Source: http://www.patentsencyclopedia.com/app/20120309119
Timestamp: 2017-02-26 08:18:50
Document Index: 5284245

Matched Legal Cases: ['art.\n5', 'art.\n13', 'arts 110', 'arts 120', 'arts 130', 'arts 110', 'arts 110', 'arts 110', 'art 110', 'art 110', 'art 110', 'art 110', 'art 110', 'art 110', 'art 110', 'art 110', 'art 110', 'art 110', 'art 110', 'art 110', 'art 110', 'art 110', 'art 120', 'art 110', 'art 120', 'art 120', 'art 120', 'art 120', 'art 110', 'art\n120', 'art 110', 'art 120', 'arts 110', 'arts 110', 'arts 120', 'arts 110', 'art 120', 'art 120', 'art 120', 'art 130', 'art 120', 'art 130', 'art 120', 'art 130', 'art 130', 'art 110', 'art 120', 'art 130', 'art 110', 'art 120', 'art 130', 'art 130', 'art 120', 'art 110', 'art 120', 'arts\n130', 'arts 110', 'arts 120', 'arts 130', 'art 120', 'arts 110', 'arts 120', 'arts 130', 'arts 110', 'art 110', 'arts 120', 'art 110', 'arts 120', 'art 110', 'art 110', 'art 110', 'arts 110', 'arts 110', 'art 110', 'art 120', 'art 110', 'art 130', 'art 120', 'art 130', 'art 130', 'art 130', 'art\n120', 'art 110', 'art 120', 'arts 120', 'arts 110', 'arts 130', 'art 110', 'art 120', 'art 130', 'art 120', 'art 110', 'art 120', 'art 130', 'art\n120', 'art\n120', 'arts\n110', 'arts 110', 'arts\n110', 'arts 110', 'arts 110', 'arts 110', 'arts 110', 'arts 110', 'arts 110', 'arts 110', 'arts 110']

VACUUM TRAY AND METHOD OF MANUFACTURING LIGHT EMITTING DEVICE USING THE SAME - Patent application
Patent application title: VACUUM TRAY AND METHOD OF MANUFACTURING LIGHT EMITTING DEVICE USING THE SAME
Jong Sup Song (Suwon, KR)
Tae Gyu Kim (Hwaseong, KR)
Jae Sung You (Suwon, KR)
Patent application number: 20120309119
There is provided a vacuum tray including a pocket part; a seating part
being stepped downwardly from a bottom surface of the pocket part and
having a light emitting device seated therein; and a cavity part being
stepped downwardly from edges of the seating part and having an electrode
terminal of the light emitting device accommodated therein. The pocket
part may include a plurality of pocket parts having a matrix structure,
such that the plurality of pocket parts are arranged in columns and rows.Claims:
1. A vacuum tray comprising: a pocket part; a seating part stepped
downwardly from a bottom surface of the pocket part and having a light
emitting device seated therein; and a cavity part stepped downwardly from
edges of the seating part and having an electrode terminal of the light
emitting device accommodated therein.
2. The vacuum tray of claim 1, wherein the pocket part comprises a
plurality of pocket parts having a matrix structure such that the
plurality of pocket parts are arranged in columns and rows.
3. The vacuum tray of claim 1, further comprising a vacuum hole provided
in a bottom surface of the cavity part and communicating with the cavity
4. The vacuum tray of claim 1, wherein the pocket part has internal side
surfaces inclined toward the light emitting device such that an area
defined by upper edges of the pocket part is wider than that of the
bottom surface of the pocket part.
5. The vacuum tray of claim 1, wherein the pocket part has an upper edge
disposed to be higher than an upper surface of the light emitting device.
6. The vacuum tray of claim 1, wherein the seating part includes a
vertical surface contacting a side surface of the light emitting device
and a flat surface extending from the vertical surface in a horizontal
manner and contacting a lower surface of the light emitting device, and
the seating part has a shape corresponding to that of the light emitting
7. The vacuum tray of claim 6, wherein the seating part further includes
a sealing member provided on the flat surface.
8. The vacuum tray of claim 2, wherein intervals between upper edges of
the pocket parts and seating parts provided within the corresponding
pocket parts are consistent.
