WO2014199926A1

WO2014199926A1 - Chromaticity coordinate inspection method for fluorescent-material-dispersed sheet, manufacturing method for fluorescent-material-dispersed sheet, manufacturing method for light conversion member, and manufacturing method for led package

Info

Publication number: WO2014199926A1
Application number: PCT/JP2014/065131
Authority: WO
Inventors: 谷田　正道; 長嶋　達雄
Original assignee: 旭硝子株式会社
Priority date: 2013-06-13
Filing date: 2014-06-06
Publication date: 2014-12-18

Abstract

A chromaticity coordinate inspection method for a fluorescent-material-dispersed sheet is provided that makes it possible to evaluate even subtle differences in product characteristics in a fluorescent-material-dispersed sheet containing a dispersed fluorescent material. A chromaticity coordinate inspection method for a fluorescent-material-dispersed sheet, which is a glass sheet containing dispersed fluorescent particles, said method having a division setting step for setting divisions having a prescribed size on a flat surface of the fluorescent-material-dispersed sheet, a spectroscopy step for causing excitation light to enter one of the divisions set in the division setting step from one surface of the division and measuring the spectrum of the transmitted light obtained through the irradiation from the fluorescent-material-dispersed sheet caused by the excitation light, a chromaticity coordinate calculation step for calculating chromaticity coordinates from the spectroscopic data obtained in the spectroscopy step, and a mapping step for repeating the spectroscopy step and chromaticity coordinate calculation step for each divisions set in the division setting step and associating and storing divisions and chromaticity coordinates.

Description

Method for inspecting chromaticity coordinates of phosphor dispersion sheet, method for producing phosphor dispersion sheet, method for producing light conversion member, and method for producing LED package

The present invention relates to a chromaticity coordinate inspection method of a phosphor dispersion sheet, a method of manufacturing a phosphor dispersion sheet, a method of manufacturing a light conversion member, and a method of manufacturing an LED package, and in particular, individual light conversion members in the phosphor dispersion sheet. The chromaticity coordinate inspection method which makes it possible to evaluate the variation in characteristics from the chromaticity coordinates corresponding to the above, a phosphor dispersion sheet manufacturing method to which the inspection method is applied, a light conversion member manufacturing method, and an LED package manufacturing method.

White LEDs are used as a low-power white illumination light source, and are expected to be applied to illumination applications. In general, the white light of a white LED is light of yellow, green, red, etc., which is a blue light emitted from a blue LED element serving as a light source and a color (wavelength) of a part of the blue light converted by a phosphor. And is obtained by synthesizing

As a light conversion member for converting the light color (wavelength) of such a light source, a material in which an inorganic phosphor is dispersed in glass is known (see, for example, Patent Document 1). The light conversion member having such a configuration can utilize the high transmittance of glass, and can efficiently release the heat generated from the LED element to the outside of the light conversion member. Moreover, the damage of the light conversion member (especially phosphor) by light and heat is low, and long-term reliability is obtained.

There is also known a light conversion member that attempts to improve light emission efficiency by scattering light from a light source by making light-dispersible particles present in a glass in which a phosphor is dispersed (see, for example, Patent Document 2). ).

JP 2003-258308 A JP 2004-111981

Incidentally, a light conversion member in which phosphor particles are dispersed in glass as described in

Patent Documents

1 and 2 or the like is generally obtained by mixing a raw material powder in which glass powder and phosphor particles are mixed in the production process. Then, a coating film is formed on a film or substrate in the form of a sheet, and this is heated and fired at a high temperature to form a phosphor-dispersed sheet containing dispersed phosphors. Further, the phosphor-dispersed sheet thus formed is desired. It is obtained by dividing into pieces by cutting into a shape (for example, a matrix).

However, in the process of forming a sheet-like coating film as described above, since the film thickness varies not a little, the thickness of the obtained light conversion member also reflects that, and the light conversion characteristics depend on the thickness. to be influenced. Furthermore, since the presence state of the encapsulated bubbles varies considerably, the light conversion characteristics are affected by the encapsulated bubbles even if the film thickness is the same. Therefore, even when the same LED light source is used and the light conversion member obtained in the same lot is used, the hue of the synthesized light (irradiation light) finally obtained may deviate from the desired hue.

Therefore, in view of the above problems, the present invention provides a chromaticity coordinate inspection method for a phosphor-dispersed sheet that enables evaluation of subtle differences in light conversion characteristics in a phosphor-dispersed sheet containing dispersed phosphors, and An object is to provide a manufacturing method of an applied LED package.

A chromaticity coordinate inspection method for a phosphor dispersion sheet according to the present invention is a chromaticity coordinate inspection method for a phosphor dispersion sheet containing phosphor particles dispersed in a glass sheet, the plane of the phosphor dispersion sheet. In the above, a section setting step for setting a section of a predetermined size, and one of the sections set in the section setting step is made to enter excitation light from one surface, and the excitation light makes the phosphor dispersion sheet A spectroscopic measurement step of spectroscopically measuring transmitted light obtained from the other surface; a chromaticity coordinate calculation step of calculating chromaticity coordinates from the spectroscopic data obtained by the spectroscopic measurement step; the spectroscopic measurement step; A chromaticity coordinate calculation step is repeatedly performed for each of the sections set in the section setting step, and includes a mapping step of storing the sections and the chromaticity coordinates in association with each other.

The method for producing a phosphor dispersion sheet according to the present invention is a method for producing a phosphor dispersion sheet containing phosphor particles dispersed in a glass sheet, and is based on the chromaticity coordinate inspection method for the phosphor dispersion sheet according to the present invention. The mapping information stored by associating sections and chromaticity coordinates with each other is added to the phosphor dispersion sheet.

The method for producing a light conversion member of the present invention is a method for producing a light conversion member for dividing the phosphor dispersion sheet obtained by the method for producing a phosphor dispersion sheet of the present invention into a predetermined size, At the time of the separation, the light conversion members are classified based on the mapping information.

