JP2005270799A - Droplet discharge apparatus having coordinate adjustment device, coordinate adjustment method, method of manufacturing electro-optic device, electro-optic device, and electronic device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a droplet discharge apparatus capable of highly precisely discharging a droplet and having a coordinate adjusting device by carrying out the adjustment of a relative position accuracy of the coordinate between a 1st movement axis for moving a head and a 2nd movement axis moving a work to improve the position accuracy before the droplet is discharged. <P>SOLUTION: The coordinate adjusting device is provided with a position deviation detecting member 40 held by a table and having a pattern 40A comprising a plurality of marks aligned with a prescribed pitch to detect the position deviation of the 1st movement axis X and the 2nd movement axis, an image pick-up section 50 for imaging the pattern 40A of the position deviation detecting member 40 while moving along the 1st movement axis X, and a control section 200 for correcting the position deviation based on the position deviation data of the 1st movement axis X and the 2nd movement axis Y from the imaged result obtained in the image pick-up section 50. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a droplet discharge device having a coordinate adjustment device having a first axis and a second axis, a coordinate adjustment method, a method for manufacturing an electro-optical device, an electro-optical device, and an electronic apparatus.

The droplet discharge device is sometimes used as a drawing system for drawing a functional liquid on a workpiece that is an object. This drawing system discharges droplets onto a workpiece by an ink jet method. Yes. This drawing system may be used in the manufacture of electro-optical elements such as flat panel displays.
As a head of an ink jet type apparatus that ejects droplets, there is a type that ejects ink onto a work such as recording paper (for example, Patent Document 1).

JP 2003-89212 A (page 4, FIG. 1)

The head of this type of ink jet recording apparatus has a structure that ejects liquid droplets onto a work by moving in a direction orthogonal to the work such as recording paper. By moving the moving direction of the work in a direction orthogonal to the moving direction of the head, droplets are discharged onto the work. Since the movement axis of the carriage that supports the head and the movement axis of the work are orthogonal to each other, the head and the work are moved within the orthogonal coordinates.
However, if the relative positional accuracy between the movement axis of the carriage supporting the head and the movement axis of the workpiece is not set correctly, the printing accuracy for the workpiece is greatly affected. Therefore, by adjusting the relative positional accuracy between the carriage movement axis that supports the head and the movement axis of the workpiece before the ejection operation for ejecting droplets onto the workpiece, the printing accuracy (ejection accuracy) is improved. There is a desire to be accurate. Conventionally, in order to sufficiently secure the relative positional accuracy between the carriage movement axis and the workpiece movement axis, it is necessary to increase the accuracy when manufacturing and assembling the droplet discharge device. It has become high.

  Therefore, the present invention solves the above-described problems, and adjusts the relative positional accuracy of the coordinates of the first movement axis that moves the head and the second movement axis that moves the workpiece before discharging the droplet. The present invention provides a droplet discharge device having a coordinate adjustment device capable of performing highly accurate droplet discharge by improving positional accuracy, a coordinate adjustment method, a method of manufacturing an electro-optical device, an electro-optical device, and an electronic apparatus. The purpose is that.

  According to the first aspect of the present invention, there is provided a droplet discharge device having a coordinate adjustment device for adjusting coordinates when discharging a droplet onto a work, wherein the coordinate adjustment device A first operation unit that moves the head to be discharged along a first movement axis; and a table for holding the workpiece when the droplet is applied to the workpiece from the head. A second operating portion that moves along a second movement axis that is orthogonal to the first movement axis; and a misalignment measurement member that is held by the table, wherein the first movement axis and the second movement axis The position deviation measuring member having a pattern composed of a plurality of marks arranged at a predetermined pitch for measuring the position deviation, and the position deviation measurement while moving along the first movement axis. For imaging the pattern of members And a control unit that obtains positional deviation data between the first movement axis and the second movement axis from the imaging result obtained by the imaging unit and corrects the positional deviation. This is achieved by the featured droplet ejection device.

According to the configuration of the first invention, the first operation unit moves the head that discharges the droplets along the first movement axis. The second operation unit has a table for holding the workpiece when droplets are applied to the workpiece from the head, and the second operation unit moves the table in a second direction orthogonal to the first movement axis. Move along the axis.
The misregistration measurement member is a misregistration measurement member held on the table. The position deviation measuring member has a pattern composed of a plurality of marks arranged at a predetermined pitch in order to measure the position deviation between the first movement axis and the second movement axis.
The imaging unit images the pattern of the displacement measurement member while moving along the first movement axis. The control unit obtains positional deviation data between the first movement axis and the second movement axis from the imaging result obtained from the imaging unit, and corrects the positional deviation.

  Accordingly, the relative positional accuracy between the first movement axis for moving the head and the second movement axis for moving the table before the discharge operation for discharging droplets onto the workpiece is improved. The positional accuracy can be improved by adjusting in advance. Thereby, when the head gives a droplet to the workpiece, the droplet can be discharged to an appropriate position of the workpiece.

According to a second invention, in the configuration of the first invention, the plurality of marks of the positional deviation measuring member are parallel to the first movement axis when the positional deviation measuring member is held on the table. It arranges so that it may become.
According to the configuration of the second invention, since the plurality of marks on the displacement measuring member are arranged in parallel with the first movement axis, the relative position between the first movement axis and the second movement axis. The accuracy can be adjusted more reliably in advance.

According to a third invention, in the configuration of the first invention or the second invention, the imaging unit is provided on a carriage that supports the head, and is moved along the first movement axis by the first operation unit. It is characterized by that.
According to the configuration of the third aspect of the invention, the imaging unit is provided on the carriage that supports the head. The imaging unit is moved along the first movement direction by the first operation unit.
Thereby, the imaging unit can be moved in the first movement direction only by being provided on the carriage.

