WO2016111095A1

WO2016111095A1 - Coating method

Info

Publication number: WO2016111095A1
Application number: PCT/JP2015/083194
Authority: WO
Inventors: 松永　正文
Original assignee: エムテックスマート株式会社
Priority date: 2015-01-08
Filing date: 2015-11-26
Publication date: 2016-07-14
Also published as: JP6682059B2; JP2016123964A

Abstract

In the present invention, coating is automated so as to coat a coating material evenly on intended sites on an object (11) to be coated while ensuring that the coating material does not adhere to the back surface or handled areas of the object (11) to be coated. The area of a tray (33) is made to be larger than the object (11) to be coated, the object (11) to be coated is positioned and loaded on the tray (33), and the coating material is coated on the object (11) to be coated. Because a mask (12) is made to be the same size as the size of the tray (33) or larger than same and coating is performed so that the coating pattern does not go beyond the tray (33) or the mask (12), the coating material does not adhere to the back surface of the tray (33). Because the object (11) to be coated is handled while loaded on the tray (33), a sequential automation from coating to drying is possible.

Description

Coating method

The present invention relates to a method and apparatus for applying a coating material such as a phosphor to a substrate such as an LED.
The application according to the present invention includes continuous or intermittent spraying of a fluid such as powder, melt, or liquid, ink jet, atomization (including fiberization) application, electrostatic atomization (including atomization) on a substrate. Including the method of applying to the substrate with particles or fibers such as fiberization application, and including micro curtain application.
A micro-curtain is a method of applying to a substrate using a portion of the liquid film before it becomes a mist when spraying a liquid etc. with an airless spray nozzle etc. Change in shape.
In addition, application of atomization (fiberization) includes particleization by spraying, but liquids and melts are subjected to ultrasonic waves, spin such as electrospinning, centrifugal force of a rotating body, meltblown device etc. It refers to the method of applying to paint.

Conventionally, when coating work such as spraying is performed, handling of the coated object is difficult because particles are scattered and adhered to places other than the coated object (this is called overspray in the industry) In particular, it has been difficult to automate, for example, to move downstream after applying the entire surface of a thin-plate type (sheet-fed) substrate to the entire surface with a spray. Although the coating material is a liquid and the thin-plated coating without unevenness can be handled by roll coating or curtain coating, the only way to uniformly apply the coating to the uneven coating is by using a spray or the like.

In Patent Document 1, a coating agent is sprayed by a spray nozzle which moves substantially straight to a printed substrate which is a to-be-coated body moving in a booth, and a to-be-coated coating agent is provided immediately below the to-be-coated body. A coating device is disclosed that recovers and reuses the oversprayed uncoated coating agent.

Patent Document 2 is a coating method or apparatus filed by the present applicant, which comprises a phosphor, a binder, and a solvent on an object such as an LED on an object mounting unit in a booth equipped with an intake and exhaust mechanism. A method and apparatus are disclosed for applying a slurry or other liquid with an applicator.

As described in the detailed description of Patent Document 1, in the case of single-sided application of the ordinary coated object by spraying, foreign matter adheres to the back surface, and conveyance is difficult when the back surface is contacted and conveyed. Even if the method of Patent Document 1 is adopted, if the depth to the bottom surface of the coating material receiving pallet is deep, for example, when it is 250 mm or more, turbulent flow occurs in the spray flow until it is collected and the back surface of the object to be coated When the distance between the bottom surface of the recovery pallet and the nozzle is short, for example, 150 mm or less, instantaneous spray on the bottom surface of the spray flow tends to cause rebound, which tends to cause more adhesion to the back surface. If the exhaust speed near the recovery pallet is increased to prevent it, the spray pattern will be affected by the spray pattern and the spray particles will be taken to the exhaust, the coating distribution of the coated object will be worse and the coating efficiency will be worse. Met.

Patent Document 2 is a ground-breaking method in which the application efficiency can be made 90% or more upon application to an A4 size object by performing pulse spray, but the end surface of the object is only marginal When applying uniformly, it is necessary to extend the splay pattern onto the heating table which is the unit for placing objects to be coated, and apply aluminum foil etc. at least outside the object on the table for the purpose of preventing adhesion to the table. It spreads, and it was made to apply the splay pattern out of the object to be coated. The operator regularly replaced and discarded aluminum foil and the like to which the paint adheres.