In the LED package manufacturing method of the present invention, the LED element is combined with a light conversion member obtained by dividing the phosphor dispersion sheet whose chromaticity coordinates are calculated by the chromaticity coordinate inspection method, and emitted from the LED element. In the method of manufacturing an LED package that enables light to be emitted to the outside through the light conversion member, an LED spectroscopic measurement step of performing spectroscopic measurement of excitation light emitted from the LED element when combining the LED element and the light conversion member A chromaticity coordinate calculation step of the LED for calculating chromaticity coordinates from the spectral data of the excitation light obtained by the LED spectroscopic measurement step, and a chromaticity coordinate of the excitation light obtained by the chromaticity coordinate calculation step of the LED And chromaticity coordinates of the phosphor dispersion sheet obtained by the chromaticity coordinate inspection method, and transmission for calculating chromaticity coordinates of virtual transmitted light obtained from the chromaticity coordinates And a combination optimization step of determining a combination of desired transmitted light from the chromaticity coordinates of the virtual transmitted light obtained in the chromaticity coordinate calculation step of the transmitted light. It is characterized by.

According to the chromaticity coordinate inspection method and the phosphor dispersion sheet manufacturing method of the phosphor dispersion sheet of the present invention, in the phosphor dispersion sheet, the chromaticity coordinates for each section are mapped and the characteristics are converted into data. For example, a subtle difference in light conversion characteristics for each product used as the light conversion member can be determined.

In addition, according to the method for manufacturing a light conversion member of the present invention, light conversion members having similar chromaticity coordinates are obtained by being assigned to a predetermined class. It can be simple.

Further, according to the LED package manufacturing method of the present invention, the chromaticity coordinates obtained by the chromaticity coordinate inspection method described above are applied, and the chromaticity coordinates of the LED elements are added to the chromaticity coordinates. It is possible to efficiently determine the optimal combination of the LED element that becomes the irradiation light and the light conversion member.

It is the figure which showed schematic structure of the chromaticity coordinate inspection apparatus used for the 1st Embodiment of this invention. It is a figure which shows an example of the division provided by a division setting process. It is the figure which showed schematic structure of the chromaticity coordinate inspection apparatus used for the 2nd Embodiment of this invention. It is the figure which showed the spectrum example of the transmitted light (combined light) for demonstrating the calculation method of a proportionality constant. It is the figure which showed an example which determines the combination of a some LED light source and a some light conversion member by ranking on chromaticity coordinate.

Hereinafter, a chromaticity coordinate inspection method according to the present invention will be described in detail with reference to the drawings.
[First Embodiment]
First, a chromaticity coordinate inspection apparatus used for the chromaticity coordinate inspection method according to the first embodiment of the present invention will be described. FIG. 1 shows an example of the configuration of the chromaticity coordinate inspection apparatus. The chromaticity coordinate inspection apparatus 1 fixes a phosphor dispersion sheet 50 in which phosphors are dispersed in a glass sheet to be inspected. The fixing unit 2 for holding, the LED light source 3 that emits excitation light to one surface of the phosphor dispersion sheet 50, and the phosphor dispersion sheet 50 that is emitted by irradiation of the excitation light from the LED light source 3. A spectrophotometer 4 that spectroscopically measures transmitted light, a chromaticity coordinate calculator 5 that calculates chromaticity coordinates from spectral data measured by the spectrophotometer 4, and a chromaticity calculated by the chromaticity coordinate calculator 5 The storage unit 6 stores the coordinates and the sections of the phosphor dispersion sheet 50 in the measurement in association with each other.

Here, the fixing part 2 is not particularly limited as long as it can fix and hold the phosphor dispersion sheet 50 to be measured at a predetermined position. In the present invention, the object to be measured is a sheet-like glass, so any material that can stably hold such a sheet-like sample may be used.

In addition, when the intensity | strength of the fluorescent substance dispersion | distribution sheet | seat 50 is high and does not deform | transform easily, it is sufficient to have only the frame type | mold which hold | maintains the edge part, and it can make the center part hollow. On the other hand, when the strength of the phosphor dispersion sheet 50 is low and it deforms due to its own weight, it is assumed that the frame mold has a transparent holding plate, and the phosphor dispersion sheet 50 is placed on the holding plate. What is necessary is just to make it hold | maintain stably in a horizontal direction. Also, care should be taken that the transparent holding plate used here is made of a material that transmits excitation light, which will be described later, so as not to hinder measurement.

The LED light source 3 emits excitation light for exciting the phosphor contained in the phosphor dispersion sheet 50 to be measured, and is arranged so that the excitation light is incident on the phosphor dispersion sheet 50 vertically. Let Here, the LED light source 3 may be appropriately selected depending on the phosphor to be measured. For example, the phosphor is Y ₃ Al ₅ O ₁₂ : Ce ³⁺ , (Y, Gd) ₃ (Al, Ga) ₅ O ₁₂ : Ce ³⁺ , Tb ₃ Al ₅ O ₁₂ : Ce ³⁺ , Ca ₃ Sc ₃ Si ₃ O ₁₂ ; Ce ³⁺ , CaSc ₂ O ₄ : Ce ³⁺ , La ₃ Si ₆ N ₁₁ : Ce ³⁺ , an LED light source that emits light having a wavelength of 440 to 480 nm may be selected. _{_{^{_{Ca, Sr, Ba) 2 SiO}}}} 4: Ce 3+, (Ca, Sr, Ba) 2 SiO 4: Eu 2+, (Ca, Sr) AlSiN 3: Eu 2+, Ca-αSiAlON: Eu 2+, (Sr, Ba) ₃ SiO ₅ : Eu ²⁺ , (Ca, Sr) ₂ Si ₅ N ₈ : Eu ²⁺ , (Ca, Sr, Ba) Si ₂ O ₂ N ₂ : Eu ²⁺ , β-SiAlON; Eu ²⁺ , L Wavelength of 300 to 480 nm when i ₂ SrSiO ₄ : Eu ³⁺ , Ba ₃ Si ₆ O ₁₂ N ₂ : Eu ²⁺ , (Ca, Sr, Ba) ₂ SiS ₄ : Eu ²⁺ , CaGa ₂ S ₄ : Eu ^2+, etc. What is necessary is just to select the LED light source which radiate | emits the light which has.