4th invention is the structure in any one of 1st invention thru | or 3rd invention, The said pattern of the said member for a position shift measurement is the 2nd pattern row | line | column parallel to the 1st pattern row | line | column and the said 1st pattern row | line | column. The image pickup unit includes a first image pickup device that picks up an image of the first pattern row, and a second image pickup device that picks up an image of the second pattern row.
According to the configuration of the fourth aspect of the invention, the pattern of the positional deviation measuring member has the first pattern row and the second pattern row. The first image sensor of the imaging unit images the first pattern row. The second image sensor of the imaging unit images the second pattern row.
Accordingly, the relative positional accuracy between the first movement axis and the second movement axis can be more accurately adjusted using the two imaging elements and the two pattern rows.

  According to the fifth aspect of the present invention, in the fifth invention, the head for discharging droplets is moved along the first movement axis by the first operation unit, and the table is orthogonal to the first movement axis by the second operation unit. A coordinate adjustment method performed before moving the droplet along the second movement axis to give the droplet to the work on the table from the head, wherein the table includes the first movement axis and the A position shift measuring member having a pattern composed of a plurality of marks arranged along the first movement axis at a predetermined pitch to measure a position shift with respect to the second movement axis is held, and an imaging unit An imaging step of imaging the pattern of the displacement measuring member while moving the first movement axis along the first movement axis, and a control unit from the imaging result obtained by the imaging unit, the first movement axis and the second Correction of misalignment with the moving axis To obtain a chromatography data, and a position correcting step of correcting the positional deviation by the coordinate adjustment method characterized by having, is achieved.

  Thereby, before discharging the droplet onto the workpiece, the relative positional accuracy between the first movement axis for moving the head and the second movement axis for moving the table is adjusted in advance. Can do. Thereby, when the head gives a droplet to the workpiece, the droplet can be discharged to an appropriate position of the workpiece.

According to a sixth aspect of the present invention, in the configuration of the fifth aspect of the present invention, the image of the pattern of the displacement measurement member is imaged while the imaging unit is moved again along the first movement axis based on the displacement correction data. The method further comprises a position confirmation step of confirming whether or not the imaging center of the imaging unit matches the pattern of the displacement measurement member.
According to the configuration of the sixth invention, in the position confirmation step, the following is performed. That is, the pattern of the displacement measurement member is imaged while the imaging unit is moved again along the first movement axis by the displacement correction data. And it is confirmed whether the imaging center of an imaging part corresponds with the pattern of the member for a position shift measurement.
Thereby, it can be confirmed whether or not the relative positional accuracy of the first movement axis and the second movement axis is correctly obtained.

According to a seventh aspect, in the configuration of the sixth aspect, when the carriage that supports the head is moved to a position outside the positional deviation correction data, the positional deviation correction data is used to complement the carriage. A position outside the misalignment correction data is determined.
According to the configuration of the seventh invention, when the head is moved to a position outside the position deviation correction data, the position outside the position deviation correction data is determined by complementing using the position deviation correction data.
As a result, even when the head ejects droplets at a position outside the positional deviation correction data, the droplet can be ejected to the correct position of the workpiece.

  According to the eighth aspect of the invention, in the eighth invention, the head for discharging the droplets is moved along the first movement axis by the first operation unit, and the table is orthogonal to the first movement axis by the second operation unit. 2. A method of manufacturing an electro-optical device that adjusts coordinates prior to manufacturing the electro-optical device by moving along two movement axes and applying the droplets to the work on the table from the head. In the coordinate adjustment, the table includes a plurality of marks arranged along the first movement axis at a predetermined pitch to measure a positional deviation between the first movement axis and the second movement axis. An image capturing step of capturing the pattern of the position shift measuring member while holding the position shift measuring member having the pattern and moving the image capturing unit along the first movement axis; and Obtained imaging results And a position correction step for obtaining positional deviation correction data between the first movement axis and the second movement axis and correcting the positional deviation. Is achieved.

  Thus, prior to the discharge operation for discharging the droplets onto the workpiece, the relative positional accuracy between the first movement axis for moving the head and the second movement axis for moving the table is set in advance. Can be adjusted. Thereby, when the head gives a droplet to the workpiece, the droplet can be discharged to an appropriate position of the workpiece. For this reason, the accuracy in manufacturing the electro-optical device is improved.

  In the ninth aspect of the invention, the head for discharging droplets is moved along the first movement axis by the first operation unit, and the table is orthogonal to the first movement axis by the second operation unit. An electro-optical device manufactured after adjusting the coordinates prior to applying the droplets from the head to the work on the table by moving along a second movement axis, wherein the coordinate adjustment is performed. Then, the table has a pattern composed of a plurality of marks arranged along the first movement axis at a predetermined pitch in order to measure a positional deviation between the first movement axis and the second movement axis. An imaging step of capturing the pattern of the displacement measurement member while holding the displacement measurement member being operated and moving the imaging unit along the first movement axis, and imaging obtained by the imaging unit From the result, the control unit An electro-optical device manufactured by performing a position correction step of obtaining positional deviation correction data between the first movement axis and the second movement axis and correcting the positional deviation. Achieved.

  Thus, prior to the discharge operation for discharging the droplets onto the workpiece, the relative positional accuracy between the first movement axis for moving the head and the second movement axis for moving the table is set in advance. Can be adjusted. Thereby, when the head gives a droplet to the workpiece, the droplet can be discharged to an appropriate position of the workpiece. For this reason, the accuracy of the electro-optical device is improved.

  A tenth aspect of the invention is an electronic apparatus equipped with the electro-optical device of the ninth aspect of the invention.

Preferred embodiments of the present invention will be described below with reference to the drawings.
FIG. 1 is a plan view showing a preferred embodiment of a droplet discharge device having a coordinate adjusting device of the present invention.
A droplet discharge device 10 shown in FIG. 1 has a coordinate adjustment device 100. The droplet discharge device 10 can be used as a drawing system. This drawing system is incorporated in a production line of, for example, an organic EL (electroluminescence) device which is a kind of so-called flat panel display. The droplet discharge device 10 can form a light emitting element to be each pixel of the organic EL device.