Japanese Patent Application Publication No. 2006-346606 WO2011 / 083841

In the case of application by spray in the general coating field, as described above, the object to be coated is a sheet-like plate, thick three-dimensional or composite material, and the object to be coated is a belt conveyor or chain conveyor. It was extremely difficult to uniformly coat the entire surface without causing the coating material to adhere to the back surface of the conveyor or the substrate when it was placed, moved, and moved relative to the spray apparatus for coating. Also, if the width of the belt conveyor is wider than that of the substrate and the back surface of the substrate is in direct contact with the belt conveyor and uniformly applied to the entire surface of the substrate so that it does not adhere to the surface of the substrate, As the coating pattern adheres to the belt conveyor, much time has been spent on its removal. Therefore, as in Patent Document 1, the back surface of the object to be coated is carried by being supported by the claws of the tips of the four crank hands. In this method, the exhaust speed and coating method are devised, for example, a method of applying large particles at a low pressure by air spray such as HVLP (high volume low pressure) and applying, or diluting to low solid content with a solvent etc. It is thought that the back side adhesion of the coated material could be prevented by making full use of know-how such as the ultra low pressure atomization method. However, in this method, there is no problem if the object to be coated has rigidity, but it is not suitable for the object to be coated such as a thin plate or a film which causes deflection even when supported at four or more points. On the other hand, in the general spray coating field, there is no way but to coat the coated object with a hanger or the like and complete automation can not be achieved. In the case of coating a flat-plate-like object to be coated by a method similar to that of Patent Document 1, there has been no other way but to handle the post-process while checking the adhesion state of the back surface by an operator.

The present invention has been made to solve the above-mentioned problems, and the object of the present invention is to automatically coat, for example, a powder, a melt such as a thermoplastic resin, or a liquid at room temperature. For example, even when using an air spray method in which the material is sprayed and atomized by a general air pressure, the desired portion is uniformly coated, and the coated object after coating is stored or dried in a magazine rack or the like (BAKING) It is to automate a series of flow up to the process. In particular, even when the phosphor is applied to a high value-added object such as an LED substrate by spraying etc., it is applied automatically and is automatically transferred downstream, for example, storage of the object in a magazine rack or baking process To provide a series of manufacturing methods and apparatus that can be automated.

The present invention is a method of applying a coating material to a substrate by means of an applicator or dispenser incorporated in an application booth equipped with at least exhaust means, the tray comprising: A first step of positioning and placing an object to be coated which is smaller than the tray, and a second step of automatically positioning and placing the tray on a table at a tray placement position outside the coating booth The third step of automatically moving the table into the coating booth by opening the shielding mechanism between the inside and the outside of the coating booth, and moving the coating mechanism and the table relative to each other. A fourth step of applying a coating material to the object to be coated in a single layer or multiple layers so that the application pattern does not protrude the tray, and after the application is completed, the table opens the shielding mechanism and the tray outside the booth The fifth work to move to the loading position When the tray placing the object to be coated on the table provides a coating method characterized by automatically removed from the table to move automatically to the downstream by an automatic machine.

In the present invention, a plurality of objects to be coated are positioned and placed on a tray in advance, the area of the tray is made larger than the sum of the areas of the objects to be coated, and the tray is positioned and placed on a table Providing a coating method characterized by

The present invention provides a coating method characterized in that a mask having the same size or larger size as the tray is positioned and placed on the object to be coated on the tray in advance.

In the present invention, a loader mechanism is provided upstream of a means for automatically placing on the table the tray on which the object to be coated is placed, and the table is a heating table, the object being heated by thermal conduction. After the coating material is applied to the coating booth and the volatile matter of the coating material on the coating material is volatilized by 95% or more, the table is moved out of the coating booth and is unloaded downstream of the automatic tray removing means. A coating method is provided, characterized in that a mechanism is provided, and the loader and unloader mechanism is a combined device.

According to the present invention, the magazine rack of the tray for the object to be coated is installed upstream of the loader mechanism and the downstream of the unloader mechanism, and the loading and unloading of the tray on which the object is placed is automatically performed on the same shelf of the magazine rack. Providing a coating method characterized by

The present invention has a first step of arranging the tray mounting position, the coating booth and the oven in this order, and the table has an adsorption function, and the mask is set on the object on the tray adsorbed on the table and moved to the coating booth A second step of applying the coating material to the coated object with the applicator with the applicator, and after the application is completed, the table is moved to the tray mounting position and the third step of removing only the mask by the automatic machine; Move the coating booth through the coating booth to the oven while stopping the adsorption of the tray and at least promote the curing of the coating on the substrate, and then start the adsorption of the tray. A fourth step of moving through the booth to the to-be-coated position, repositioning the mask on the to-be-coated, moving the table to the coating booth, and applying the to-be-coated by the applicator The fifth to laminate paint to To provide a coating method characterized by comprising the extent.