9. The vacuum tray of claim 1, wherein the pocket part includes at least
one seating part and at least one cavity part therein.
10. A method of manufacturing a light emitting device, the method
comprising: preparing a vacuum tray including a pocket part, a seating
part stepped downwardly from a bottom surface of the pocket part and
having a light emitting device seated therein, and a cavity part stepped
downwardly from edges of the seating part and having an electrode
terminal of the light emitting device accommodated therein; mounting the
light emitting device in the seating part within the pocket part such
that the electrode terminal formed on a lower surface of the light
emitting device is accommodated in the cavity part; forming a phosphor
layer by filling the pocket part with a resin containing a phosphor
material while covering the light emitting device; and separating the
light emitting device having the phosphor layer formed thereon from the
pocket part of the vacuum tray.
11. The method of claim 10, wherein the pocket part comprises a plurality
of pocket parts having a matrix structure such that the plurality of
pocket parts are arranged in columns and rows.
12. The method of claim 10, wherein the mounting of the light emitting
device includes fixing the light emitting device to the seating part
using a vacuum hole communicating with the cavity part.
13. The method of claim 10, wherein the forming of the phosphor layer
includes: providing the resin to the pocket part to be even with an upper
surface of the vacuum tray to thereby obtain planarization; and hardening
14. The method of claim 13, wherein the planarization is performed by
removing an excess amount of the resin protruded upwardly from the upper
surface of the vacuum tray from the pocket part using a squeegee.
15. The method of claim 13, further comprising polishing an upper surface
of the phosphor layer being hardened.Description:
No. 10-2011-0051457 filed on May 30, 2011, in the Korean Intellectual
[0003] The present invention relates to a vacuum tray and a method of
manufacturing a light emitting device using the same.
[0005] In recent years, various electronic devices, as well as mobile
communications devices such as a personal mobile phone, a personal
digital assistant (PDA) and the like, have used a light emitting diode
(LED), emitting light according to electrical signals, as a light source.
[0006] LEDs, a type of light emitting devices, are capable of producing
light of various colors by altering semiconductor compounds such as GaAs,
AlGaAs, GaN, InGaP, and the like.
[0007] LEDs may emit red light, blue light, green light or ultraviolet
light according to compounds contained therein. White light may be
produced by combining red light, blue light, and green light emitted from
the respective LEDs. However, such a method of producing white light
requires the use of a plurality of LEDs and difficulties in color
uniformity may occur.
[0008] Accordingly, a phosphor material for a wavelength conversion of
light is generally mixed with a resin such as silicon or the like and a
mixture thereof is applied to form a white LED. Due to the mixture, blue
light or ultraviolet light emitted from the LED is converted into white
light, and thus monochromatic white light may be produced.
[0009] However, such a method of mixing the phosphor material with the
resin and applying the mixture thereof has a problem in that the
thickness of a phosphor layer formed on a surface of the LED may be
uneven. In particular, in the case of LEDs manufactured on a mass
production basis, the requirements for the distribution of the thickness
of the phosphor layer may not be satisfied.
[0010] An aspect of the present invention provides a vacuum tray
satisfying requirements for the distribution of the thickness of a
phosphor layer formed on a surface of a light emitting device when
manufactured on a mass production basis and a method of manufacturing a
light emitting device using the same.
a vacuum tray including: a pocket part; a seating part stepped downwardly
from a bottom surface of the pocket part and having a light emitting
device seated therein; and a cavity part stepped downwardly from edges of
the seating part and having an electrode terminal of the light emitting
device accommodated therein.
[0012] The pocket part may include a plurality of pocket parts having a
matrix structure such that the plurality of pocket parts are arranged in
[0013] The vacuum tray may further include a vacuum hole provided in a
bottom surface of the cavity part and communicating with the cavity part.
[0014] The pocket part may have internal side surfaces inclined toward the
light emitting device such that an area defined by upper edges of the
pocket part is wider than that of the bottom surface of the pocket part.
[0015] The pocket part may have an upper edge disposed to be higher than
an upper surface of the light emitting device.