The spectrometer 4 measures the spectral data of the transmitted light emitted from the phosphor dispersion sheet 50 when irradiated with the excitation light from the LED light source 3, and a known spectrometer can be used. Examples of spectroscopic instruments that can be used here include TM series mini-spectrometers manufactured by Hamamatsu Photonics Co., Ltd., C10082CA and C10083CA, and multi-channel spectrometers manufactured by Konica Minolta Co., Ltd. In this specification, “transmitted light” means “transmitted excitation light” in which excitation light is transmitted through the phosphor dispersion sheet 50 without being wavelength-converted, and excitation light is wavelength-converted and emitted from the phosphor dispersion sheet 50. The “converted light” is synthesized and refers to light (synthesized light) actually emitted from the surface of the phosphor dispersion sheet 50. Note that both the transmitted excitation light and the converted light are scattered light that scatters on the surface of the phosphor dispersion sheet 50, and therefore, the synthesized light is also obtained as scattered light.
In addition, this spectrometer 4 should just be able to measure the transmitted light radiate | emitted from the fluorescent substance dispersion sheet 50, and the measurement distance from the irradiation part of the excitation light in the LED light source 3 to the spectrometer 4 is the same. It is preferable. When the measurement distance is different, it is necessary to correct the measurement distance to enable comparison and evaluation with other data. Therefore, in order to avoid the complicated operation such as correction by making the above measurement distances equal even when the measurement angle changes, it is preferable that the spectrometer 4 can move the measurement position by gonio drive. Here, the measurement by the gonio drive is performed by moving on the circumference around the intersection of the excitation light spot-irradiated from the LED light source 3 and the surface of the phosphor dispersion sheet 50 on the spectroscopic measuring instrument 4 side. This means measurement that enables spectroscopic measurement while maintaining the same, and can be achieved, for example, by driving the spectrophotometer 4 of FIG. 1 on an arc indicated by a dotted line. As a result, measurement at an arbitrary scattering angle θ is possible.

The chromaticity coordinate calculation unit 5 calculates chromaticity coordinates from the spectral data obtained by the spectrophotometer 4, and the chromaticity coordinates are obtained by performing a predetermined calculation process on the spectral data. Specific contents of the arithmetic processing performed at this time will be described in a chromaticity coordinate inspection method described later.

In addition, as this chromaticity coordinate calculation part 5, the well-known arithmetic device which can perform arithmetic processing is mentioned, For example, the arithmetic device comprised with CPU, ROM, RAM, etc. can be illustrated. Here, the CPU is composed of a microprocessor or the like, and enables various arithmetic processing described later. A program for performing various arithmetic processing is stored in advance in the ROM, and the RAM is used for control and arithmetic processing. It is used to read and write various data at the time.

The storage unit 6 stores the chromaticity coordinates calculated by the chromaticity coordinate calculation unit 5 and the measured sections of the phosphor dispersion sheet 50 in association with each other, and includes known storage devices such as a hard disk device and a memory. It is done. In addition, when calculating the chromaticity coordinate of LED mentioned later, the chromaticity coordinate of virtual transmitted light, etc. in this memory | storage part 6, those data can also be memorize | stored.

As shown in FIG. 1, the transmitted light used here is a synthetic light emitted from the phosphor dispersion sheet 50, and is a scattered light as described above. Since this transmitted light is diffused in all directions from the surface of the phosphor dispersion sheet 50 in a hemispherical shape, it can be measured from any direction. That is, the transmitted light having an angle θ with respect to a perpendicular line on the surface of the phosphor dispersion sheet 50 in the range of 0 ° or more and less than 90 ° can be used for measurement. In this case, the transmitted light having an angle θ of more than 0 ° is preferable.

This angle θ is such that the intensity ratio between the transmitted excitation light and the converted light is close to the intensity ratio between the transmitted excitation light and the converted light in a state where the wavelength conversion member is mounted on the actual product, that is, the LED element. Angle is preferred. However, the preferred angle varies also by adjusting the intensity of the excitation light. By the way, in the present invention, the transmitted excitation light transmitted through the phosphor dispersion sheet is less scattered than the case where the actual product is transmitted and is close to the collected parallel light. The linear transmitted light intensity tends to be stronger than the actual one, and the scattered transmitted light intensity tends to be weaker than the actual one. Along with this, the orientation distribution tends to be narrow for transmitted excitation light and relatively wide for converted light. Although it depends on the excitation light intensity, the angle θ of the transmitted light used for the spectroscopic measurement is preferably 45 ± 10 degrees, for example.

In an actual product, the light distribution varies depending on the conditions under which the LED and the light conversion member are mounted. Therefore, it is preferable to determine the angle θ of transmitted light used for spectroscopic measurement according to the light distribution. . For example, when the light distribution of the product is narrow, among the transmitted excitation light, there is a tendency that the linearly transmitted light tends to be strong, so in the present embodiment, it is preferable to employ an angle θ smaller than 45 degrees, When the light distribution is wide, the converted light tends to be strongly emitted. Therefore, in the present embodiment, it is preferable to employ one having an angle θ larger than 45 degrees.

Next, the chromaticity coordinate inspection method of the present invention will be described by taking an inspection method using the chromaticity coordinate inspection apparatus 1 of FIG. 1 as an example. In this chromaticity coordinate inspection method, as described above, in the plane of the phosphor dispersion sheet, the section setting step (S1) for setting a section of a predetermined size and one of the sections set in the section setting step are performed. Obtained by the spectroscopic measurement step (S2), in which excitation light is incident from one surface, transmitted through the phosphor dispersion sheet by the excitation light, and transmitted from the other surface is spectroscopically measured (S2). The chromaticity coordinate calculation step (S3) for calculating chromaticity coordinates from the obtained spectral data, the spectroscopic measurement step and the chromaticity coordinate calculation steps (S2 to S3) are repeated for each of the sections set in the section setting step. A mapping step (S4) for storing the sections and chromaticity coordinates in association with each other. Hereinafter, each process is demonstrated in order.

First, a section setting step (S1) for setting sections of a predetermined size on the plane of the phosphor dispersion sheet 50 is performed.