In the present invention, the inlets and outlets of a plurality of coating devices (COATER) are arranged in series, and the tray on which the object is placed is automatically conveyed to the inlet of each coating device, and the tray on which the object is placed is an automatic machine The table is moved to the table on the tray mounting position of the coating device, positioned and placed on the table, the table is moved into the coating booth, and the coating material is coated on the object to be coated by the coating device. Move to the tray loading position, move the coated object to the inlet of the coating device with the automatic machine, and dry or cure the coating material between the coating device and the downstream coating device with a conveyor or another automatic machine Transfer to an accelerating oven to accelerate the drying or curing of the substrate, and then apply the coating material to the substrate with the coating device further downstream with a coating device, and promote drying or curing in a downstream oven. Provide a coating method characterized by

In the present invention, the mask is set on the object placed on the tray and at least the tray and the object are adsorbed by the table having the adsorption function, and the table is moved to the coating booth to perform the coating operation. After completion, the mask of the substrate transferred to the inlet of the coating apparatus is removed, and only the tray and the substrate are transferred to the oven to promote drying or curing.

The present invention provides a coating method characterized in that the removed mask is conveyed by an automatic machine or another conveyor and set on the substrate again at the downstream of the inlet of the coating apparatus.

In the present invention, at least one object to be coated is positioned and mounted on the tray, and the mask is positioned and mounted on the object to be coated, and the external dimension of the mask is the same as or larger than that of the tray, The area is in the order of tray> coated object (total of one or more), and the tray is positioned and placed on a table having a heating and suction function by an automatic machine, and the table is moved to a coating booth to be a table and The applicator moves relative to each other to apply the coating material to the substrate so as not to protrude from the mask, and the tray on the table is automatically moved downstream.

In the present invention, the coating material is a slurry (SLURRY) containing a solvent, and the slurry attached to the mask is dissolved and recovered with a solvent, the solvent is volatilized, a solvent is newly added, the slurry is recycled and reused. The application method characterized by the above is provided.

In the present invention, the object to be coated is an LED or a member for an LED, the coating material is a slurry comprising a phosphor and a silicone binder and a solvent, or a phosphor and a solvent, and the coating is a spray coating method. Provided is a coating method characterized by

The present invention is a method for applying a coating material to a substrate by means of an applicator incorporated in a coating booth equipped with at least exhaust means, comprising positioning and placing one or more substrates on a tray. And a first step of positioning and placing a mask larger than the substrate on the substrate to form a substrate assembly, and the substrate assembly is transferred to the inside and outside of the coating booth by a conveyor. And the second step of automatically moving the coating mechanism into the coating booth and closing the shielding mechanism, and the coating pattern and the coating assembly move relative to each other and the coating pattern moves the mask. In the third step of applying at least one layer of the coating material to the object to prevent the coating from sticking out, and after the application is completed, the application assembly opens the shielding mechanism or the shielding mechanism on the opposite side and moves out of the booth and further Move downstream It provides a coating method comprising Rukoto.

In the present invention, the object to be coated stored in the magazine rack is transported from the loader to the coating booth, the coating material is automatically applied by the applicator in the coating booth, and is transported from the coating booth to the unloader and the magazine rack is unloaded. Device for storing the object to be coated, positioning the object to be coated on a tray and placing it on the tray, and storing the tray on which the object to be coated is placed in a magazine rack, and the magazine rack And the second step of setting the tray in the loader-unloader combination device, and extruding the tray on the conveyor and lifting the tray by an automatic machine at a predetermined position in the moving direction of the conveyor to place the tray outside the coating booth A third step of positioning and placing on a heating / suction table at a position, and said table moving in the booth with the shutter open and a fourth step of closing the shutter The object to be coated on the table moves relative to the applicator and the fifth step of applying at least one layer of the coating material by the applicator, and after the application is completed, the table opens the shutter to the tray loading position To provide a coating system characterized in that it moves, the tray is lifted by the automatic machine and moved to the conveyor and placed on the conveyor, and the tray moves in the conveyor and is stored in the magazine rack by the unloader. .

According to the coating method and apparatus of the present invention, a desired article to be coated is placed on a tray having a larger area than the article to be coated, and is applied to a smaller area than the tray. Furthermore, a mask with the same size as the tray or a larger outside dimension can be set and applied to the substrate. By doing so, even if the coating is air-spraying, the coating material can be applied without protruding from the mask. In particular, for example, an air and paint such as an impact pulse system and the like can be sprayed in a pulsing manner so long as the particles have an angular directivity within 30 degrees, preferably within 20 degrees, and a desired speed. If a micro-curtain device is used to form a liquid film at a low pressure of 0.1 to 0.5 MPa using a spray nozzle or the like and apply the liquid film, the object to be coated is adsorbed on the tray. There is no back of the coating on the object, and when the mask is set, the coating can be applied without scattering to an area smaller than that of the mask, and the coating does not adhere to the back of the tray.