The droplet discharge device 10 can be used as, for example, an ink jet drawing device. The droplet discharge device 10 is for forming a light emitting element of an organic EL device by a droplet discharge method (inkjet method). The head of the droplet discharge device 10 (also referred to as a functional droplet discharge head) can form an organic EL element light emitting element. Specifically, in the manufacturing process of the organic EL element, the head in which the light emitting functional material is introduced is relative to the substrate (an example of a workpiece) on which the bank part is formed through the bank part forming process and the plasma processing process. By performing scanning in this manner, the droplet discharge device 10 can form the hole injection / transport layer and the light emitting layer film forming portion corresponding to the position of the pixel electrode on the substrate.
For example, by preparing two droplet discharge devices 10, the first droplet discharge device 10 forms a hole injection / transport layer, and the other droplet discharge device 10 has R (red), G Light emitting layers of three colors (green) and B (blue) can be formed.

The droplet discharge device 10 of FIG. 1 is accommodated in a chamber 12. The chamber 12 has another chamber 13. In the chamber 13, a work carry-in / out table 14 is accommodated. The workpiece carry-in / out table 14 is a table for carrying workpieces onto the table 30 in the chamber 12 or carrying workpieces out of the table 30 in the chamber 12.
A chamber 12 shown in FIG. 1 accommodates a maintenance unit 15 that performs maintenance of the head 11. A recovery unit 16 is provided outside the chamber 12.

Here, the maintenance unit 15 and the collection unit 16 will be briefly described. Although not shown, the maintenance unit 15 includes a flushing unit, a suction unit, a wiping unit, a discharge inspection unit, a weight measurement unit, and the like. The flushing unit is for receiving droplets preliminarily ejected from the head 11. The suction unit is for sucking ink and bubbles from the nozzle plate surface of the head 11. The wiping unit is for wiping off dirt adhering to the nozzle plate surface with a wiping member. The discharge inspection unit inspects the discharge state of the droplets discharged from the head 11. The weight measurement unit measures the weight of the droplets ejected from the head 11.
The recovery unit 16 includes, for example, a droplet recovery system that recovers droplets and a cleaning liquid supply system that supplies a cleaning solvent used after wiping.

  The chamber 12 and the chamber 13 are individually air-controlled so that the atmosphere in the chamber 12 and the chamber 13 does not vary. The reason why the chamber 12 and the chamber 13 are used in this way is that, for example, in the case of manufacturing an organic EL element, the influence of the atmosphere can be eliminated because the moisture in the atmosphere is disliked. A dry air atmosphere is maintained by continuously introducing and exhausting dry air into the chamber 12 and the chamber 13.

Next, components in the chamber 12 shown in FIG. 1 will be described.
In the chamber 12, a frame 20, a head 11, a carriage 19, a first operation unit 21, a second operation unit 22, a table 30, a mask 40, an imaging unit 50, and a guide base 17 are accommodated.
The frame 20 in FIG. 1 is provided horizontally along the X-axis direction. The guide base 17 is provided horizontally along the Y axis. The frame 20 is above the guide base 17. The X axis corresponds to the first movement axis, and the Y axis corresponds to the second movement axis. The X axis and the Y axis are orthogonal to each other, and are also orthogonal to the Z axis. The Z axis is a direction perpendicular to the paper surface in FIG.
The coordinate adjustment apparatus 100 includes a first operation unit 21, a second operation unit 22, a mask 40, an imaging unit 50, and a control unit 200. The control unit 200 is provided outside the chamber 12.

Here, each component of the coordinate adjustment apparatus 100 is demonstrated sequentially.
The first operation unit 21 is for linearly reciprocating and positioning the carriage 19, the head 11, and the imaging unit 50 along the X-axis direction along the frame 20.
The second operation unit 22 has a table 30. A mask 40 as shown in FIG. 1 can be detachably mounted on the table 30, and a work (not shown) can be mounted instead of the mask 40. The table 30 of the second operation unit 22 holds the workpiece when droplets are applied from the head 11 to the workpiece. And the 2nd operation part 22 can position a workpiece | work on the guide base 17 linearly along a Y-axis.

  The first operation unit 21 includes a motor 21A for linearly moving the head 11 and the imaging unit 50 in the X-axis direction and positioning them. The motor 21A can linearly move the head 11 and the imaging unit 50 in the X-axis direction by using, for example, a feed screw. The motor 21A may be a rotary electric motor or a linear motor. The motor 22A of the second operation unit 22 can also position the table 30 by linearly moving the table 30 in the Y-axis direction. As the motor 22A, for example, a rotary electric motor that rotates a feed screw can be used. As the motor 22A, a linear motor can be used in addition to the rotary motor.

  The table 30 of the second operation unit 22 has a mounting surface 30A. The mounting surface 30A is a surface perpendicular to the Z direction in FIG. The mounting surface 30A has a suction portion 30B. The suction portion 30B can suck the mask 40 or the workpiece by vacuum suction. Thereby, a mask or a workpiece | work can be reliably detachably fixed, without shifting | deviating with respect to the mounting surface 30A.

  The mask 40 shown in FIG. 1 is an example of a displacement measurement member. As the mask 40, for example, a rectangular glass mask can be used. The mask 40 has a pattern 40A. This pattern 40 </ b> A is an object to be imaged by the imaging unit 50. The pattern 40A has a first pattern row 41 and a second pattern row 42, for example.

  FIG. 2 shows an example of the shape of the mask 40. The first pattern row 41 of the mask 40 is formed on one long side portion 40B side of the mask 40. The second pattern row 42 is formed on the other long side portion 40C side. The first pattern row 41 and the second pattern row 42 are parallel to the X-axis direction. The first pattern row 41 and the second pattern row 42 are located at positions close to the long side portions 40B and 40C, respectively, and the first pattern row 41 and the second pattern row 42 are formed so as to be separated from each other. The adjustment accuracy when the relative coordinate adjustment is performed can be increased.

