is, after the start of (ST31) in FIG. 16, it is always monitored whether or not the specified interval specified in the execution result standard 84 of the correction execution condition data 83 has elapsed or whether the application execution condition has been changed. The Here, if NO, it is determined that the properties of the resin 8 and the phosphor concentration are little changed and the application execution conditions are not changed, and the production application is executed while maintaining the same actual production application amount 81b. Repeat (ST31). If it is determined YES in (ST32), it is determined that there is a possibility of variation in the amount of resin applied due to changes in the properties of the resin 8, the phosphor concentration, or variations in application execution conditions, and the process returns to (ST22). A light emission color correction process for correcting the appropriate resin coating amount based on the measurement of the light emission characteristics and the measurement result is executed. During the production application execution (ST31), the monitoring of (ST32) is always performed, and the emission color correction is repeatedly executed according to the monitoring result to finish the resin application for a predetermined number of LED mounting portions 4b. Thus, the coating operation by the resin coating apparatus M4 is completed (ST33).

  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. 19C, 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 present embodiment individually measures in advance 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. 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; The map data 18 associated with each of the substrates 4 is created on the basis of the map data creating means, the map data 18 and the resin application information 14. The appropriate resin coating amount of the resin 8 for having a light emission characteristic of, and has a structure in which 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 that is trial-coated on the translucent member 43 and a production coating process that is applied to the LED element 5 for actual production, and a light source unit 45 that emits excitation light that excites the phosphor. In the measurement coating process, the light transmitting member mounting portion 41 on which the light transmitting member 43 on which the resin 8 is trial-coated is placed, and the resin in which the excitation light emitted from the light source portion 45 is applied to the light transmitting member 43 A light emission characteristic measuring unit for measuring the light emission characteristic of light emitted from the resin 8 by irradiating the light, and correcting the appropriate resin coating amount based on the measurement result of the light emission characteristic measuring part and the predetermined light emission characteristic. LED By instructing the application control unit 36 to apply the derived appropriate resin application amount to the application amount derivation processing unit 38 for deriving the appropriate resin application amount for actual production to be applied to the child 5, It is configured to include a production execution processing unit 37 that executes a production application process for applying resin to the LED elements 5 and records the execution results of the production application process.

  In the above-described configuration, the control function of the application control unit 36 makes a trial application in which the resin 8 is applied to the translucent member 43 for light emission characteristic measurement. Execute the production coating process by performing a production color coating process, which is a series of processes for deriving an appropriate amount of resin to be applied to the LED element 5 for actual production based on the measurement of the light emission characteristics and the measurement result. It is executed every time when the actual result passes a predetermined interval or when the application execution condition by the dispenser 33 is changed.

  As a result, even when the emission wavelengths of the individual LED elements 5 vary, the emission characteristics of the LED package 50 are made uniform by the emission color correction process to improve the production yield and the execution timing of the emission color correction process. Can be set rationally, and the number of required emission color correction processes can be reduced to improve productivity.

  The resin coating apparatus and resin coating method of the present invention can improve the production yield by making the light emission characteristics of the LED package uniform by the light emission color correction processing even when the light emission wavelength of the individual LED elements varies. Field of manufacturing an LED package having an effect that the productivity can be improved by reducing the number of required emission color correction processes, and the LED element is covered with a resin containing a phosphor. Is available in

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, 140 Trial strike / measurement unit 40a Trial strike stage 41, 141 Translucent member mounting portion 42 Spectroscope 43 Transparent Optical member 44 Integrating sphere 46 Irradiation part 50 LED package

Claims (6)

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;
Appropriateness of the resin to be applied to the LED element for actual production based on the measurement result of the light emission characteristic measuring unit and the light emission characteristic of the resin applied with an appropriate resin application amount defined by measuring in advance A coating amount derivation processing unit for deriving a resin coating amount;
A production execution process for recording the execution results of the production application process while causing the application control unit to instruct the application control unit to execute the production application process for applying the resin of the appropriate resin application amount to the LED element. With
The application control unit causes the test application, the measurement of light emission characteristics, and the derivation of the appropriate resin application amount of the resin each time when a predetermined interval in which the execution result of the production application process is set in advance elapses. Resin coating device.   The number of the substrates on which the resin is applied by the resin application unit, the number of times of resin application by the resin application unit, or the continuous execution time of the production application process is used as the execution result. 1. The resin coating apparatus according to 1.   3. The resin coating apparatus according to claim 1, wherein an LED element is used as the light source unit. A resin coating method 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 applying the resin to cover the LED element mounted on the substrate. There,
An application process for measurement in which the resin is applied to the translucent member for light emission characteristic measurement by a resin application part 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 the translucent member placement section;
A light emission characteristic measuring step of measuring a light emission characteristic of light emitted from the resin by irradiating the resin applied to the light transmitting member with excitation light emitted from a light source unit that emits excitation light for exciting the phosphor; ,
Appropriate resin of the resin to be applied to the LED element for actual production based on the measurement result in the light emission characteristic measuring step and the light emission characteristic of the resin applied with the appropriate resin application amount defined by measuring in advance A coating amount derivation process for deriving a coating amount;
By instructing the derived appropriate resin application amount to the application control unit that controls the resin application unit, the production application process for applying the appropriate resin application amount of resin to the LED element is executed and the production application process is performed. Production execution process to record the execution results of
The resin coating method, wherein the measurement coating step, the light emission characteristic measurement step, and the coating amount derivation step are executed each time a predetermined interval in which the execution results of the production coating processing are set in advance elapses.   The number of the substrates on which the resin is applied by the resin application unit, the number of times of resin application by the resin application unit, or the continuous execution time of the production application process is used as the execution result. 4. The resin coating method according to 4. Using the LED element sealed with a resin that does not contain a phosphor as the light source part, the light emission characteristics of the resin applied with the appropriate resin application amount defined by the measurement in advance were applied to the LED element. 5. The normal light emission characteristics required for a finished product in which the resin is cured are light emission characteristics that are biased by a difference in light emission characteristics due to the resin being in an uncured state. Or the resin coating method of 5.

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