The object to be coated is not limited in shape or size, but sheet-fed type such as semiconductor substrate, LED ceramic substrate or wafer level LED or film is preferable from the viewpoint of handling, and tray does not matter in material, shape, weight etc. May be a flat panel, or may be a tray such as a tray with a shallow bottom, such as round or square. Regardless of the shape, provide pins for positioning the object to be coated, set a counterbore on the shape of the object to be coated, and set the object to be prevented from moving on the tray. Is important. Even in such a case, the table can be vacuum-adsorbed, and if the object to be coated is adsorbed through the holes formed not only in the tray but also in the tray, more accurate positioning and fixing can be performed, and the table is heated. It is preferable because the heat transfer rate to the substrate is high.

It is desirable that the pins provided on the table should have holes pre-machined in the tray to enable positioning, and if the table is a heating table, vacuum suction on the table through a plurality of holes machined in the tray It is suitable from the viewpoint of heat conduction as well as fixing. The tray material is selected from copper, aluminum, brass, etc. from the viewpoint of good heat transfer and cost, and silver, nickel plating etc. with heat conductivity and conductivity are preferable to them, and the object to be coated is semiconductor related When the added value of products or semi-finished products is high, stainless steel may be used, and ceramics such as aluminum nitride, silicon nitride, silicon carbide and alumina, which have higher thermal conductivity, may be used. Furthermore, if it is desired to apply immediately after placing the object on the tray on the heating table, the tray made of the above-mentioned material with good thermal conductivity etc. should be as thin as possible, for example 1 mm or less, strongly on the table It is good to make it adsorb.

In order to perform positioning more accurately, it is preferable to use linear expansion coefficients of the tray and the coated material that are comparable to each other, and the table is made of aluminum or copper or their system, and the surface is electroconductive nickel plated When processing, etc., the tray should be aluminum or copper or their system, and the surface such as gold, silver or nickel plating, which is also conductive in terms of safety in the booth and protection of objects to be coated from static electricity It is good to do processing. If it is desired to use a fluorine-based or ceramic-based surface coating on a table or tray, it is preferable to make the coating impossible or allow the pins and holes to be grounded.

The mask may be adsorbed together with the object to be coated, but if it serves as a heavy stone, it should be a thick plate such as stainless steel, iron or spring steel with a high specific gravity, such as twice or more that of aluminum. It is preferable to carry out a ceramic film treatment or the like, and in the case of recovering a coating material attached to a mask, it is preferable to use a material such as ceramics which does not have the possibility of contamination to provide a surface with enhanced releasability. If you make the mask thicker, it will be easy to make shadows when you spray etc., so the part near the surface to be coated will be a sharp edge, for example at an angle of 45 degrees or less so that the effect will not come out It is good to process it.

In the present invention, a tray or a mask having a larger area than the object to be coated is used, and the coating material can be applied by an applicator which is less likely to scatter the coating material, so handling of the tray or mask becomes easy. Can be

If the tray and mask have the same size, the structure of the automatic machine can be simplified in terms of desorption, which is advantageous in initial cost, but if any coating material adheres to the side of the tray, it is hardened in the baking process and extra time for peeling It is more preferable to make the mask wider than the tray because
When using a silicone-based binder, etc., usually with a thermosetting type, if the table temperature is 60 ° C. or less and curing is not promoted for a long time, the coating material attached to the mask is easy to use an ultrasonic cleaner when using a solvent It can be dissolved and washed, and solid content can be recovered and reused, but if curing or hardening accelerates, peeling becomes difficult. If you want to reuse, you need to carefully examine the binder and the process.
When the coating material is powder, there is no need to heat the table, and the coating device is applied in stripes so that the powder does not scatter by applying, for example, JP-A-289955, and the powder supply method is the ejector method However, for example, the powder adhered to the tray or the mask can be removed by suction and removed for reuse. If the powder is made of a thermoplastic resin or a thermosetting resin, it can be heated for leveling to form a film, and if it does not contain a binder, the binder can be applied and set from the top of the powder layer.

As described above, according to the present invention, the object to be coated is positioned and placed on a tray having a larger area than the total area of the objects to be coated, and the mask is similarly positioned and mounted on the tray. The alignment holes may be inserted into pins provided on the tray so that the object or mask does not move during conveyance. By doing so, automation can be achieved more easily by handling three layers of a tray, an object to be coated, and a mask, which are set in advance, as one work.