The first pattern row 41 has a plurality of marks M at equal intervals (predetermined pitch) between the left end mark ML and the right end mark MR. The second pattern row 42 has a plurality of marks N at equal intervals (predetermined pitch) between the left end mark NL and the right end mark NR. The arrangement pitch of the marks M in the first pattern row 41 is the same as the arrangement pitch of the marks N in the second pattern row 42.
Thus, the first pattern row 41 and the second pattern row 42 are formed in a direction parallel to the X-axis direction in which the head 11 and the carriage 19 holding the head 11 move linearly.

Next, referring to FIGS. 3 and 4, structural examples of the carriage 19, the head 11, and the imaging unit 50 will be described.
FIG. 3 is a perspective view showing an example of the shape around the carriage 19, the head 11, and the imaging unit 50, and FIG. 4 is an example of a front view seen from the direction E of FIG.
The carriage 19 can be positioned by moving in the X-axis direction by a motor 21A shown in FIG. The carriage 19 shown in FIGS. 3 and 4 uses a head holder 61 to detachably hold the head 11.

  The imaging unit 50 is held with respect to the head holder 61 of the carriage 19, for example. When the motor 62 shown in FIG. 3 operates, the head holder 61, the head 11, and the imaging unit 50 can be positioned by moving up and down along the Z direction with respect to the carriage 19. When the other motor 63 is operated, the head 11 and the imaging unit 50 are rotatable in the θ direction about the U axis.

  As shown in FIG. 3, the head 11 has a nozzle plate 64. The nozzle plate 64 has a plurality of nozzle openings 65. The head 11 is connected to a functional liquid storage unit (not shown). The functional liquid in the functional liquid storage unit can be ejected from the nozzle opening 65 by, for example, an ink jet method by an expansion / contraction operation of a piezoelectric vibrator. As shown in FIG. 4, the operations of the motors 62 and 63 are controlled by the control unit 200.

  3 and 4, the imaging unit 50 is held with respect to the head holder 61 of the carriage 19. However, the present invention is not limited to this, and the imaging unit 50 may be held in another part of the carriage 19 so that it can rotate in the θ direction around the U axis.

Next, the imaging unit 50 will be described with reference to FIGS. 1 and 2.
The imaging unit 50 includes a support unit 70, a first camera 71, and a second camera 72. The support part 70 is a long member, for example, and the first camera 71 and the second camera 72 are provided at one end and the other end of the support part 70. The first camera 71 is at a position corresponding to the first pattern row 41, and the second camera 72 is at a position corresponding to the second pattern row 42. The first camera 71 is an example of a first image sensor, and the second camera 72 is an example of a second image sensor. As the first camera 71 and the second camera 72, for example, a CCD (charge coupled device) camera or other types of cameras can be used.
The support portion 70 can be positioned by rotating in the θ direction around the above-described U axis. The U axis is a direction perpendicular to the paper surface of FIG. 2 and is parallel to the Z axis. This U-axis is also the center of rotation of the head 11 in FIG.

Next, an embodiment of a coordinate adjustment method by the coordinate adjustment device 100 of the droplet discharge device 10 according to the embodiment of the present invention will be described with reference to FIGS.
FIG. 5 shows that the first camera 71 and the second camera 72 in FIG. 2 recognize the images of the marks M in the first pattern row 41 and the marks N in the second pattern row 42, respectively. An example in which the relative positional accuracy of the axes is detected is shown.
FIG. 6 shows the image recognition as shown in FIG. 5, and the relative misalignment correction data between the X axis and the Y axis is obtained from the imaging result obtained by the imaging unit 50, and the misalignment is corrected. An example of a state is shown.

FIG. 7 is a flowchart showing a preferred embodiment of the coordinate adjustment method of the present invention.
The coordinate adjustment method shown in FIG. 7 includes a mask mounting step ST1, a step ST20 for adjusting the posture of the mask 40 on the table 30 in FIG. 2, an imaging step ST6, a position correction step ST30, and a position confirmation (reproduction confirmation) step ST12. have.

Mask mounting step ST1
In the mask mounting step ST1, the mask 40 is mounted on the table 30 shown in FIGS. When mounting, the mask 40 is positioned and set at a predetermined position on the table 30.

Step ST20 for adjusting the posture of the mask on the table
This step ST20 includes steps ST2 to ST5.
Step ST20 is a step for adjusting the posture of the mask 40 on the table 30 with respect to the table 30 in advance. In step ST2, adjustment is made so that the left end mark ML of the first pattern row 41 falls within one pixel of the first camera 71 shown in FIG. In step ST 3, the table 30 is moved in the Y-axis direction (+ direction) and adjusted so that the left end mark NL of the second pattern row 42 falls within one pixel of the first camera 71.

Next, in step ST4, the table 30 is moved in the Y-axis (− direction) and adjusted so that the left end mark ML of the first pattern row 41 falls within one pixel of the second camera 72. In step ST5, the table 30 is moved in the Y-axis direction (+ direction) and adjusted so that the left end mark NL of the second pattern row 42 enters one pixel of the second camera 72.
In this way, the left end mark ML of the first pattern row 41 and the left end mark NL of the second pattern row 42 are observed for each of the first camera 71 and the second camera 72, and falls within one pixel of each of the cameras 71 and 72. Like that. Thereby, the mask 40 can be adjusted to a substantially correct posture with respect to the X axis and the Y axis on the table 30.
Such an adjustment of the posture of the mask on the table can be manually performed by an operator, for example. Thereafter, the suction portion 30B of FIG. 1 sucks and fixes the mask 40 to the mounting surface 30A so that the mask 40 does not move.

