JP2003202535A - Manufacturing method and device for liquid crystal display element - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To realize a liquid crystal panel assembling line of high speed and high accuracy wherein a tact time and a lead time are short by performing lamination, alignment and compression-bonding stages by using respective devices separately and connecting these as a line. <P>SOLUTION: This manufacturing method is characterized in that the alignment stage is performed after the sticking stage, that the lamination, the alignment and the compression-bonding stages are performed by using respective devices separately, that two or more devices of these are connected to form a series of lines and that devices used in pre- and post-stages thereof are connected thereto to form a series of lines. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a method for manufacturing a liquid crystal display device.

[0002]

2. Description of the Related Art As a conventional technique, Japanese Patent Application Publication No.
As described in Japanese Patent Laid-Open No. 3-129319, after aligning two substrates with high accuracy, a method of laminating and three steps of aligning, laminating and pressure bonding are performed.
A method of working with a board assembly device of a table is known.

Further, as described in Japanese Patent Application Laid-Open No. 3-68364, a magazine lifter (elevator) and the above-mentioned substrate assembling apparatus are connected through a transfer device to form a single line. It is also known how to configure. (Fig. 5)

[0004]

However, in the conventional manufacturing method in which the work is performed in the order of high-accuracy alignment → bonding, in order to prevent the positional deviation that occurs during the movement between the devices, these two Since it is difficult to separate the process into two devices, and the process of crimping is subsequently performed, 1
Since three machines are used to perform three processes, the cycle time is long and it is not suitable for mass production.

Further, since a single device has a positioning function that requires a highly accurate multi-axis moving mechanism and a crimping function that requires a highly rigid pressurizing mechanism, the scale of the device becomes enormous. However, due to the complicated multi-axis mechanism, the rigidity of the device is inevitably lowered, and the positional displacement of the substrate occurs when pressure bonding is performed.

Further, since the tact is long, if a process with a shorter tact, which is before or after this process, is connected through a transfer device to form one line, the device with a shorter tact has a poor operating rate. If the number of devices is increased by separating the board assembly equipment to increase the operation rate, an extra elevator for material supply and material removal for the board assembly equipment is required, and the number of man-hours for material supply and removal is reduced. It had a problem that it took a lot of time.

The present invention solves the above-mentioned problems of the prior art. The object of the present invention is to reduce the scale of each device, the rigidity thereof, the displacement of the substrate during the pressure bonding, and the short tact time. It can be mass-produced and can be combined into a single line by connecting with a process with short tact, which is before or after bonding, positioning, and crimping processes, through a transfer device. It is an object of the present invention to provide a method for manufacturing a liquid crystal display device, which can reduce the number of steps.

[0008]

A method of manufacturing a liquid crystal display element according to the present invention comprises: a first substrate; and a plurality of second substrates having a shape smaller than the first substrate, with a sealing material interposed therebetween, A bonding step of bonding a first substrate and the plurality of second substrates, a first alignment pattern formed on the first substrate, and a plurality of second substrates formed on the second substrate After aligning the first substrate and the plurality of second substrates with the second alignment pattern as a reference, the seal material is temporarily cured to separate the first substrate and the second substrate from each other. The method is characterized by including a positioning step of temporarily fixing and a step of curing the sealing material.

Further, in the liquid crystal display device manufacturing apparatus of the present invention, the first substrate and a plurality of second substrates having a shape smaller than the first substrate are interposed by a sealing material, and the first substrate is formed. And a plurality of second substrates, a bonding device, a first alignment pattern formed on the first substrate, and a second position formed on the plurality of second substrates. The positioning device comprises a positioning device for positioning the first substrate and the plurality of second substrates on the basis of an alignment pattern, and a curing device for curing the sealing material. It is characterized in that a provisional fixing means for temporarily curing the sealing material to fix the first substrate and the second substrate is provided.

[0010]

According to the above method of the present invention, the mutual substrates are bonded to each other before they are aligned with high precision. Therefore, the positional deviation caused by the bonding and the movement between the two devices may occur. The positional deviation that occurs can be corrected during alignment, the bonding process and the alignment process can be separated, and the pressure bonding process can also be separated. By performing these three steps by separate devices, the highly precise multi-axis moving mechanism of the alignment device and the highly rigid pressure mechanism of the crimping device can be separated, and the scale of each device can be increased. Smaller size, more accurate positioning, higher rigidity, and pressure bonding with less displacement due to pressure.