By adopting such a method or apparatus, even coating by means of spray, which was conventionally considered impossible, can be applied and baked automatically, and it is possible to recover and reuse the coating material adhered to the mask. can do.

1 is a schematic front cross-sectional view of an apparatus according to an embodiment of the present invention. Figure 2 is a schematic front sectional view of a detail according to an embodiment of the present invention; It is a table (suction) top view concerning an embodiment of the invention. It is a top view of a tray concerning an embodiment of the invention. It is a top view of the to-be-coated-article on the tray which concerns on embodiment of this invention. It is a top view of the mask concerning an embodiment of the invention. It is sectional drawing of the side of the table, tray, to-be-coated-article, and mask which concern on embodiment of this invention. FIG. 1 is a schematic plan view according to an embodiment of the present invention. 1 is a schematic front sectional view according to an embodiment of the present invention. It is a schematic front sectional view of an automatic coating device according to another embodiment of the present invention. It is a top view of the mask concerning an embodiment of the invention.

Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings. The following embodiment is merely an example for facilitating the understanding of the invention, and excludes addition, substitution, modification and the like that can be implemented by those skilled in the art without departing from the technical concept of the present invention. is not.

The drawings schematically illustrate the preferred embodiments of the present invention.

In FIG. 1, the object assembly 11 is stored in the magazine rack 102 and set in the unloader / loader apparatus 101, and the magazine rack 102 is moved up and down according to the downstream movement of the object and storage after application. The object assembly is pushed by a pusher (push / pull mechanism) 103 and moved on a conveyor 106. The workpiece assembly on the conveyor is stopped at the loading / unloading point lifted by the automatic machine 104 which is a handling device. The workpiece assembly 11 is lifted by the claw 105 of the automatic machine, moved to the workpiece assembly mounting position above the table 5 and placed on the table 5. The table may be heated or cooled if necessary, and in order to maintain positional reproducibility, it is preferable to adopt a structure capable of adsorbing the object after placement. The to-be-coated-article assembly 11 on a table opens the shielding mechanism 116 in the coating booth 111, and moves by the Y-axis 114 connected with the table. A shielding belt 115 moving along the Y axis 114 simultaneously with the table 5 is configured to shield the booth 111 and the lower part of the coating apparatus. The mechanism 116 for shielding the booth and the outside is closed, and the object to be coated is applied by moving the Y axis with the applicator 112 connected to the X axis 113 orthogonal to the Y axis. The applicator 112 may be a spray device. Furthermore, a pulsed spray device is preferable from the viewpoint of the deposition efficiency. Since the table 5 also moves synchronously with the application booth 111 and the belt 115 that shields the lower part of the booth, the exhaust system is a nearly closed system except for the intake port 170 upstream of the intake filter 190 and the exhaust port 160 downstream of the exhaust filter not shown. Since suction is performed by an exhaust device (not shown) connected downstream of the mouth, even if the applicator 112 is a spray device, the spray particles do not flow out of the coating booth or to other parts of the coating device 110 and adversely affect. The substrate in the substrate assembly applied to the desired number of coating layers is moved to the mounting position of the substrate assembly, lifted by the substrate assembly 115 of the automatic machine, and moved onto the conveyor 106 And placed on the conveyor. When the coating material contains volatile matter such as a solvent, it is necessary to volatilize 95% or more, preferably 100% or more, of the volatile matter before moving the coated article after coating out of the booth. In order to promote volatilization of the coating film, the table is preferably a heating table, and the table temperature is raised to 75 ° C. or less so that the coating does not have problems such as bumps due to solvent vapor or the like. It is preferable to make settings. The workpiece assembly is accurately moved to the magazine rack by a conveyor such as a belt or chain by the hooks 108 of the hook moving device 107 moving in synchronization with the conveyor. The pusher 103 may be a push and pull mechanism. Alternatively, the object assembly 11 may place the object on the tray without the mask.

FIG. 2 shows a mechanism for moving the object to be coated after application from the conveyor 106 to the magazine rack. The hooks 108 need to be raised when moving to the magazine rack and to be flipped when moving toward the application device 110.

FIG. 3 is a detailed view of the table 5, in which suction holes 31 for a tray, an object to be coated, etc. are processed, and pins 41 for positioning the tray etc. are provided. The pins may be commercially available dowel pins, but if they are machined conically, even if the table is heated and the tray is at room temperature, placement of the tray is easy even if the automatic machine has some variations .

FIG. 4 shows a tray 33, in which a positioning pin hole 42 with the positioning pin 41 of the table of FIG. 3 is processed. Further, the object suction holes 32 are processed, and an object positioning pin 52 is also provided. In addition, a recess 85 for fitting a tab 205 for positioning when removing and conveying the tray is also processed.