Here, for the phosphor dispersion sheet 50, which is a material for manufacturing a light conversion member as a product, a section having a predetermined size is set with respect to the plane. For example, as shown in the plan view of the phosphor dispersion sheet 50 in FIG. 2, the sections can be set in a matrix shape indicated by a broken line to distinguish each section. Just do it. FIG. 2 shows an example in which an alphabet starting from A in the X direction in the X direction and an integer starting from 1 in the Y direction from the top are given as codes. As a result, it is possible to distinguish each section, such as “A-1” in the upper left section, “C-5” in the third section from the left and the fifth section from the top. .

In FIG. 2, the description has been made by taking 64 partitions of 8 × 8 as an example, but this is a simple configuration for the sake of explanation. When manufacturing a light conversion member, for example, a phosphor dispersion sheet having a 100 mm square planar shape is prepared, and a 1000 μm square light conversion member is formed in a matrix on the phosphor dispersion sheet. Many products are once formed integrally in one sheet. Thereafter, the phosphor-dispersed sheet is cut into a desired shape and singulated to obtain a product. In the above case, the number of products is 10,000 with 100 × 100. Therefore, the number of sections described here is preferably 10,000 or more.

In general, this section may have a size and shape corresponding to the size of the product (light conversion member obtained by dividing into individual pieces). In this way, the characteristics of each product are expressed. Chromaticity coordinates are obtained. However, this section can be arbitrarily set, and two or more chromaticity coordinates may be obtained for one product. In that case, more detailed characteristic information for one product can be obtained. Therefore, for example, when two or more chromaticity coordinates are acquired, and the deviation of the obtained chromaticity coordinates is larger than a predetermined value, it is determined as a rejected product, and the product It can also be used to maintain the quality of

Next, excitation light is incident on one of the sections set in the section setting step from one surface, and the transmitted light obtained by emitting from the other surface of the phosphor dispersion sheet is spectroscopically measured by the excitation light. A spectroscopic measurement process (S2) is performed.

As shown by the broken line in FIG. 1, excitation light for exciting the phosphor contained therein is emitted from the LED light source 3 to the phosphor dispersion sheet 50. The emitted excitation light is incident from one surface of the phosphor dispersion sheet 50, passes through the phosphor dispersion sheet 50, is scattered, is converted into light, and is emitted from the other surface. Then, the transmitted light (the combined light of the transmitted excitation light and the converted light; the alternate long and short dash line in FIG. 1) is measured by the spectrometer 4 to acquire the spectral data of the transmitted light. This transmitted light is transmitted light having an angle θ with respect to a normal line dropped on the surface of the phosphor dispersion sheet 50 in a range of 0 ° or more and less than 90 °, and preferably transmitted light having an angle θ of more than 0 °.

As a method of measuring the spectral data of the transmitted light, a known spectral data measuring method may be used, and for example, it can be measured using a microspectrophotometer (for example, C10082CA manufactured by Hamamatsu Photonics Co., Ltd.). Conditions for measuring the spectroscopic data include, for example, measuring a glass substrate serving as a reference with a spot diameter of 500 μm and measuring a spectroscopic spectrum with a spot diameter of 500 μm in a flat film thickness region. For example, the obtained spectral data is preferably in the data format of spectral transmittance (%) in increments of 5 nm from 400 to 800 nm.

Next, a chromaticity coordinate calculation step (S3) for calculating chromaticity coordinates from the spectral data obtained in the spectroscopic measurement step is performed.

The chromaticity coordinate calculation step in the present embodiment is a step of obtaining chromaticity coordinates of the measured area of the phosphor dispersion sheet 50 using the data obtained by the spectral data measurement step.

In order to obtain the chromaticity coordinates from the data obtained by the spectral data measurement process, for example, the chromaticity coordinates (x , Y) and the method of calculating the luminance Y.

When the chromaticity coordinates of one section measured as described above are obtained, the spectroscopic measurement process and the chromaticity coordinate calculation process (S2 to S3) are repeated for each section set in the section setting step. And a mapping step (S4) for storing chromaticity coordinates in association with each other.

Here, for example, if the chromaticity coordinates of the section A-1 are calculated as shown in FIG. 2, then the chromaticity coordinates of the section A-2, the chromaticity coordinates of the section A-3, and so on. After calculating the chromaticity coordinates of the A column in order, and calculating the chromaticity coordinates of the entire A column, the chromaticity coordinates of each section of the B column are then calculated, and the chromaticity coordinates of the entire B column are calculated. After the calculation, the chromaticity coordinates of each section are calculated in the order of C column, then D column,..., And chromaticity coordinates are calculated for all the sections provided by the phosphor dispersion sheet 50. At this time, the calculated chromaticity coordinates are stored in the storage unit 6 in association with the section (mapping).

This mapping step is performed while moving the section to be measured. At this time, the fixing unit 2 (phosphor dispersion sheet 50) is left as it is, and the optical system including the LED light source 3 and the spectrometer 4 is moved. On the contrary, the fixing unit 2 (phosphor dispersion sheet 50) may be moved while the optical system is kept as it is. In order to stably perform the spectroscopic measurement, it is preferable to perform the mapping step by moving the fixing unit 2 (phosphor dispersion sheet 50) without moving the optical system. Moreover, what is necessary is just to perform a movement of a division so that the excitation light from LED light source 3 may inject into the division to measure next after a spectroscopic measurement process is complete | finished. By the way, in order to inspect at a high speed, it is better to keep the movement of a section continuous and detect the measurement of one section at the same time within a predetermined time within the movement time of the section. In addition, the movement in this embodiment will not be limited if it can move so that the excitation light from LED3 may enter perpendicularly and equidistantly with respect to the surface of the fluorescent substance dispersion | distribution sheet | seat 50. FIG. However, in general, since it is affected by gravity, the phosphor dispersion sheet 50 is fixed so that the surface of the phosphor dispersion sheet 50 is horizontal as shown in FIG. 1, and the above movement is also moved in the horizontal direction. An apparatus configuration is preferable.

Furthermore, in the present embodiment, it is preferable to provide a thickness measuring device and measure the sheet thickness of the section simultaneously with calculating the chromaticity coordinates. In this case, in addition to the chromaticity coordinates, the thickness data is stored in association with the section.

If the thickness data is acquired in this way, the thickness data can be used as follows.
For example, if the thickness of the light conversion member is large, the excitation light is easily diffused, and backscattering (backscattering) and light absorption are also likely to occur. Since the opportunity to perform this increases, the converted light increases.