Next, the process proceeds to imaging step ST6 in FIG.
Imaging step ST6
In the imaging step ST6, as shown in FIG. 2, the mask 40 is mounted on the table 30 in a state where the posture is correct in the manner described above. The imaging unit 50 moves linearly along the X axis, so that the first camera 71 and the second camera 72 of the imaging unit 50 mark the mark M in the first pattern row 41 and the mark N in the second pattern row 42, respectively. Images will be taken sequentially.

In this case, the first camera 71 and the second camera 72 together with the carriage 19 and the head 11 send the mark M by one pitch in the + direction of the X-axis direction, so that the plurality of marks M in the first pattern row 41 A plurality of marks N in the second pattern row 42 can be imaged by the first camera 71 and the second camera 72, respectively.
The first camera 71 images the mark M from the left end mark ML to the right end mark MR of the first pattern row 41 by one pitch. At the same time, the second camera 72 images the mark N one pitch at a time from the left end mark NL to the right end mark NR of the second pattern row 42.

  FIG. 5 representatively shows an example of imaging the mark M in the middle of the first pattern row 41 and the mark N in the middle of the second pattern row 42. FIG. 5 shows an example of the marks M1 and M2 in the first pattern row 41 and the marks N1 and N2 in the second pattern row 42. Each mark is formed by a reference line BL and each cross line CL as shown in FIG. The reference line BL is a line parallel to the X axis. The intersecting line CL is a line segment formed at the same pitch from the left end mark ML to the right end mark MR and formed in a direction orthogonal to the reference line BL.

In the example shown in FIG. 5, examples of the marks M1 and M2 and the marks N1 and N2 are enlarged.
In the mark M1, the imaging center CC of the first camera 71 is at a position shifted from the reference line BL and the intersection line CL. In this case, the imaging center CC is at a position shifted from the origin 0 by + ΔX1 and + ΔY1. In the mark N1, the imaging center CC of the second camera 72 is at a position shifted from the origin 0 by −ΔX2 and −ΔY2.

  Similarly, in the mark M2, the imaging center CC of the first camera 71 is shifted from the origin 0 by −ΔX3 and + ΔY3. At the mark N2, the imaging center of the second camera 72 is shifted from the origin 0 by + ΔX4 and −ΔY4. Thereby, the inclination line LD1 connecting the imaging center CC and the imaging center CC due to the occurrence of a shift between the imaging center CC of the first camera 71 and the imaging center CC of the second camera 72 at the mark M1 and the mark N1 is represented by the Y axis. Is inclined by an angle θ1.

Similarly, for the mark M2 and the mark N2, an inclination line LD2 connecting the imaging center CC of the first camera 71 and the imaging center CC of the second camera 72 is inclined by an angle θ2 with respect to the Y axis.
From this, the imaging center CC of the first camera 71 with respect to the mark M1 is the coordinates (ΔX1, ΔY1, Δθ1) with respect to the origin 0. Similarly, in the mark N1, the imaging center CC of the second camera 72 is the coordinates (−ΔX2, −ΔY2, Δθ1).
Further, for the mark M2, the imaging center CC of the first camera 71 is at coordinates (−ΔX3, ΔY3, Δθ2) with respect to the origin 0. Regarding the mark N2, the imaging center CC of the second camera 72 is the coordinates (ΔX4, −ΔY4, Δθ2).

  FIG. 5 representatively shows four marks M1, M2, N1, and N2. However, from the left end mark ML to each mark M of the right end mark MR and from the left end mark NL to the right end mark NR, the first camera 71 and the second camera 72 can perform image recognition in the same manner. The imaging center CC of the first camera 71 and the imaging center CC of the second camera 72 are adjusted with respect to coordinates (ΔX, ΔY, Δθ) that are shifted from the origin 0, and the imaging center CC is set to the center of each mark. In order to correct the position by moving to the origin 0, the position correction step ST30 of FIG. 7 is performed.

Position correction step ST30
The position correction step ST30 includes steps ST7 to ST9.
In step ST7, the mark M of the pattern in the first pattern row 41 falls within one pixel of the first camera 71, and the mark N of the pattern in the second pattern row falls within one pixel of the second camera 72 ( Adjust the X, Y, and U axes.
When the positions of the marks M1, M2, N1, and N2 shown as representatives are adjusted, for example, FIG. 6 is obtained. In each mark, the imaging center CC of the first camera 71 and the imaging center CC of the second camera 72 are adjusted so as to be at the origin 0, respectively.

In step ST8, in this case, with respect to the adjusted amounts of the X, Y, and U axes of the respective coordinates, the amounts of the X axis, the Y axis, and the θ axis are changed according to the encoder pulse to the data storage unit 201 of the control unit 200 in FIG. To record. In this way, the adjustment amount for the adjusted (X, Y, U) axes is recorded in step ST8, and is sent by one pitch for each mark M in the first pattern row 41 and each mark N in the second pattern row. However, the corrected amount after adjustment for the (X, Y, U) axes is recorded.
In this manner, the amount of deviation of the imaging center CC between the first camera 71 and the second camera 72 is corrected as shown in FIG. In this position correction, the relative positional accuracy with respect to the X axis and the Y axis can be improved by correcting the angle θ with respect to the X axis, the Y axis, and the U axis.

Position confirmation (reproduction confirmation) step ST12
In step ST12, the position correction data relating to the (X, Y, U) axis recorded in the data storage unit 201 of the control unit 200 in FIG. 50, the marks M and N of the first pattern row 41 and the second pattern row 42 are sent so as to correspond to one pitch.
As a result, as shown in FIG. 6, the imaging center CC of the first camera 71 is positioned at the origin 0 of the marks M1, M2 of the first pattern row 41, and at the origin 0 of the marks N1, N2 of the second pattern row 42. It is confirmed whether the imaging center CC of the second camera 72 is located. That is, the carriage 19, the head 11, and the imaging unit 50 send each mark M and N within one pixel of the first camera 71 and the second camera 72 while sending one pitch of the pattern mark to the X axis. It is confirmed whether it is.