FIG. 5 shows that the object to be coated 50 is placed on the tray 33, and the object to be coated 50 is positioned by the object positioning pins 52 of the tray. Furthermore, in order to adsorb the mask, holes may be drilled at the same position of the tray using the holes 51 of the substrate (suction holes 86 in FIG. 4).

FIG. 6 shows a mask 12 covering the object 50 of FIG. The tray positioning pins 41 of the table of FIG. 3 pass through the positioning holes 42 of the tray of FIG. 5 and reach the positioning holes 43 of the mask. If the hole is drilled to half the thickness of the mask to shorten the length of the positioning pin, the positioning hole can not be penetrated. Further, the mask can be adsorbed by the mask suction holes 51 of the object 50 of FIG. In the case where the positioning pin 52 for an object to be coated shown in FIG. The opening 48 for applying the mask may be the effective application area of the object 50 of FIG. 5 and the area is smaller than that of the object.

In FIG. 7, the tray 33, the object to be coated 50, and the mask 12 are positioned and placed on the table 5 in order. The tray, the object to be coated, and the mask will be described below as the object assembly 11.

In FIG. 8, the inlets of a plurality of coating devices 1 are connected by a belt conveyor 10 for drying line. The belt conveyor may be a chain conveyor. The to-be-painted object assembly 11 of the tray, the to-be-coated object, and the mask is transferred from the unloader 7 by the belt conveyor 10 and transferred to the mounting position of the to-be-coated object assembly on the table 5 by the automatic machine 6 such as a robot at the inlet of the applicator. Is positioned and mounted by the pins 41 of the table 5. The table is opened in the coating booth with the shielding means 116 at the coating booth 2 entrance open, and moved relative to the coating machine (not shown) to apply the coating material to the substrate. The intake air to the application booth is taken in through the air intake port and discharged through an exhaust port (not shown) under the booth. The air intake may be natural air intake, or forced air supply and exhaust (Push & Pull of air flow to the booth). When the coating amount is desired to be constant, the coating weight is automatically measured in the coating weight measuring chamber to confirm that the coating weight is stable, and then the coating is stabilized in quality. The coated object assembly is conveyed by the automatic machine 6 to the conveyor belt 10 at the entrance of the coating apparatus 1, and only the tray 12 is removed and conveyed to another conveyor belt moving in parallel with the conveyor line to be downstream of the coating machine Move to the line. The substrate 50 on the tray 33 is conveyed by the conveyor belt 10 to the downstream baking oven 9 and the curing of the coating material is promoted by IR and hot air. After the predetermined time, the mask used in the first coating machine is placed on the substrate 50 on the tray which has been moved from the baking oven to the next coating machine inlet, carried to the booth in the coating machine, and the coating material is laminated. Ru. The mask used in the first application may be recovered and a new mask may be used. The following coated object assemblies can also be automatically transported and applied one by one.

FIG. 9 shows the application type of FIG. 1 and after the application to the object to be coated is completed in the application booth 211, only the mask of the object assembly 11 which has moved to the object assembly mounting position of the table 5 is the automatic detaching device 205. The substrate on the tray is moved under the baking means 200 to stop the tray adsorption on the table to heat the substrate. After heating for a desired time, the tray is adsorbed on the table, passes through the coating booth, moves to the position where the object to be coated is placed, and the mask is placed again on the object to be coated. Then, it moves to the booth 211 again and laminates the coating material. Since the mask is not heated by the baking means, the coating material adhered to the mask can be peeled off by the ultrasonic cleaning device and recovered and reused.

FIG. 10 shows a general coating apparatus, in which a substrate to be coated is placed on a tray from the loader 301 and conveyed, and a coating material is coated on the substrate by the coating unit 312 in the coating booth 311. In this method, the object to be coated is placed on a table and is not heated, so the object to be coated placed on the tray is transported by being placed on a belt conveyor 330 or a chain. Therefore, a first-in first-out method is adopted as a flow operation, and after application, it is stored in a magazine rack of the unloader 302 or the like.

FIG. 11 shows a special mask. For example, if a lead frame type LED or a ceramic substrate type LED is coated with phosphor only on the LED chip, it may not only be economical but also cause performance degradation such as generation of a yellow ring. A mask made by etching or the like on a film or metal thin plate is adsorbed onto the substrate on such a substrate with a high mounting density of LEDs or laminated through an adhesive or the like, and a mask as shown in FIG. 6 is finally obtained. Although it is possible to use a mask having an opening 48 'only at a necessary place for an LED or the like in which the LED is an assembly of multichips, the phosphor attached to the mask may be recovered and reused It is reasonable. The opening may be a circle, an ellipse, or a polygon according to the shape of the LED.