In other words, thickness is a major factor that fluctuates the balance between transmitted excitation light and converted light, and changes chromaticity, so it can be used to provide stable products with little variation in characteristics by managing thickness data. it can.

Also, the characteristic judgment by measuring the thickness can be used in the following cases. For example, in the phosphor dispersion sheet 50, there may be a plurality of sections having the same chromaticity coordinates among the obtained chromaticity coordinates. However, even if the numerical values of the chromaticity coordinates are the same, it cannot be immediately determined that the light conversion characteristics are the same. Specifically, if the chromaticity coordinates are out of alignment with the desired one, whether it is due to the thick sheet or the inclusion bubbles during the sheet production, etc. The cause of this cannot be determined.

On the other hand, if thickness information is acquired in addition to the chromaticity coordinates, one judgment material for judging whether the above-described characteristic deviation is caused by the thickness or by the included bubbles. It becomes. For example, in the above case, if it is caused by the increased thickness, there is no problem in applying it as a product. ) Or multiple scattering, the amount of light flux decreases, and the light utilization efficiency decreases. Therefore, in such a case, the product can be judged more appropriately, for example, the product is rejected, and a product with stable quality can be provided.

In general, the thickness of the phosphor dispersion sheet in the light conversion member is 100 to 1000 μm, and this thickness can be measured by a known thickness measuring method. It is preferable that the thickness measurement is performed by an optical measurement method using laser light from the viewpoint that a minute portion can be measured at high speed without contact.

Furthermore, by the above chromaticity coordinate inspection method, mapping information in which the sections and chromaticity coordinates are associated can be added and provided to the phosphor dispersion sheet. By adding this mapping information, the provided phosphor dispersion sheet is obtained. Similarly to the above, it is possible to determine a subtle difference in characteristics for each product used as the light conversion member. Adding the mapping information represents a state in which information on the target phosphor dispersion sheet is associated, and is not limited to physically adding the mapping information to the target phosphor dispersion sheet.

In addition, when such a phosphor dispersion sheet is separated into a predetermined size and used as a light conversion member, the light conversion member is classified based on the mapping information, so that light having similar characteristics can be obtained. The conversion members can be collected and manufactured. Thereby, the combination with LED mentioned later can also be made simple. Here, the classification is based on the chromaticity coordinates calculated above. For example, as shown in FIG. 5 to be described later, an arbitrary chromaticity coordinate area (class A to F) is set, and What is necessary is just to determine the class of the light conversion member.

[Second Embodiment]
Next, a second embodiment of the present invention will be described. An example of the configuration of the chromaticity coordinate inspection apparatus used in the second embodiment is shown in FIG. The chromaticity coordinate inspection apparatus 11 includes a fixing unit 2 for fixing and holding the phosphor dispersion sheet 50 to be inspected, and an LED light source 3 that emits excitation light to one surface of the phosphor dispersion sheet 50. The spectrophotometer 4 that spectroscopically measures the transmitted light emitted from the phosphor dispersion sheet 50 by irradiation of the excitation light from the LED light source 3, and the chromaticity coordinates are calculated from the spectroscopic data measured by the spectrophotometer 4 A chromaticity coordinate calculation unit 5 that performs the storage, and a storage unit 6 that stores the chromaticity coordinates calculated by the chromaticity coordinate calculation unit 5 in association with the sections of the phosphor dispersion sheet 50 in the measurement.

Further, the chromaticity coordinate inspection apparatus 11 is an example in which the transmitted light emitted from the phosphor dispersion sheet 50 is incident on the spectrometer 4 at a plurality of measurement angles by irradiation of excitation light from the LED light source 3. The spectrophotometer 4 in the chromaticity coordinate inspection apparatus 11 is preferably capable of being gonio-driven as in the first embodiment. In this way, first, spectral data of transmitted light at the scattering angle θ ₁ is acquired, and then scattering angle θ as that acquires spectral data of the transmitted light in _two, the spectral data of a plurality of scattering angles of the transmitted light can be easily obtained. Further, it is not necessary to perform correction based on the measurement distance, and the operation becomes simple. In the present embodiment, in order to measure the light at each scattering angle of the plurality of transmitted light as the light to be spectrally measured in this way, the spectroscopic data measured by the spectrophotometer 4 is data including the scattering angle dependence of the synthesized light. It becomes.

As is clear from the above and FIG. 3, the chromaticity coordinate inspection apparatus 11 basically has the same configuration as the chromaticity coordinate inspection apparatus of FIG. 1, and includes a fixing unit 2, an LED light source 3, a spectroscopic measurement. The device 4, the chromaticity coordinate calculation unit 5, and the storage unit 6 are the same as those in the first embodiment. Hereinafter, a configuration different from that of the first embodiment will be described.

The transmitted light used here is a range in which the scattering angles θ ₁ and θ ₂ with respect to the normal of the phosphor dispersion sheet are in the range of 0 ° to less than 90 °, and θ ₁ and θ ₂ are two transmitted lights having different angles. . In addition, when transmitted light having a plurality of scattering angles is used in this way, the transmitted light angles θ of the plurality of scattering angles are not biased and are close to actual illumination light. Is averaged ((θ ₁ + θ ₂ ) / 2), the average value is preferably in the range of 45 ± 10 degrees.

Note that FIG. 3 specifically illustrates the case where two transmitted lights are used, but three or more transmitted lights may be used. By performing spectroscopic measurement using a plurality of transmitted light in this way, data closer to actual transmitted light (synthetic light) can be acquired, and the characteristics of the light conversion member can be more accurately evaluated. Even when three or more transmitted lights are used, when the angles θ of the plurality of transmitted lights are averaged, the average value is preferably in the range of 45 ± 10 degrees.

[Third Embodiment]
Next, an embodiment of the LED package manufacturing method of the present invention will be described. The basic LED package can be manufactured by a conventionally known method of applying a light conversion member to an LED element and packaging it by sealing or the like. The present invention is for optimizing the combination of an LED element and a light conversion member in order to obtain a desired color of transmitted light (synthetic light) in the manufacture of such an LED package. Specifically, the light conversion member is obtained by cutting the above-described phosphor dispersion sheet into a desired shape and dividing into individual pieces. In this embodiment, the light conversion member obtained by dividing into pieces is the above-described embodiment. Since the information of the chromaticity coordinates obtained from the mapping information of the chromaticity coordinates described in the embodiment is known, the light conversion member suitable for obtaining the desired irradiation light in consideration of the characteristics of the applied LED element Selection can be performed simply and effectively.