[0016] The seating part may include a vertical surface contacting a side
surface of the light emitting device and a flat surface extending from
the vertical surface in a horizontal manner and contacting a lower
surface of the light emitting device, and the seating part may have a
shape corresponding to that of the light emitting device.
[0017] The seating part may further include a sealing member provided on
[0018] Intervals between upper edges of the pocket parts and seating parts
provided within the corresponding pocket parts may be consistent.
[0019] The pocket part may include at least one seating part and at least
one cavity part therein.
provided a method of manufacturing a light emitting device, the method
including: preparing a vacuum tray including a pocket part, a seating
[0021] The pocket part may include a plurality of pocket parts having a
[0022] The mounting of the light emitting device may include fixing the
light emitting device to the seating part using a vacuum hole
communicating with the cavity part.
[0023] The forming of the phosphor layer may include providing the resin
to the pocket part to be even with an upper surface of the vacuum tray to
thereby obtain planarization; and hardening the resin.
[0024] The planarization may be performed by removing an excess amount of
the resin protruded upwardly from the upper surface of the vacuum tray
from the pocket part using a squeegee.
[0025] The method may further include polishing an upper surface of the
phosphor layer being hardened.
[0026] The above and other aspects, features and other advantages of the
[0027] FIGS. 1A and 1B are schematic views of a vacuum tray according to
[0028] FIG. 2 is a schematic view of a pocket part in the vacuum tray of
[0029] FIGS. 3A and 3B are schematic views of a seating part of FIG. 2;
[0030] FIG. 4 is a schematic view of a vacuum tray according to another
[0031] FIGS. 5A through 10 are schematic views illustrating a method of
manufacturing a light emitting device according to an embodiment of the
[0032] FIG. 11 is a schematic view of a lighting module including a light
emitting device manufactured according to an embodiment of the present
[0033] Embodiments of the present invention will now be described in
[0034] The invention may, however, be embodied in many different forms and
[0035] In the drawings, the shapes and dimensions of elements may be
[0036] A vacuum tray according to an embodiment of the present invention
will be described with reference to FIGS. 1A through 3.
[0037] FIGS. 1A and 1B are schematic views of a vacuum tray according to
an embodiment of the present invention; FIG. 2 is a schematic view of a
pocket part in the vacuum tray of FIGS. 1A and 1B; and FIGS. 3A and 3B
are schematic views of a seating part of FIG. 2.
[0038] With reference to FIGS. 1A and 1B, a vacuum tray according to an
embodiment of the present invention may be a metallic plate structure and
include a plurality of pocket parts 110, and seating parts 120 and cavity
parts 130 provided within the individual pocket parts 110.
[0039] The plurality of pocket parts 110 may be recessed in a surface of
the vacuum tray 100 as shown in FIGS. 1A and 1B and may have a matrix
structure in which the plurality of pocket parts 110 are arranged in
[0040] The pocket part 110 is a space within the vacuum tray 100 for
accommodating a light emitting device 10. An area defined by upper edges
of the pocket part 110 is wider than that of a bottom surface 112 thereof
on which the light emitting device 10 is seated, such that the pocket
part 110 has an inverted pyramid structure in which an internal side
surface 111 thereof is inclined toward the light emitting device 10.
[0041] The pocket part 110 has a depth greater than the thickness of the
light emitting device 10 such that the upper edge of the pocket part 110
is disposed to be higher than an upper surface 11 of the light emitting
device 10 disposed within the pocket part 110. Specifically, in a case in
which the light emitting device 10 is mounted on the bottom surface 112
of the packet part 110, the upper surface 11 of the light emitting device
10 is not exposed above the upper edge of the packet part 110.
[0042] A space between the light emitting device 10 mounted on the bottom
surface 112 of the pocket part 110 and the internal side surface 111 of
the pocket part 110 and a space between the upper surface 11 of the light
emitting device 10 and the upper edge of the pocket part 110 define the
thickness of a phosphor layer 20. Specifically, when a resin for the
phosphor layer 20 is injected in a state in which the light emitting
device 10 is mounted within the pocket part 110, the resin fills the
space between the light emitting device 10 and the pocket part 110,
thereby forming the phosphor layer 20. Therefore, the thickness of the
phosphor layer 20 may be adjusted by altering the depth of the pocket
part 110, a distance between the internal side surface 111 and the light
emitting device 10, and the like.