In the present invention, when an applicator sprays an air spray or a coating material into particles in a particle production apparatus and then transports and applies particles in a jet stream, their pattern width on the surface of a substrate such as an LED substrate is 1 to 15 mm. It is preferable to set the spray angle to 20 degrees or less so as to achieve an extent and to prevent rebound.
When the tray or mask is made 1.5 times or more, preferably twice or more as large as the coating pattern, from the end face of the object to the end face, especially when using the aforementioned impact pulse method or micro curtain method There are no spray particles coming out of the

Further, the coating method of the present invention can be applied to the formation of fuel cell electrodes such as PEFC. The coating material can be used as a fuel cell electrode catalyst, and the object to be coated can be used as a GDL (gas diffusion layer) or an electrolyte membrane. In particular, when the electrode catalyst is spray-coated onto an electrolyte membrane which is instantaneously deformed with a solvent or moisture, it is important to apply a thin film while heat-adsorbing the electrolyte membrane. Since the catalyst is expensive and has a risk of ignition, it is important not to scatter spray particles other than the tray and the mask.

According to the present invention, even when using the spray method, it is not necessary to apply the coating material to the extent that the coating material sticks out from the tray on which the coating material is placed. Further, by using a mask, for example, expensive phosphors on the mask can be recovered and reused while maintaining high value-added LEDs with high quality, so that significant cost reduction can be achieved.

DESCRIPTION OF

SYMBOLS

1, 110, 210, 310

Coating apparatus

2, 111, 211, 311 Coating booth 3, 170 Air intake 4 Coating weight measurement apparatus 5 Tables 6, 104, 204

Automatic machine

7, 101, 201, 301

Loader

8, 302 Unloader 9 oven 10 line conveyor 11 object assembly 12 mask 15 used mask unloader 31 suction hole (for tray)
32 adsorption holes (for the object to be coated)
33 tray 41 positioning pin 42 positioning hole (tray)
43 Positioning hole (mask)
48, 48 'mask opening (coated object effective application part)
50 to be coated 51 to be coated hole (mask adsorption hole)
52 Dowel pins for objects to be coated 85 Recess 86

Mask suction hole

90, 115 Booth

lower shielding belt

102, 202

Magazine rack

103, 203 Push /

pull mechanism

105, 205

Tab

106, 206 Conveyor (for L / UL)
107, 207 Hook moving device 108

Hook

111, 211, 311

Coating booth

112, 212, 312

Coating device

113, 213, 313

X axis

114, 214, 314

Y axis

116, 216, 316 Shielding mechanism 160 Exhaust port 180 Damper
190 Air Intake Filter 200 Baking Means