In order to achieve the object, an LED package manufacturing method according to the present invention includes an LED spectroscopic measurement process for spectroscopically measuring excitation light emitted from an LED element, and an LED spectroscopic measurement when combining the LED element and the light conversion member. LED chromaticity coordinate calculation step for calculating chromaticity coordinates from spectral data of excitation light obtained in the step, chromaticity coordinates of excitation light obtained in the LED chromaticity coordinate calculation step, and the first embodiment Alternatively, the chromaticity coordinates of the phosphor dispersion sheet obtained by the phosphor dispersion sheet chromaticity coordinate inspection method described in the second embodiment and the estimated chromaticity coordinates of transmitted light obtained from the “virtual coordinates” are calculated. Combination optimization step of determining a combination of desired transmitted light from the chromaticity coordinates obtained by the chromaticity coordinate calculation step of “transmitted light” and the chromaticity coordinate calculation step of “virtual transmitted light” It has a. Hereinafter, each step will be described in detail.

The LED spectroscopic measurement step in the present embodiment is a step of spectroscopically measuring the excitation light emitted from the LED element when combining the LED element and the light conversion member obtained by dividing into pieces.

The spectroscopic measurement in this step is performed by the same operation and method as the spectroscopic measurement of the phosphor-dispersed sheet described in the first embodiment except that the light emitted from the LED element to be measured is directly measured.

The LED chromaticity coordinate calculation step in the present embodiment is a step of calculating chromaticity coordinates from spectral data of excitation light obtained by the LED spectroscopic measurement step.

The chromaticity coordinate calculation step in this step is the same operation as the spectral measurement of the phosphor-dispersed sheet described in the first embodiment, except that the spectral data is excitation light data obtained by the LED spectral measurement step. Done by the method.

The “virtual transmitted light” chromaticity coordinate calculation step in this embodiment is obtained by the chromaticity coordinate of the excitation light obtained in the LED chromaticity coordinate calculation step and the chromaticity coordinate inspection method of the phosphor dispersion sheet. This is a step of calculating the chromaticity coordinates of the “virtual transmitted light” obtained from the chromaticity coordinates of the phosphor dispersion sheet.

In this step, when the chromaticity coordinates of the excitation light and the chromaticity coordinates of the phosphor dispersion sheet are mounted in actual combination, the color of the transmitted light (synthetic light) is calculated by, for example, processing on a computer. The chromaticity coordinates of the virtual transmitted light obtained here are the chromaticity coordinates estimated from the calculation.

This calculation process is specifically performed as follows. The spectrum at the time of measurement of the phosphor dispersion sheet includes both a spectrum of transmitted excitation light through which excitation light is transmitted as it is and a spectrum of converted light in which excitation light is absorbed and converted by the phosphor. By subtracting the transmitted light of the excitation light at the time of measuring the phosphor dispersion sheet, that is, the transmitted excitation light, from the spectral spectrum at the time of measuring the phosphor dispersion sheet, a spectrum of almost only converted light can be calculated. On the other hand, the transmitted excitation light when measuring the phosphor dispersion sheet is often different from the transmitted excitation light when actually mounted on the LED chip. In this case, it can be obtained by multiplying the spectral intensity of the transmitted excitation light at the time of measurement of the phosphor dispersion sheet by a certain proportionality constant and approximating the intensity of the transmitted excitation light when actually mounted on the LED chip. The spectrum of transmitted light can be approximated by the combined light of the converted light obtained in the above calculation and the transmitted excitation light calculated in the above approximation. The proportionality constant can be set by correlating the spectrum in the actual combination with the spectrum obtained at the time of measuring the phosphor dispersion sheet. At least one correlation is sufficient, and taking a plurality of samples improves the accuracy of the proportionality constant. If there is a correlation between the spectral spectrum of the transmitted excitation light and the spectral spectrum of the LED light combined with the approximate calculation, the conversion obtained by the above calculation by multiplying the spectral spectrum of the combined LED by the proportional coefficient according to the correlation. By combining with light, the spectrum of transmitted light (synthetic light) can be approximated.

The proportionality constant can be set as follows, for example.
The separated light conversion member is mounted on an LED chip, the spectrum data actually combined is measured with an integrating sphere, and the amounts of transmitted excitation light and converted light are calculated. When the spectrum data obtained at this time is as shown in FIG. 4, the radiation intensity ΦEXr of the transmitted excitation light may be integrated with the measured intensity corresponding to the transmitted excitation light having a wavelength of 400 to 500 nm. can get.

(Where Φer (λ) represents a function of the wavelength of the emitted light intensity measured from the actual illumination source)
The radiation amount ΦEMr of the converted light may be obtained by integrating the measured intensity corresponding to the converted light having a wavelength of 500 to 800 nm, and is obtained by the following equation (2).

(Where Φer (λ) represents a function of the wavelength of the emitted light intensity measured from the actual illumination source)
Here, it is only necessary to calculate the radiation amount, and it is not necessary to include the visibility.

Next, the measured intensities of the transmitted excitation light and the converted light are calculated from the spectral spectrum data obtained in the first embodiment or the second embodiment in the light conversion member mounted on the LED chip. The amount of transmitted excitation light ΦEXm is a measured intensity at a wavelength of 400 to 500 nm and can be expressed by the following equation (3).

(Where Φem (λ) represents a function of the emitted light intensity measured in the spectroscopic measurement step depending on the wavelength)
The radiation amount ΦEMm of the converted light is a measured intensity at a wavelength of 500 to 800 nm, and can be expressed by the following equation (4).

(Where Φem (λ) represents a function of the emitted light intensity measured in the spectroscopic measurement step depending on the wavelength)

The proportionality constant approximates the spectrum data obtained in the first embodiment or the second embodiment to actual spectrum data. Specifically, for example, the balance between the transmitted excitation light and the converted light is adjusted. To approximate. Accordingly, the calculation of the proportionality constant C is expressed by the following formula (5), which may be modified and calculated by the formula (6).