[0043] The seating part 120 is stepped by being recessed downwardly from
the bottom surface 112 of the pocket part 110 and has the light emitting
device 10 seated therein.
[0044] As shown in FIG. 2, the seating part 120 includes a vertical
surface 121 contacting a side surface 13 of the light emitting device 10
and a flat surface 122 extending from the vertical surface 121 in a
horizontal manner and contacting a lower surface 12 of the light emitting
device 10. The seating part 120 has a shape corresponding to that of the
light emitting device 10. Therefore, in a case in which the light
emitting device 10 is seated on the seating part 120, edge portions of
the lower surface 12 of the light emitting device 10 and the individual
side surfaces 13 adjacent thereto contact the flat surface 122 and the
vertical surface 121, respectively, and are supported thereby.
[0045] The seating part 120 is parallel to the upper edge of the pocket
part 110. When the light emitting device 10 is seated in the seating part
120, the upper surface 11 of the light emitting device 10 is parallel to
an upper surface 101 of the vacuum tray 100. An interval (i.e., depth)
between the upper edge of the pocket part 110 and the seating part 120 is
consistent. In particular, in a case in which the plurality of pocket
parts 110 are formed, intervals between the upper edges of the individual
pocket parts 110 and the seating parts 120 provided within the
corresponding pocket parts 110 are entirely consistent.
[0046] The seating part 120 may include a sealing member 150, formed of an
insulating material such as an o-ring, on the flat surface 122 as shown
in FIG. 3A. When the light emitting device 10 is mounted in the seating
part 120, the sealing member 150 may act as a buffer to protect the light
emitting device 10 and prevent a gap between the seating part 120 and the
light emitting device 10.
[0047] The sealing member 150 may be provided on the flat surface 122, and
may be also provided on the vertical surface 121 as shown in FIG. 3B.
[0048] The cavity part 130 is stepped by being recessed downwardly from
edges of the seating part 120 and accommodates an electrode terminal 14
of the light emitting device 10. The light emitting device 10 may be a
bare chip having the electrode terminal 14 formed on the lower surface
12. Although not shown, a solder bump may be further provided on the
electrode terminal 14.
[0049] As shown in FIG. 2, the cavity part 130 is stepped downwardly from
edges of the seating part 120, that is, edges of the flat surface 122.
The cavity part 130 may have a depth greater than a protruding height of
the electrode terminal 14 such that the cavity part 130 accommodates the
electrode terminal 14 formed on the lower surface 12 of the light
emitting device 10 therein.
[0050] Therefore, in a case in which the light emitting device 10 is
mounted within the pocket part 110, the light emitting device 10 is
seated in the seating part 120 while being supported and fixed thereby,
the electrode terminal 14 of the light emitting device 10 is accommodated
within the cavity part 130 without contact between the electrode terminal
14 and the vacuum tray 100. This structure allows the light emitting
device 10 to be mounted within the pocket part 110 while being fixedly
supported by the seating part 120.
[0051] Meanwhile, a vacuum hole 140 may be formed in the bottom surface of
the cavity part 130 to communicate with the cavity part 130. The vacuum
hole 140 is coupled to an external vacuum pump (not shown), whereby the
light emitting device 10 is firmly fixed to the seating part 120 within
the pocket part 110 through vacuum suction so as not to be easily
separated from the seating part 120.
[0052] The single vacuum hole 140 is formed in the individual cavity parts
130; however, the invention is not limited thereto. The number of the
vacuum hole 140 may be varied.
[0053] Hereinafter, a vacuum tray according to another embodiment of the
invention will be described with reference to FIG. 4.
[0054] The vacuum tray according to the embodiment of FIG. 4 has
substantially the same basic structure as that of the vacuum tray
according to the embodiment of FIGS. 1A through 3. Since a seating part
and a cavity part in this embodiment have different structures to those
of the embodiment of FIGS. 1A through 3, a detailed description thereof
will be provided with omissions of descriptions of the same structure.