Claims

An application method in which a coating material (Coating Material) is applied to a substrate by an applicator or dispenser incorporated in at least an application booth equipped with an evacuation means, and the tray is sized from the tray to the tray A first step of positioning and placing a small object to be coated, a second step of automatically positioning and placing the tray on a table at a tray placement position outside the coating booth, and the table The third step of opening the shielding mechanism between the inside of the coating booth and the outside and automatically moving it into the coating booth and closing the shielding mechanism, the relative movement between the applicator and the table, and the coating pattern The fourth step of applying a coating material to the object to be coated in a single layer or multiple layers so that the tray does not protrude, and after the application is completed, the table opens the shielding mechanism and moves to the tray placement position outside the booth The fifth step of Coating method tray placing the object to be coated on the Le, characterized in that the automatically move automatically to downstream removed from the table by an automatic machine.
A plurality of objects to be coated are previously positioned and placed on a tray, the area of the tray is made larger than the sum of the areas of the plurality of substrates, and the tray is positioned and placed on a table. 1 application method.
The coating method according to claim 1, wherein a mask having a size equal to or larger than that of the tray is positioned and placed on the object to be coated on the tray in advance.
A loader mechanism is provided upstream of the means for automatically placing the tray on which the object to be coated is placed on the table, and the table is a heating table, and the object to be coated heated by heat conduction is coated in the coating booth. After the material is applied to volatilize the volatile matter of the coating material on the substrate by 95% or more, the table is moved out of the coating booth, and an unloader mechanism is provided downstream of the tray automatic removal means. The coating method according to claim 1, wherein the unloader mechanism is a combined device.
The magazine rack of the tray for the object to be coated is installed upstream of the loader mechanism and the downstream of the unloader mechanism, and loading and unloading of the tray on which the object is placed is automatically performed on the same shelf of the magazine rack. The application method according to claim 4.
The first step of arranging the tray mounting position, the coating booth and the oven in this order, and the table has an adsorption function, and the mask is set on the object to be coated on the tray adsorbed on the table and the table is moved to the coating booth The second step of applying the above-mentioned to-be-coated-article with an applicator with a coating device, and the third step of removing only the mask with an automatic machine after the application is completed, the table moves to a tray mounting position, and the table is a tray Move the coating booth through the coating booth, move to the oven, stop adsorption and accelerate at least the curing of the coating on the coating, then start adsorption and pass through the booth to the tray. A fourth step of moving to the placement position, and fifthly of re-loading the mask on the article, moving the table to the coating booth, and laminating a coating material on the article by the applicator. Characterized by the process Coating method to.
The inlet and outlet ports of a plurality of coating devices (COATER) are arranged in series, and the tray on which the object to be coated is placed is automatically conveyed to the inlet of each coating device, and the tray on which the object to be coated is placed is applied by an automatic machine. The table is moved to the table on the tray mounting position, positioned and mounted on the table, the table is moved into the coating booth, applied to the object by the applicator, and the table is moved to the tray mounting position. After the tray is moved to the coating apparatus inlet by the automatic machine and transferred to the oven between the coating apparatus and the downstream coating apparatus by the conveyor or another automatic machine to accelerate the curing or hardening of the substrate And coating a coating material on the substrate with a coating device further downstream with a coating device, and promoting curing or hardening with an oven downstream.
A mask is set on the to-be-coated object placed on the tray, and at least the tray and the to-be-coated object are adsorbed by a table having an adsorption function, the table is moved to a coating booth to perform coating operation, and the coating is finished 8. A coating method according to claim 7, wherein the mask of the substrate transferred to the post coating apparatus inlet is removed to move only the tray and the substrate to an oven to promote drying or curing.
9. The coating method according to claim 8, wherein the removed mask is conveyed by an automatic machine or another conveyor and set on the substrate again at the inlet of the downstream coating device.
The coating material is a slurry containing slurry (SLURRY), and the slurry attached to the mask is dissolved and recovered with a solvent, the solvent is volatilized, a solvent is newly added, the slurry is added and reused. The application method according to any one of claims 1 to 9.
The object to be coated is an LED or a member for an LED, and the coating material is a SLURRY consisting of a phosphor, a silicone binder and a solvent, or a phosphor and a solvent, and the coating is a spray coating method. The application method according to claim 10.
At least one object to be coated is positioned and placed on a tray of aluminum or copper base material with a thickness of 1 mm or less, and the specific gravity is twice that of aluminum with a thickness of 1 mm or more on the object. The mask made of the above base material is positioned and placed, the mask being equal to or larger than the external dimensions of the tray, and the area being a sequence of tray> coated object (total of one or more), The tray is positioned and placed on a table with a heating and suction function by an automatic machine, and the table is moved to the coating booth so that the table and the applicator move relative to each other so that the coating material does not protrude from the mask 4. A method according to claim 3, wherein the tray on the table is automatically moved downstream.
A method of applying a coating material to a substrate by means of an applicator incorporated in a coating booth equipped with at least exhaust means, positioning and placing one or more substrates on a tray, and further The first step of positioning and placing a mask larger than the object to be coated on the object to be coated to form an object assembly, the object assembly shields the interior of the coating booth from the outside by a conveyor The second step of opening the mechanism and automatically moving into the coating booth and closing the shielding mechanism, and the coating device and the object assembly move relative to each other so that the coating pattern does not protrude the mask. As described in the third step of applying at least one layer of the coating material to the substrate, and after the application is completed, the substrate assembly moves the outside of the booth with the shielding mechanism or the shielding mechanism on the opposite side open and further downstream Move to Coating method according to claim.
The object stored in the magazine rack is transported from the loader to the coating booth, the coating material is automatically applied by the applicator in the coating booth, transported from the coating booth to the unloader, and coated onto the magazine rack by the unloader. A first step of positioning and mounting a coated object on a tray and storing the tray on which the coated object is mounted in a magazine rack, and loading the magazine rack The second step of setting in the unloader combination device, extruding the tray onto the conveyor, lifting the tray by an automatic machine at a predetermined position in the moving direction of the conveyor, and heating the tray at a tray mounting position outside the coating booth A third step of positioning and placing on a suction table, a fourth step of moving the table by opening the shutter into the booth and closing the shutter, and The object to be coated on the bull moves relative to the applicator and the fifth step of applying at least one layer of the coating material by the applicator, and after the application is completed, the table opens the shutter and moves to the tray mounting position And the tray is lifted by the automatic machine and moved to the conveyor to be disposed on the conveyor, and the tray is accommodated in the magazine by the unloader while being moved by the conveyor.