Method for manufacturing led, apparatus for manufacturing led, and led

Abstract

Provided are a high-quality LED and LED member, and a method and a device with which it is possible to manufacture the same in large quantities and at minimal manufacturing cost. The present invention comprises a detachment/attachment unit for the LED or the LED member, a coating unit for performing automatic coating, and a drying unit. A coating is applied using the coating unit, and provisional drying is performed or hardening is accelerated using the drying device. Alternatively, coating and drying are repeated multiple times, after which drying or hardening is finally performed.

1 - 8 . (canceled) 
     
     
         9 . A method for manufacturing an LED or an LED component by applying a coating material to an LED or an LED component, characterized by comprising:
 setting the LED or the LED component on a coated object support unit;   then applying at least one kind of coating material to the LED or the LED component to form at least one coating layer in a coating booth using at least one applicator while moving the coated object support unit and the applicator in a relative manner;   then transferring said coated object support unit to a drying device and promoting at least temporary drying of the LED or the LED component or curing of a binder;   then transferring said coated object support unit to the coating booth and applying said at least one kind of coating material to the LED or the LED component to form a layer using said at least one applicator;   then transferring said coated object support unit to the drying device and promoting at least temporary drying or curing;   executing the above steps a predetermined number of times; and   then finally drying or curing said LED or LED component.   
     
     
         10 . A method for manufacturing an LED or an LED component according to  claim 9 , characterized in that said coated object support unit is transferred directly to said drying device. 
     
     
         11 . A method for manufacturing an LED or an LED component according to  claim 9 , characterized in that said coated object support unit is transferred to said drying device after the LED or the LED component is detached from said coated object support unit, placed in a storage or on a plate, and set on the coated object support unit again. 
     
     
         12 . A method for manufacturing an LED or an LED component according to  claim 9 , characterized in that said at least one kind of coating material is a slurry containing at least a phosphor and a binder. 
     
     
         13 . A method for manufacturing an LED or an LED component according to  claim 9 , characterized in that the number of layers, the number of times of at least temporary drying performed in said drying device, or the number of times of at least processing for promoting curing of the binder contained in a slurry performed in said drying device is selected in the range between 2 and 30. 
     
     
         14 . A method for manufacturing an LED or an LED component according to  claim 9 , characterized in that the amount of coating applied to the LED or the LED component or the color temperature is measured directly or indirectly at least at the time when coating of the second last layer is finished, and if the amount of coating or the color temperature falls out of a predetermined range, coating is performed with a corrected variation amount so that the final amount of coating or color temperature falls within the predetermined range. 
     
     
         15 . A method for manufacturing an LED or an LED component according to  claim 9 , characterized in that said LED comprises a group of LEDs, the coated object support unit is a heating table by which the group of LEDs or the LED component is heated to a temperature between 30° C. and 90° C. at the time of application of a slurry, and the drying device is selected from at least one of a vacuum drying device, hot air drying device, far-infrared drying device, ultraviolet drying device, electrical induction heating drying device, and curing by microwave oven drying device. 
     
     
         16 . A method for manufacturing an LED or an LED component according to  claim 9 , characterized in that said applicator is a fine particle generating device, a portion of the LED or the LED component that need not be coated is masked, and the fine particle generating device and the LED or the LED component are moved relatively pitch-by-pitch, and the phase of the pitch being varied every time at least one layer is applied. 
     
     
         17 . A method for manufacturing an LED or an LED component according to  claim 16 , characterized in that said fine particle generating device is an air spray device, the distance between an ejection part at an end of the air spray device and the LED or the group of LEDs is adjustable in the range between 5 and 80 millimeters, the ejection part at the end of the air spray device and the LED or the group of LEDs are moved relatively at a pitch of 2 to 15 millimeters, and the phase is varied by an amount between 0.1 and 7.5 millimeters every time one layer is applied during coating. 
     
     
         18 . A method for manufacturing an LED or an LED component according to  claim 9 , characterized in that said slurry contains a solvent, the slurry has a viscosity between 1 and 100 mPa·s, and spraying is performed in a pulsed manner. 
     
     
         19 . A method for manufacturing an LED or an LED component according to  claim 18 , characterized in that the weight ratio of the phosphor and the binder is in the range between 1:3 and 10:1, the weight ratio of nonvolatile components and volatile components is in the range between 4:1 and 1:4. 
     
     
         20 . A method for manufacturing an LED or an LED component according to  claim 9 , characterized in that at least one kind of slurry is atomized into particles, and the particles are charged with electricity and applied to the LED or the LED component to form a layer. 
     
     
         21 . A method for manufacturing an LED or an LED component according to any one of  claims 9 - 20 , characterized by comprising: a first step of setting the LED or the LED component on the coated object support unit in a setting/detaching zone outside the coating booth; a second step of transferring the coated object support unit into the booth; a third step of applying a slurry to the LED or the LED component to form at least one layer; a fourth step of transferring the coated object support unit to the drying device outside the booth to promote at least temporary drying or curing; and a fifth step of transferring the coated object support unit into the booth and applying the slurry to form a layer, wherein after repeating the fourth and fifth steps once or multiple times again, the coated object support unit is moved to said setting/detaching zone, the LED or the LED component is detached from the coated object support unit, and the LED or the LED component thus detached is finally dried or cured. 
     
     
         22 - 24 . (canceled)