  After the adjustment as described above, it is possible to perform drawing by discharging droplets onto the workpiece using the droplet discharge device 10 of FIG. In this case, the mask on the table 30 is removed, and instead, a substrate of the organic EL device is mounted on the table 30 and sucked by the suction unit 30B. The carriage 19, the head 11 and the imaging unit 50 in FIG. 2 eject the light emitting functional material while moving in the X axis and Y axis with respect to the workpiece, thereby forming the hole injection / transport layer and the light emitting layer film forming unit. Can be formed.

  Since the relative positional accuracy of the X axis and the Y axis has already been adjusted using the coordinate adjusting apparatus 100, the film forming unit can be formed at an accurate position with respect to such a substrate. Thereby, it is possible to improve the manufacturing quality of the obtained substrate and a display such as an organic EL device having the substrate.

  As described above, the droplet discharge device according to the embodiment of the present invention can be used as long as the X-axis and the Y-axis have accurate linearity and are manufactured and assembled so as to be perpendicular to each other. It is conceivable that the imaging center coincides with the origin of each mark. However, in practice, when the imaging unit 50 moves along the X axis, displacement (error) (ΔX, ΔY, Δθ) occurs between the imaging center CC and the origin of the mark.

Therefore, the control unit 200 of the coordinate adjustment apparatus of FIG. 2 according to the embodiment of the present invention displaces (displacement amount) between one pixel (imaging center) of the first camera and the origin of each mark M in the first pattern row. And a displacement (amount of displacement) between one pixel (imaging center) of the second camera and the origin of each mark N in the second pattern row, and then the displacement is corrected for each mark M, N Get the data. Then, the control unit 200 corrects the relative misalignment between the X axis and the Y axis based on the correction data, and captures the marks M and N with the first camera and the second camera again, thereby correcting the misalignment. It is confirmed whether it was made.
Thus, by adjusting the relative positional accuracy of the coordinates of the first moving axis (X axis) and the second moving axis (Y axis) to improve the positional accuracy, a highly accurate droplet discharge operation can be performed. It will be.

Next, another embodiment of the present invention will be described.
FIG. 8 shows another embodiment of a mask mounted on the table 30. The mask 40 is an example of a positioning measurement member. The mask 40 includes a first pattern row 41 and a second pattern row 42. In this case, when the assembly of the carriage, the head, and the imaging unit 50 moves to a region outside the right end mark MR and the right end mark NR of the first pattern row 41, for example, complementation is performed as follows. Data can be obtained.

  FIG. 9A shows the right end mark MR of the first pattern row 41. A region indicated by a broken line on the right side of the right end mark MR is a region deviated from the first pattern row 41. That is, in the above-described embodiment, this is a region at a position outside the data subjected to position correction. When obtaining data (ΔX50, ΔY50, Δθ50) for correcting the relative positional relationship between the X axis and the Y axis in the region T outside such position correction data, it is shown in FIG. For example, by a complementing method using linearity, for example, the coordinates (ΔX50, ΔY46, Δθ50), (ΔX50, ΔY47, It can be estimated using (Δθ50), (ΔX50, ΔY48, Δθ50), (ΔX50, ΔY49, Δθ50). In this example, the angle θ is set to the same θ50 for simplification.

FIG. 10 shows yet another embodiment of the present invention.
The embodiment shown in FIG. 10 differs from the embodiment shown in FIG. 2 in the configuration of the mask 40 and the imaging unit 50. Since the components other than the mask 40 and the imaging unit 50 are the same as those in the embodiment of FIG. 2, the same reference numerals are used and description thereof is used.

The mask 40 has only one pattern row 41. Correspondingly, the imaging unit has one camera 71. This also makes it possible to adjust the relative positions of the X axis and the Y axis with the pattern row 41 as a reference.
However, in the embodiment shown in FIG. 2, since the first pattern row 41 and the second pattern row 42 and the first camera 71 and the second camera 72 are used as compared with the embodiment of FIG. Position accuracy can be adjusted.

  FIG. 11A and FIG. 11B show another embodiment of the imaging unit 50. The imaging unit 50 in FIG. 11A includes a first camera 71, a second camera 72, and a support unit 70, and the U axis that is the rotation center of the support unit 70 is at the center of the first camera 71. There are some differences. In the embodiment of FIG. 11B, the imaging unit 50 includes one camera 72 and a support unit 70. The camera 72 is provided at one end of the support unit 70, but the U-axis is provided at the other end of the support unit 70.

  The embodiment of the droplet discharge device having the coordinate adjusting device of the present invention can be used to manufacture an electro-optical device (device) as described above. Examples of the electro-optical device include a liquid crystal display device, an organic EL (Electro-Luminescence) device, an electron emission device, a PDP (Plasma Display Panel) device, an electrophoretic display device, and the like. The electron emission device is a concept including a so-called FED (Field Emission Display) device. Further, as the electro-optical device, various devices including metal wiring formation, lens formation, resist formation, and light diffuser formation can be considered.

  FIG. 12 shows a structural example of an organic EL device when the droplet discharge device of the present invention is used as a drawing device for manufacturing an organic EL device which is a kind of flat panel display. The organic EL device 701 is provided for an organic EL element 702 including a substrate 711, a circuit element portion 721, a pixel electrode 731, a bank portion 741, a light emitting element 751, a cathode 761 (counter electrode), and a sealing substrate 771. A wiring of a flexible substrate (not shown) and a driving IC (not shown) are connected.

  A circuit element portion 721 is formed on the substrate 711 of the organic EL element 702, and a plurality of pixel electrodes 731 are aligned on the circuit element portion 721. Bank portions 741 are formed in a lattice pattern between the pixel electrodes 731, and light emitting elements 751 are formed in the recess openings 744 generated by the bank portions 741. A cathode 761 is formed on the entire upper surface of the bank portion 741 and the light emitting element 751, and a sealing substrate 771 is laminated on the cathode 761.