(In the formula, C represents a proportionality constant, and ΦEXr, ΦEMr, ΦEXm, and ΦEMm are the same as described above.)

Note that the integration range may be appropriately selected depending on the excitation wavelength and emission wavelength of the target material. In general, the proportionality constant C is 1 or less because the transmitted excitation light in the above embodiment tends to be strong and the converted light tends to be weak. Since it is also affected by θ, it may exceed 1.

These operations can be more simply approximated using chromaticity coordinates. The chromaticity coordinates of the “virtual transmitted light” can be approximated to be located between the chromaticity coordinates of the LED light and the chromaticity coordinates of the converted light of the phosphor dispersion sheet. Therefore, the chromaticity coordinates of the LED light and the phosphor dispersion are calculated by weighting and calculating the chromaticity coordinates of the LED light with a proportionality constant obtained from the correlation with the chromaticity coordinates of the transmitted light obtained in an actual combination. It is possible to specify and calculate the chromaticity coordinates located near the midpoint of the chromaticity coordinates of the converted light of the sheet.

According to such arithmetic processing, if information on the chromaticity coordinates of the LED element and the phosphor dispersion sheet, which are materials to be combined, is obtained, the chromaticity coordinates of transmitted light (synthetic light) assumed by the combination are obtained. As a result, many results can be easily obtained. Therefore, it is useful as a judgment material when selecting an actual combination.

That is, for one LED element, 64 when combined with each section of the phosphor dispersion sheet as shown in FIG. 2 (for example, when one section corresponds to one light conversion member as a product). It is possible to easily estimate the chromaticity coordinates of the virtual transmitted light on the street.

According to this method, since it is not necessary to actually obtain the transmitted light in combination, the time and cost in manufacturing the LED package can be greatly reduced.

In calculating the chromaticity coordinates of the virtual transmitted light, when there are a plurality of LED elements, it is preferable to calculate the chromaticity coordinates for each of these LED elements. For example, since the LED element is generally manufactured by forming a plurality of LED elements in a matrix on the substrate, the LED element is similar to that mapped in the phosphor dispersion sheet 50 described above. The chromaticity coordinates are stored in association with each other (LED mapping step). Then, even if a huge number of combinations of a plurality of LED elements and a plurality of light conversion members obtained by singulation are calculated, it is preferable because it is immediately understood which material should be combined. . If there is a large variation in the LED element and the excitation wavelength to be emitted differs greatly, the intensity of the converted light will also be greatly affected, so it should be approximated to the transmitted light when actually mounted on the LED chip by simple addition. However, at least the tendency of chromaticity of transmitted light can be calculated.

Then, the combination optimization process in the present embodiment is based on the chromaticity coordinates obtained in the chromaticity coordinate calculation process of the virtual transmitted light, and the combination that will be the desired transmitted light when actually mounted on the LED chip. It is a step of determining.

This step enables selection of a combination in which the chromaticity coordinates of the above-described virtual transmitted light fall within a desired chromaticity coordinate range. This selection is actually performed with respect to the design range of the desired chromaticity coordinates. The chromaticity coordinates of the virtual transmitted light assumed when mounted on the chip are included in the design range. Since the visibility of chromaticity coordinates is taken into consideration, even if the spectrum of transmitted light is different, the same color is visually recognized if the chromaticity coordinates are equal. Therefore, it is important to match the chromaticity coordinates of the transmitted light when it is finally mounted on the LED chip, but here the spectrum of the transmitted light when actually mounted on the LED chip is adjusted. It is not necessary to go.

In this step, first, in order to determine the design range of chromaticity coordinates, an illumination light source that combines a typical LED light source and a light conversion member that can obtain desired transmitted light is actually mounted and manufactured. At this time, in order to adjust the intensity of transmitted light, there are methods such as increasing the content of phosphor particles in the light conversion member or increasing the thickness of the light conversion member. It can be selected and fine-tuned to be. As a result, as one example for obtaining transmitted light having target chromaticity coordinates (u _T ′, v _T ′) in the inspection measurement, target chromaticity coordinates (u _Ltyp ′, v _Ltyp ′) of the LED light source. the target chromaticity coordinates of the light converting member _{_{(u Styp ', v Styp'}} ) can be determined, the chromaticity coordinates of the transmitted light to be thereby target _{(k · u Ltyp '+ (} 1-k) · u Styp' , K · v _Ltyp '+ (1-k) v _Type '). Note that k is a proportional constant that satisfies the condition of 0 <k <1, and the target chromaticity coordinates (u _T ′, v _T ′) and the target chromaticity coordinates of the LED light source (u _Ltyp ′, v _Ltyp ′) It can be determined from the target chromaticity coordinates (u _Type ', v _Type ') of the light conversion member.

Next, from the chromaticity coordinates (u _Ln ′, v _Ln ′) of the actual LED light source to be considered for combination and the chromaticity coordinates (u _Sm ′, v _Sm ′) of the light conversion member, virtual transmission is performed in the same manner as described above. Light chromaticity coordinates can be calculated easily. In the above chromaticity coordinates, n is 1, 2,..., N, m is 1, 2,..., M, and there are as many types as there are LED light sources (n) and light conversion members (m) Represents. For example, when the case of one LED light source is considered (n = 1), the combination is calculated from the chromaticity coordinates (k · u _L1 ′ + (1−k) · u _Sm ′, k · v _L1 ′ + ( _{1-k) · v Sm '} ) to become. This is a range (design range) approximated to the chromaticity coordinates (k · u _Ltyp '+ (1-k) · u _Type ', k · v _Ltyp '(1-k) · + v _Type ') of the transmitted light. Select the optimal combination so that That is, a combination that satisfies the following expressions (7) and (8) may be determined.

k · u _L1 ′ + (1−k) · u _Sm ′ ≒ k · u _Ltyp ′ (1−k) · + u _Type ′ (7)
k · v _L1 ′ + (1−k) · v _Sm ′ ≈ k · v _Ltyp ′ + (1−k) · v _Type ′ (8)

This is an arbitrary LED light source that considers a combination with an LED light source having a design target chromaticity coordinate on the chromaticity coordinates (u ′, v ′) and a line segment connecting the chromaticity coordinates of the light conversion member. In addition, the intersection of the line segments connecting the chromaticity coordinates of the light conversion member is calculated, and the combination is selected so that the intersection is closest to the chromaticity coordinates of the target transmitted light. This “target transmitted light chromaticity coordinate” is located on a line segment connecting the chromaticity coordinates of the LED light source and the light conversion member having the designed target chromaticity coordinates.