[0055] FIG. 4 is a schematic view of a vacuum tray according to another
[0056] As shown in FIG. 4, each of the pocket parts 110 includes a
plurality of seating parts 120' and a plurality of cavity parts 130'
formed on the bottom surface 112 thereof. That is, contrary to the case
of FIG. 1 in which the single seating part 120 is formed within the
individual pocket parts 110, the plurality of seating parts 120' and the
plurality of cavity parts 130' may be formed within each of the pocket
parts 110. Therefore, the plurality of light emitting devices 10 may be
mounted within the single pocket part 110.
[0057] Intervals between the plurality of seating parts 120' and the upper
edge of the pocket part 110 may be consistent. Accordingly, intervals
between the upper surfaces of the individual light emitting devices 10
seated in the individual seating parts 120' and the upper edge of the
pocket part 110 may be consistent.
[0058] In a case in which the plurality of light emitting devices 10 are
mounted within the pocket part 110, the pocket part 110 is filled with a
resin to thereby form a phosphor layer. In this case, the phosphor layer
is integrally formed with respect to the plurality of light emitting
devices 10, whereby mass production may be facilitated. In addition, a
multichip formed of the plurality of light emitting devices may be
manufactured. In particular, the thickness of the phosphor layer formed
on the individual light emitting devices is consistent, so that a
plurality of light emitting devices having the same light characteristics
may be manufactured at the same time.
[0059] With reference to FIGS. 5A through 10, a method of manufacturing a
light emitting device according to an embodiment of the invention will be
described below. FIGS. 5A through 10 are schematic views illustrating
individual operations included in a method of manufacturing a light
emitting device according to an embodiment of the invention.
[0060] First of all, the vacuum tray 100 for the mounting of the light
emitting devices 10 as shown in FIGS. 1A through 4 is prepared.
[0061] The vacuum tray 100 includes the plurality of pocket parts 110, in
which the respective light emitting devices 10 are mounted, and has a
matrix structure in which the plurality of pocket parts 110 are arranged
in columns and rows.
[0062] Each pocket part 110 includes the seating part 120 being stepped by
being downwardly recessed from the bottom surface of the pocket part 110
and allowing the light emitting device 10 to be seated therein. Further,
the cavity part 130 is provided to be stepped by being downwardly
recessed from the edges of the bottom surface of the seating part 120,
and the electrode terminal 14 of the light emitting device 10 is
accommodated within the cavity part 130.
[0063] Meanwhile, the vacuum hole 140 may be formed in the bottom surface
of the cavity part 130 to communicate with the cavity part 130. The
vacuum hole 140 is coupled to an external vacuum pump (not shown),
whereby the light emitting device 10 is firmly fixed to the seating part
120 within the pocket part 110 through vacuum suction so as not to be
easily separated from the seating part 120.
[0064] Next, as shown in FIGS. 5A and 5B, the light emitting devices 10
are respectively mounted in the seating parts 120 within the individual
pocket parts 110 while allowing the electrode terminals 14 formed on the
lower surfaces 12 of the light emitting devices 10 to be accommodated
within the cavity parts 130. The light emitting device 10 may be a bare
chip having the electrode terminal 14 formed on the lower surface 12
while the phosphor layer 20 is not yet formed on a surface thereof. Each
pocket part 110 may have a single light emitting device or a plurality of
light emitting devices mounted therein.
[0065] As shown in FIG. 6, in order to prevent the light emitting device
10 from being separated from the seating part 120, the vacuum hole 140
communicating with the cavity part 130 is provided to fix the light
emitting device 10 to the seating part 120. In this manner, the light
emitting device 10 may be stably fixed while maintaining a horizontal
state within the pocket part 110 during the manufacturing thereof.
[0066] The vacuum hole 140 may be coupled to a vacuum pump (not shown) to
thereby allow for the fixation of the light emitting device 10 through
vacuum suction generated by the operation of the vacuum pump. In a case
in which the light emitting device 10 is seated in the seating part 120,
the cavity part 130 may be airtight. To enable this, the sealing member
150 formed of an insulating material may be provided on the seating part
120. When the light emitting device 10 is mounted in the seating part
120, the sealing member 150 may act as a buffer to protect the light
[0067] Next, as shown in FIGS. 7A through 8, the individual pocket parts
110 are filled with a resin 20' containing a phosphor material to cover
the light emitting devices 10, thereby forming the phosphor layer 20.