A manufacturing process of the organic EL element 702 includes a bank part forming process for forming the bank part 741, a plasma treatment process for appropriately forming the light emitting element 751, a light emitting element forming process for forming the light emitting element 751, and a cathode 761. And a sealing step in which a sealing substrate 771 is stacked on the cathode 761 and sealed.
That is, the organic EL element 702 is formed by forming the bank portion 741 at a predetermined position on the substrate 711 (work W) on which the circuit element portion 721 and the pixel electrode 731 are formed in advance, and then performing plasma treatment, the light emitting element 751 and the cathode 761 (opposing Electrode) are sequentially formed, and further, a sealing substrate 771 is laminated on the cathode 761 and sealed. Note that the organic EL element 702 is easily deteriorated by the influence of moisture in the atmosphere, and therefore, the organic EL element 702 is manufactured in a dry air or inert gas (nitrogen, argon, helium, etc.) atmosphere. preferable.

Each light emitting element 751 includes a hole injection / transport layer 752 and a film forming portion including a light emitting layer 753 colored in any one color of R (red), G (green), and B (blue). The light emitting element forming step includes a hole injecting / transporting layer forming step for forming the hole injecting / transporting layer 752 and a light emitting layer forming step for forming the three-color light emitting layer 753. .
The organic EL device 701 is manufactured by manufacturing the organic EL element 702 and then connecting the wiring of the flexible substrate to the cathode 761 of the organic EL element 702 and connecting the wiring of the circuit element unit 721 to the driving IC.

Next, the case where the droplet discharge device 10 according to the embodiment of the present invention is applied to the manufacture of a liquid crystal display device will be described.
FIG. 13 shows a cross-sectional structure of the liquid crystal display device 801. The liquid crystal display device 801 includes a color filter 802, a counter substrate 803, a liquid crystal composition 804 sealed between the color filter 802 and the counter substrate 803, and a backlight (not shown).
On the inner surface of the counter substrate 803, pixel electrodes 805 and TFT (thin film transistor) elements (not shown) are formed in a matrix. Red, green, and blue colored layers 813 of the color filter 802 are arranged at positions facing the pixel electrode 805. An alignment film 806 for aligning liquid crystal molecules in a certain direction is formed on the inner surfaces of the color filter 802 and the counter substrate 803, and a polarizing plate 807 is formed on the outer surfaces of the color filter 802 and the counter substrate 803. Is glued.

  The color filter 802 includes a translucent transparent substrate 811, a large number of pixels (filter elements) 812 arranged in a matrix on the transparent substrate 811, a colored layer 813 formed on the pixels 812, and each pixel 812. A light-shielding partition 814 for partitioning. An overcoat layer 815 and an electrode layer 816 are formed on the top surfaces of the colored layer 813 and the partition 814.

  A manufacturing method of the liquid crystal display device 801 will be described. First, a partition 814 is formed in the transparent substrate 811, and then a colored layer 813 of R (red), G (green), and B (blue) is formed in the pixel 812 portion. . Then, an overcoat layer 815 is formed by spin coating with a transparent acrylic resin paint, and an electrode layer 816 made of ITO (Indium Tin Oxide) is further formed to form a color filter 802.

  A pixel electrode 805 and a TFT element are formed in the counter substrate 803. Next, after applying the alignment film 806 to the counter substrate 803 on which the color filter 802 and the pixel electrode 805 are formed, they are bonded to each other. Then, after the liquid crystal composition 804 is sealed between the color filter 802 and the counter substrate 803, a polarizing plate 807 and a backlight are stacked.

Embodiments of the droplet discharge device of the present invention can be used to form the filter elements (R (red), G (green), and B (blue) colored layers 813) of the color filter. Further, by using a liquid material corresponding to the pixel electrode 805, the pixel electrode 805 can be used.
In addition, as other electro-optical devices, devices including preparation of a preparation in addition to metal wiring formation, lens formation, resist formation, and light diffuser formation are conceivable. Various electro-optical devices can be efficiently manufactured by using the above-described droplet discharge device for manufacturing various electro-optical devices (devices).

  The electronic apparatus of the present invention is equipped with the electro-optical device. In this case, the electronic apparatus corresponds to various electric products in addition to a mobile phone and a personal computer equipped with a so-called flat panel display.

  FIG. 14 shows a shape example of a mobile phone 1000 which is an example of an electronic device. A cellular phone 1000 includes a main body portion 1001 and a display portion 1002. The display unit 1002 uses, for example, an organic EL device 701 or a liquid crystal display device 801 which is an electro-optical device as described above.

  FIG. 15 illustrates a computer 1100 that is another example of the electronic apparatus. A computer 1100 includes a main body portion 1101 and a display portion 1102. The display unit 1102 can use the organic EL device 701 and the liquid crystal display device 801 which are examples of the electro-optical device as described above.

In the embodiment of the present invention, the relative movement between the first movement axis for linearly moving the head and the second movement axis for linearly moving the workpiece before discharging the droplet onto the workpiece. The position accuracy can be adjusted in advance. Thereby, when the head gives a droplet to the workpiece, the droplet can be discharged to an appropriate position of the workpiece. The imaging unit can be linearly moved in the first movement direction only by being provided on the head. The relative positional accuracy between the first movement axis and the second movement axis can be adjusted more accurately using the two imaging elements and the two pattern rows. It can be confirmed whether or not the relative positional accuracy of the first movement axis and the second movement axis is obtained correctly. Even when the head ejects liquid droplets at a position outside the positional deviation correction data, the liquid droplets can be ejected to the correct position of the workpiece.
Note that the imaging unit may be provided in a part different from the carriage. A portion different from the carriage can be positioned by linear movement by the first operating portion along the X-axis direction.

  The present invention is not limited to the above embodiment, and various modifications can be made without departing from the scope of the claims. Furthermore, the above-described embodiments may be combined with each other.