Further, by operating the three processes which were conventionally performed by one device by using different devices, the tact time is reduced to about 1/3, the production amount is increased about 3 times, and the large amount is increased. Production becomes possible.

Furthermore, since the tact is reduced, the tact is originally short, and it is connected to a process such as the seal printing in the previous process and the scattering of the gap material, and the curing of the seal material by irradiation of ultraviolet (UV) in the subsequent process to form one line. In addition, it is possible to build a high-speed production line with less tact variation between processes and no loss time. This line does not need a buffer for filling the difference in tact between processes (apparatuses) or a feeding / removing material apparatus (elevator etc.), which enables continuous integrated production and shortens the lead time.

[0013]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to the drawings. FIG. 1 is configured such that the bonding, positioning, and pressure bonding processes are performed by different devices, each device is connected through a transfer device, and further, a sealing material curing device (ultraviolet irradiation device) in a subsequent process. FIG. 6 is a schematic view showing the operation of the liquid crystal display device manufacturing apparatus, in which the above are also connected to form a series of lines.

The substrate 1 which has been subjected to a predetermined pretreatment and the counter substrate 2 are fed by elevators 4 and 5.

The bonding device 6 positions the supplied counter substrate 2 at the bonding portion 12 to the extent of the outer shape reference of the substrate (± several tens to several 100 μm), and bonds the substrate 1 and the counter substrate 2 to each other. To match.

The bonded substrates 3 are transferred by the transfer device 13
To move to the high precision alignment device 7. In the alignment device 7, the highly accurate alignment unit 14 holds one or more counter substrates 2 on the substrate 1 one by one,
The substrate 1 and the counter substrate 2 are X-pressed while being weakly pressed in the Z-axis direction.
Align with high accuracy (within ± several μm) in the Yθ direction.
When the alignment is completed, the counter substrate 2 is hard to be displaced by increasing the pressure so that the displacement does not occur during the transfer to the next process, or the sealing material of one part is hardened by ultraviolet irradiation or the like. , Temporarily fix it so that it does not move in the XYθ directions.

The substrate 3 for which the alignment has been completed is moved to the pressure bonding device 8 by the transfer device. In the pressure bonding device 8, the high rigidity and high precision pressure bonding machine 15 pressurizes the substrate 1 and the counter substrate 2 to form a gap between the substrate 1 and the counter substrate 2 (a gap into which liquid crystal enters).
To be uniform (several μm ± 1 μm). After the crimping is completed, in order to prevent the gap from expanding due to the elasticity of the seal, irradiate ultraviolet rays or the like from the backside with the irradiation device 16 while applying pressure to temporarily cure the sealing material and fix it so that it does not move in the Z direction. To do. If you are using a thermosetting sealant,
The pressing surface is heated to a predetermined temperature and fixed.

The substrate 3 that has been pressure-bonded and fixed is moved to the seal material curing device 9 by the transfer device, and is irradiated with ultraviolet rays or the like from the front side by the irradiation device 17, and the seal material is fully cured. When a thermosetting sealing material is used, it is placed in an oven and heated to fully cure the sealing material.

The substrate 3 on which the bonding of the substrate 1 and the counter substrate 2 has been completed, the positioning, the pressure bonding, and the curing of the sealing material has been completed is removed by the elevator 10 and sent to the subsequent process.

By the above-described operations, the steps of bonding the substrate 1 and the counter substrate 2, the positioning, and the pressure bonding can be performed by different devices. In addition, it is possible to function as a mass production line with short tact by connecting each device as a series of lines and also connecting a sealing material curing device which is a post process.

FIG. 2 is a sectional view showing an outline of the bonding section 12 of the bonding apparatus 6.

The board 21 is positioned on the board jig 23 by the positioning pins 25, and the counter board 22 is positioned on the counter board jig 24 by the shoulders 26 of the positioning grooves. (± several tens to several 100 μm
Positioned). The counter substrate jig 24 descends and the counter substrate 22 is bonded to the substrate 21. The counter substrate jig 24 is lifted away from the counter substrate 22, and the bonding is completed.

Here, there is no need for a mechanism for highly accurate positioning or a mechanism for crimping at high pressure, and the mechanism is simple and the tact time is short. Further, even when there are a plurality of counter substrates 22, they can be bonded together, so that there is no change in tact.