Incidentally, the LED light source and the light conversion member separated from the phosphor dispersion sheet have variations. In the above description, the case where the number of LED light sources is one (n = 1) has been described as an example, but actually, a plurality of LED light sources are prepared and obtained by dividing a plurality of LED light sources and a plurality of pieces. An optimum combination is selected from the light conversion members. At that time, it is preferable to classify each of the LED light source and the light conversion member by chromaticity coordinates and to determine a combination of classes that can obtain desired chromaticity coordinates. At this time, the combination of classes may be determined so that the chromaticity coordinates closest to the design target chromaticity coordinates can be obtained, but the variation is minimized by considering all the combinations of classes. It is preferable to determine such a combination. As a result, it is possible to obtain a group of LED illumination light sources with less variation in transmitted light (synthetic light) having desired chromaticity coordinates with respect to the obtained transmitted light (synthesized light).

FIG. 6 shows an example in the case of determining the combination that minimizes the variation. FIG. 6 shows that the light conversion member is classified into 6 classes (1 to 6) and the LED light source is classified into 6 classes (A to A) according to chromaticity coordinates. This is an example of combination with 1-F, 2-E, 3-D, 4-C, 5-B, and 6-A when classified into F). In this way, when the line segment of the chromaticity coordinates of the combined LED light source and the light conversion member is drawn so that the intersection of each line segment is in the narrowest range, an LED illumination light source with a stable color tone with little variation can be obtained. .

DESCRIPTION OF SYMBOLS 1 ... Chromaticity coordinate inspection apparatus, 2 ... Fixed part, 3 ... LED light source, 4 ... Spectrometer, 5 ... Chromaticity coordinate calculation part, 6 ... Memory | storage part, 11 ... Chromaticity coordinate inspection apparatus, 50 ... Phosphor dispersion | distribution Sheet.

Claims

A method for inspecting chromaticity coordinates of a phosphor dispersion sheet containing phosphor particles dispersed in a glass sheet,
A section setting step for setting a section of a predetermined size in the plane of the phosphor dispersion sheet;
Spectroscopy in which excitation light is incident on one of the sections set in the section setting step, and transmitted light obtained from the other surface of the phosphor dispersion sheet is spectroscopically measured by the excitation light. Measuring process;
A chromaticity coordinate calculating step of calculating chromaticity coordinates from the spectral data obtained by the spectroscopic measurement step;
A mapping step of repeatedly performing the spectroscopic measurement step and the chromaticity coordinate calculation step for each partition set in the partition setting step, and storing the partition and the chromaticity coordinate in association with each other;
A method for inspecting chromaticity coordinates of a phosphor-dispersed sheet, comprising:
Simultaneously with the spectroscopic measurement step, a thickness measurement step of measuring the thickness of the phosphor dispersion sheet in the section is performed,
The chromaticity coordinate inspection method for a phosphor-dispersed sheet according to claim 1, wherein, in the mapping step, the thickness measured in the thickness measurement step in addition to the chromaticity coordinate is stored in association with the section.
The chromaticity coordinate inspection method for a phosphor dispersion sheet according to claim 1 or 2, wherein, in the spectroscopic measurement step, two or more transmitted lights having different angles scattered from the surface of the phosphor dispersion sheet are used as the transmitted light.
The phosphor dispersion sheet according to any one of claims 1 to 3, wherein after the spectroscopic measurement step is completed, the phosphor dispersion sheet is moved so that the excitation light is incident on a section to be measured next. Chromaticity coordinate inspection method.
A method for producing a phosphor dispersion sheet containing phosphor particles dispersed in a glass sheet,
5. The phosphor dispersion sheet according to claim 1, wherein mapping information stored in association with sections and chromaticity coordinates is added to the phosphor dispersion sheet by the chromaticity coordinate inspection method for the phosphor dispersion sheet according to any one of claims 1 to 4. A method for producing a phosphor-dispersed sheet.
The method for producing a phosphor-dispersed sheet according to claim 5, further comprising thickness data for each section as the mapping information.
A phosphor conversion sheet obtained by the phosphor dispersion sheet manufacturing method according to claim 5 or 6, wherein the phosphor conversion sheet is separated into a predetermined size.
The method of manufacturing a light conversion member, wherein the light conversion member is classified into classes based on the mapping information when the pieces are separated.
5. The LED element is combined with a light conversion member obtained by dividing the phosphor dispersion sheet whose chromaticity coordinates are calculated by the chromaticity coordinate inspection method according to any one of claims 1 to 4, and emitted from the LED element. In the manufacturing method of the LED package that enables the light to be emitted to the outside through the light conversion member,
In combining the LED element and the light conversion member, an LED spectroscopic measurement step of spectroscopically measuring the excitation light emitted from the LED element;
LED chromaticity coordinate calculation step of calculating chromaticity coordinates from spectral data of excitation light obtained by the LED spectroscopic measurement step;
The chromaticity of the virtual transmitted light obtained from the chromaticity coordinate of the excitation light obtained in the chromaticity coordinate calculation step of the LED and the chromaticity coordinate of the phosphor dispersion sheet obtained by the chromaticity coordinate inspection method A chromaticity coordinate calculation step of transmitted light for calculating coordinates;
A combination optimizing step for determining a combination to be a desired transmitted light from the chromaticity coordinates of the virtual transmitted light obtained in the chromaticity coordinate calculating step of the transmitted light;
A method for manufacturing an LED package, comprising:
The LED element is a plurality of LED elements, and the LED spectroscopic measurement step and the LED chromaticity coordinate calculation step are repeated for each of the plurality of LED elements, and the LED element and the excitation light The LED package manufacturing method according to claim 8, further comprising an LED mapping step of storing the chromaticity coordinates in association with each other.