The top view which shows preferable embodiment of the droplet discharge apparatus which has the coordinate adjustment apparatus of this invention. The top view which shows preferable embodiment of the coordinate adjustment apparatus of the droplet discharge apparatus of FIG. The perspective view which shows the example of a shape of a carriage, a head, and an imaging part. The front view which shows a carriage, a head, and an imaging part. The figure which shows the example in which the 1st camera and the 2nd camera are image-recognizing the 1st pattern sequence and the 2nd pattern sequence. The figure which shows the example after position adjustment after image recognition. The flowchart which shows an example of the coordinate adjustment method of this invention. The figure which shows another embodiment of this invention. The figure explaining embodiment of FIG. 8 in more detail. The top view which shows another embodiment of this invention. The figure which shows another embodiment of this invention. Sectional drawing which shows the example of a shape of the organic electroluminescent apparatus manufactured with the droplet discharge apparatus of this invention. Sectional drawing which shows the structural example of the liquid crystal display device manufactured with the droplet discharge apparatus of this invention. The perspective view which shows the mobile telephone which is an example of an electronic device provided with the display apparatus manufactured by this invention. The perspective view which shows the computer which is another example of an electronic device.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 10 ... Droplet discharge apparatus, 21 ... 1st operation part, 22 ... 2nd operation part, 30 ... Table, 40 ... Mask, 40A ... Pattern, 41 ... 1st 1 pattern row, 42... Second pattern row, 50... Imaging unit, 71... First camera (first imaging device), 72. ..Coordinate adjustment device, 200 ... control unit, X axis ... first movement axis, Y axis ... second movement axis

Claims (10)

A droplet discharge device having a coordinate adjustment device for adjusting coordinates when discharging a droplet onto a workpiece,
The coordinate adjusting device includes:
A first operation unit that moves a head for discharging droplets along a first movement axis;
A table for holding the work when the liquid droplets are applied from the head to the work, and the table is moved along a second movement axis perpendicular to the first movement axis; 2 operation units;
A position deviation measuring member held on the table, the pattern having a plurality of marks arranged at a predetermined pitch for measuring the position deviation between the first movement axis and the second movement axis. The positional deviation measuring member
An imaging unit for imaging the pattern of the displacement measuring member while moving along the first movement axis;
A droplet that includes: a controller that obtains positional deviation data between the first movement axis and the second movement axis from an imaging result obtained by the imaging unit and corrects the positional deviation. Discharge device.   The plurality of marks on the positional deviation measuring member are arranged so as to be parallel to the first movement axis when the positional deviation measuring member is held on the table. The droplet discharge device according to 1.   3. The droplet discharge device according to claim 1, wherein the imaging unit is provided on a carriage that supports the head and is moved along the first movement axis by the first operation unit. 4. . The pattern of the displacement measuring member has a first pattern row and a second pattern row parallel to the first pattern row,
The said imaging part has a 1st image sensor which images the said 1st pattern row | line | column, and a 2nd image sensor which images the said 2nd pattern row | line | column, Any of Claim 1 thru | or 3 characterized by the above-mentioned. A droplet discharge device according to claim 1. The head for discharging droplets is moved along the first movement axis by the first operation unit, and the table is moved along the second movement axis perpendicular to the first movement axis by the second operation unit. A coordinate adjustment method that is performed prior to applying the droplet to the workpiece on the table,
The table has a pattern composed of a plurality of marks arranged along the first movement axis at a predetermined pitch in order to measure a positional deviation between the first movement axis and the second movement axis. An imaging step of capturing the pattern of the positional deviation measuring member while holding the positional deviation measuring member and moving the imaging unit along the first movement axis;
A position correction step in which the control unit obtains positional deviation correction data between the first movement axis and the second movement axis from the imaging result obtained by the imaging unit, and corrects the positional deviation. Characteristic coordinate adjustment method.   By capturing the pattern of the displacement measurement member while moving the imaging unit along the first movement axis again according to the displacement correction data, the imaging center of the imaging unit becomes the displacement measurement member. 6. The coordinate adjustment method according to claim 5, further comprising a position confirmation step of confirming whether or not the pattern matches.   When the carriage supporting the head is moved to a position outside the position deviation correction data, the position outside the position deviation correction data is determined by complementing using the position deviation correction data. The coordinate adjustment method according to claim 6. The head for discharging droplets is moved along the first movement axis by the first operation unit, and the table is moved along the second movement axis perpendicular to the first movement axis by the second operation unit. An electro-optical device manufacturing method for adjusting coordinates prior to manufacturing the electro-optical device by applying the droplets to the work on the table,
In the coordinate adjustment,
The table has a pattern composed of a plurality of marks arranged along the first movement axis at a predetermined pitch in order to measure a positional deviation between the first movement axis and the second movement axis. An imaging step of capturing the pattern of the positional deviation measuring member while holding the positional deviation measuring member and moving the imaging unit along the first movement axis;
A position correction step in which the control unit obtains positional deviation correction data between the first movement axis and the second movement axis from the imaging result obtained by the imaging unit, and corrects the positional deviation. A method for manufacturing an electro-optical device. The head for discharging droplets is moved along the first movement axis by the first operation unit, and the table is moved along the second movement axis perpendicular to the first movement axis by the second operation unit. An electro-optical device manufactured after adjusting coordinates prior to applying the droplet to the work on the table,
In the coordinate adjustment,
The table has a pattern composed of a plurality of marks arranged along the first movement axis at a predetermined pitch in order to measure a positional deviation between the first movement axis and the second movement axis. An imaging step of capturing the pattern of the positional deviation measuring member while holding the positional deviation measuring member and moving the imaging unit along the first movement axis;
The control unit obtains positional deviation correction data between the first movement axis and the second movement axis from the imaging result obtained by the imaging unit, and performs a position correction step for correcting the positional deviation. An electro-optical device manufactured later.   An electronic apparatus comprising the electro-optical device according to claim 9.

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