FIG. 3 is a sectional view showing the outline of the alignment section 14 of the alignment apparatus 7.

The substrate 31 is suction-held on the substrate jig 33 and is carried to the alignment section together with the substrate jig 33. When transported to the alignment section, the counter substrate jig 34 descends to adsorb and hold the counter substrate 32, and continues to apply a weak pressure as it is. The pattern 36 for aligning the substrate and the counter substrate is observed by the microscope 36, and the relative positional deviation between the substrate 31 and the counter substrate 32 is calculated by image processing. Substrate 3 according to the amount of displacement
1 is moved in the XY direction, and the counter substrate 32 is moved in the θ direction, and both are aligned with high accuracy (within ± several μm). When the alignment is completed, the counter substrate jig 34 lifts the counter substrate 32 apart.

When there are a plurality of counter substrates 32, the substrate 31 is replaced by X.
By moving in the Y direction, the next counter substrate is placed under the counter substrate jig 34, and the alignment is continued.

Since only a mechanism for highly accurate positioning is required here, and a mechanism for crimping at high pressure is not required, it is possible to perform highly accurate positioning with a compact XYθ table with low rigidity.

FIG. 4 is a sectional view showing the outline of the crimping portion of the crimping device 8 between the crimping machine 15 and the irradiation machine 16. The substrate 41 and the counter substrate 42 that have completed the alignment are made of a table 44 made of a transparent material such as glass through which irradiation light can easily pass.
And is pressurized at a high pressure by the pressure plate 43. It is heated by the heater 46 to soften the sealing material and shorten the pressing time. When the predetermined distance between the substrates is obtained, ultraviolet rays (UV) 45 or the like is irradiated from the back surface by an irradiator to temporarily cure the sealing material so that the gap (distance between the substrates) does not widen even when pressure is stopped. . When a thermosetting sealing material is used, the sealing material is temporarily hardened by heating with the heater 46. When the sealing material is cured to a certain extent, the pressure is released, the substrate is removed, and the sealing material is sent to the sealing material curing device 9 in order to be completely cured.

Here, only a mechanism for pressurizing with high precision and high pressure is required. The movable part has only the Z-axis for pressurization, and has a simple structure in which the pressurizing plate 43 is attached to the Z-axis with high accuracy and high rigidity. Since it has only one axis, it is possible to easily construct a highly rigid table as compared with a multi-axis combination mechanism. Further, since the structure is simple, it is easy to incorporate a heater 46 or the like for heating the sealing material to soften it and shorten the pressing time into the pressing plate 43. In this device, as the parts for the mechanical structure, it is difficult to process the glass and it is very difficult to use the glass.
It can be used as a material. This is because the structure is simple, the table 44 does not move, the suction groove for the substrate 41, the positioning pin, etc. are not required, and the hole processing on the glass is not necessary at all.

As shown in FIG. 1, the steps of laminating, aligning, and pressure bonding are constituted by separate devices, arranged in the order shown in FIG. 1, and formed into a series of lines. Separation of the two processes reduces tact and increases production. In this example, since the tact as a line is reduced, the tact is originally short, and the sealing material curing device by UV irradiation in the subsequent process is connected to form a series of lines, so a buffer or elevator that enters between processes is required. It has been eliminated and a continuous high-speed integrated production line with no loss time has been built, and the lead time has been shortened.

Further, since the positioning is performed with high accuracy after the bonding with low accuracy, the positional deviation between the substrates caused by the bonding or the movement between the bonding device and the positioning device occurs. It is possible to correct the positional deviation that occurs. By separating the positioning device from the crimping device, it is possible to pursue only the mechanism for highly accurate positioning in the positioning device and only the mechanism for pressurizing with high pressure in the crimping device. In addition to making it smaller, it is possible to perform more accurate positioning, higher rigidity and higher accuracy, and crimping with less displacement due to pressure.

Further, the alignment device has high rigidity,
Since it does not use a heavy table, it can be driven at high speed and can be aligned at high speed and with high accuracy, and it does not affect the tact as a line even when there are multiple opposing substrates. Also, because the mechanism of each device is simplified, other mechanisms (heating by heater, temporary curing of seal by ultraviolet rays, etc.)
Can be added to improve accuracy and tact without sacrificing accuracy, rigidity and tact.