[0068] As shown in FIGS. 7A and 7B, a certain amount of the resin 20'
containing the phosphor material is applied to the upper surface 101 of
the vacuum tray 100 using a dispenser (not shown) or the like. The amount
of the resin 20' may be sufficient to fill the entirety of the plurality
of pocket parts 110 formed in the vacuum tray 100.
[0069] In a state in which the resin 20' is applied to the pocket parts
110, the resin 20' may be spread from one end of the vacuum tray 100
towards the other end thereof using a squeegee S or the like, and thus,
the individual pocket parts 110 may be filled with the resin 20' applied
to the upper surface 101 of the vacuum tray 100 in a printing scheme.
[0070] As shown in FIG. 8, an excess amount of the resin 20' protruded
upwardly from the upper surface 101 of the vacuum tray 100 is removed
from the individual pocket parts 110 using the squeegee S or the like,
such that the resin 20' filling the individual pocket parts 110 may be
even with the upper surface 101 of the vacuum tray 100 to obtain
[0071] Then, the resin 20' is hardened to thereby form the phosphor layer
20. Therefore, the phosphor layer 20 formed within the individual pocket
parts 110 may have the same height.
[0072] As described above, the plurality of pocket parts 110 may be filled
with the resin 20' containing the phosphor material by a single printing
process, whereby manufacturing time may be reduced. In addition, the
phosphor layer having the same height may be formed.
[0073] The phosphor layer 20 converts a wavelength of light emitted from
the light emitting device 10 to a wavelength of light having a desired
color. For example, the phosphor layer 20 may convert monochromatic light
such as red light or blue light to white light. To enable this, the resin
for the phosphor layer 20 may contain at least one phosphor material. In
addition, an ultraviolet absorbent may be further included therein in
order to absorb ultraviolet rays emitted from the light emitting device
[0074] The phosphor layer 20 may be formed within the pocket parts 110 by
the filling and hardening of the resin 20'. The resin 20' for the
phosphor layer 20 may be a resin having high transparency allowing light
produced in the light emitting device 10 to pass therethrough while
minimizing light loss. For example, an elastic resin may be used
therefor. An elastic resin is a gel-type resin such as silicon or the
like and has superior optical characteristics since it is minimally
affected by yellowing caused by short wavelength light or the like, and
has high refractivity. Unlike an epoxy resin, the elastic resin may
maintain a gel or elastomer state even after the hardening thereof, such
that it may allow the light emitting device to be more stable with regard
to thermal stress, vibrations, external impacts or the like. Also, since
the phosphor layer 20 is hardened after the pocket parts 110 are filled
therewith in a liquid state, during the hardening process, bubbles
therein may be exposed to the air and move outwardly.
[0075] Then, as shown in FIG. 9, an upper surface of the hardened phosphor
layer 20 and the upper surface 101 of the vacuum tray 100 are both
polished by a polishing device P or the like. Accordingly, the hardened
resin remaining on a portion of the upper surface 101 of the vacuum tray
100 may be completely removed therefrom.
[0076] Then, as shown in FIG. 10, the light emitting devices 10 are
separated from the individual pocket parts 110 of the vacuum tray 100,
thereby achieving mass production of light emitting devices 10', each of
which has the phosphor layer 20 formed on a surface thereof.
[0077] In the mass-produced plurality of light emitting devices 10', the
thickness of the phosphor layer is uniform, such that the requirements
for the distribution of the thickness of the phosphor layer may be
satisfied. Therefore, defective rates may be minimized and improved
productivity may be achieved.
[0078] As shown in FIG. 11, a lighting module 1 may be manufactured by
mounting the light emitting device 10' having the phosphor layer 20
formed thereon on a substrate B in a flip-chip bonding scheme. In this
case, a separate phosphor application process or the like is not
required, whereby manufacturing process is simplified and production
[0079] As set forth above, a vacuum tray according to embodiments of the
invention satisfies requirements for the distribution of the thickness of
a phosphor layer formed on a surface of a light emitting device when
manufactured on a mass production basis.
[0080] While the present invention has been shown and described in
Patent applications by Jae Sung You, Suwon KR
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