The embodiment described here is merely one embodiment, and a series of lines are formed by connecting devices such as sticker printing in the previous step of bonding and scattering of gap material, or liquid crystal injection in the subsequent step. Alternatively, a method of manufacturing liquid crystal display elements having various configurations, such as separating the rear of the alignment device or the pressure bonding device and inserting an inspection process or a buffer, can be considered.

[0034]

According to the method and apparatus for manufacturing a liquid crystal display element of the present invention described above, the positional deviation caused by the bonding can be corrected by performing the positioning after bonding the substrates. , The alignment accuracy is improved. The takt time is shortened by performing the three processes of laminating, aligning, and crimping with different devices, and by connecting these devices and the devices of the preceding and following processes into a series of lines, production is possible. Increased quantity and reduced lead time.

Further, there are three processes of bonding, positioning and pressure bonding.
By separating the two processes, it is possible to pursue only the mechanism for highly accurate alignment with the alignment device and only the mechanism for highly accurate pressurization with the crimping device. , Faster and more accurate alignment, more rigid and highly accurate pressure bonding with less displacement due to pressure.

Furthermore, since the mechanism of each device is simple, it is possible to easily add another mechanism for improving accuracy and tact.

[Brief description of drawings]

FIG. 1 is a schematic diagram showing an operation of a liquid crystal display element manufacturing apparatus using a liquid crystal display element manufacturing method according to an embodiment of the present invention.

FIG. 2 is a cross-sectional view showing an outline of a bonding section of the bonding apparatus.

FIG. 3 is a cross-sectional view showing an outline of an alignment unit of the alignment device.

FIG. 4 is a cross-sectional view schematically showing a crimping portion of the crimping device.

FIG. 5 is a schematic view showing an operation of a conventional liquid crystal display element manufacturing apparatus configured to perform positioning, bonding, and pressure bonding with a single apparatus.

[Explanation of symbols]

1 Liquid crystal display element substrate 2 Liquid crystal display element counter substrate 3 Assembled liquid crystal display element substrate 4 Elevator for substrate supply 5 Elevator for counter substrate supply 6 Laminating device 7 Positioning device 8 Crimping device 9 Sealant curing device 10 Elevator for removing substrate 11 Counter substrate reversing mechanism 12 Laminating part 13 Substrate transfer device 14 Positioning unit 15 Crimping machine 16 Irradiator 17 Irradiator 21 Liquid crystal display element substrate 22 Liquid crystal display element counter substrate 23 Substrate suction jig 24 Counter substrate suction jig 25 Positioning pin 26 Shoulder of positioning groove 31 Liquid crystal display element substrate 32 Liquid crystal display element counter substrate 33 Substrate suction jig 34 Counter substrate suction jig 35 Alignment pattern 36 microscope 41 Liquid crystal display element substrate 42 Liquid crystal display element counter substrate 43 Crimping plate 44 glass table 45 Irradiation light (ultraviolet rays, etc.) 51 Liquid crystal display element substrate 52 Liquid crystal display element counter substrate 53 Assembled liquid crystal display element substrate 54 Elevator for substrate supply 55 Elevator for counter substrate supply 56 Laminating / positioning / crimping device 60 Elevator for removing substrate 61 Counter substrate reversing mechanism 62 Bonding / Crimping part 63 Substrate transfer device 64 Positioning unit

Claims (2)

[Claims] 1. A first substrate and a plurality of second substrates having a shape smaller than that of the first substrate are bonded to each other with a sealing material interposed between the first substrate and the plurality of second substrates. The bonding step, the first alignment pattern formed on the first substrate, and the second alignment patterns formed on the plurality of second substrates Aligning the first substrate and the plurality of second substrates, and then temporarily curing the sealing material to temporarily fix the first substrate and the second substrate; and a step of curing the sealing material. A method for manufacturing a liquid crystal display device, comprising: 2. A first substrate and a plurality of second substrates having a shape smaller than that of the first substrate are bonded to each other with a sealing material interposed between the first substrate and the plurality of second substrates. The bonding device for matching, the first alignment pattern formed on the first substrate, and the second alignment patterns formed on the plurality of second substrates are used as a reference, and the first alignment pattern is formed. And a curing device that cures the sealing material, the alignment device temporarily curing the sealing material and the first substrate. An apparatus for manufacturing a liquid crystal display element, comprising: and a temporary fixing means for the second substrate.