JP2006003588A - Alignment method of liquid crystal panel lighting inspecting device, and liquid crystal panel lighting inspecting device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To align liquid crystal panels by considering a difference even when the difference exists in an amount of expansion and contraction due to thermal expansion between the liquid crystal panels when inspecting a plurality of the liquid crystal panels of the same specifications by lighting. <P>SOLUTION: A first liquid crystal panel is aligned by using three alignment marks on the panel and three cameras on a probe stage, and an alignment state of a probe and an electrode of the panel is confirmed by using a microscope. On and after a second liquid crystal panel of the same specification, after the liquid crystal panel is temporarily positioned on the basis of two alignment marks 56 and 58, a prescribed deviation Δx is found concerning a third alignment mark 62 to shift the liquid crystal panel only by its half in an X direction. Thereby alignment between a data side probe 26 and a data electrode 60 is accurate, and even when a large sized liquid crystal panel is illuminated with a high brightness backlight, alignment inferiority can be avoided. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a method for aligning a liquid crystal panel with respect to a probe in a liquid crystal panel lighting inspection apparatus, and to a liquid crystal panel lighting inspection apparatus for carrying out the method.

As a conventional liquid crystal panel inspection apparatus, one disclosed in the following Patent Document 1 is known.
JP 2001-74778 A

  The liquid crystal panel inspection apparatus disclosed in Patent Document 1 can align a liquid crystal panel using three alignment marks formed on the liquid crystal panel. On two adjacent sides (X side and Y side) of the rectangular liquid crystal panel, a plurality of electrodes are formed side by side along the side. A first alignment mark and a second alignment mark are formed near both ends on the Y side. Further, the first alignment mark described above and a new third alignment mark are formed near both ends on the X side. Therefore, alignment marks are respectively formed at the three corners of the liquid crystal panel. Three alignment cameras are mounted on the probe stage of the inspection device, and these cameras can observe the three alignment marks on the liquid crystal panel.

  In the liquid crystal panel lighting inspection device, light is applied to the back surface of the liquid crystal panel to create a state illuminated by a backlight, and in that state, the presence or absence of defects when driving each pixel of the liquid crystal panel is inspected. The alignment of liquid crystal panels is carried out as follows when a plurality of liquid crystal panels with the same specifications are inspected one after another. First, the first LCD panel is placed on the inspection stage. The inspection stage keeps the backlight on. The reason is that it takes time until the luminance is stabilized after the voltage is applied to the backlight. After the LCD panel is placed on the inspection stage, the inspection stage is appropriately moved so that the alignment mark matches the camera origin mark. Then, using a microscope, confirm that all the probes on the probe stage are actually in contact with all the electrodes on the liquid crystal panel. If the probe position and the electrode position are misaligned, finely adjust the movement of the inspection stage. When the fine adjustment is completed, how much each alignment mark is deviated from the origin mark of each camera is obtained, and the value is stored as the standard coordinates of each alignment mark. These standard coordinates serve as a reference for alignment of the second and subsequent liquid crystal panels having the same specifications. When aligning the second and subsequent liquid crystal display panels, the inspection stage is appropriately moved so that the alignment mark is positioned at the above-mentioned standard coordinates with respect to the camera origin mark.

  According to the alignment method described above, when a plurality of liquid crystal panels having the same specifications are inspected for lighting, only the first liquid crystal panel has the same positions as the electrodes of the liquid crystal panel and the probe of the inspection apparatus. The standard coordinates are obtained with a microscope. The time required for this alignment operation is about 10 to 30 minutes. After this alignment operation, the inspection stage is raised, the electrodes of the liquid crystal panel are brought into contact with the probe of the inspection device, the liquid crystal panel is fully lit, and a visual lighting inspection is performed. The time required for the visual lighting inspection is about one minute. For the second and subsequent liquid crystal panels, the alignment operation itself is completed in a few seconds because the inspection stage is simply moved so that the alignment mark is positioned at the above-mentioned standard coordinates with respect to the camera origin mark. That is, for the second and subsequent liquid crystal panels, the matching state between the electrodes of the liquid crystal panel and the probe of the inspection apparatus is not confirmed with a microscope. The visual lighting inspection is completed in about 1 minute.

  When the first liquid crystal panel is aligned, it takes about 10 to 30 minutes as described above. During this time, the liquid crystal panel receives backlight illumination, and the temperature rises by about 20 ° C. For example, the temperature of the liquid crystal panel rises from room temperature 20 ° C. to 40 ° C. On the other hand, the second and subsequent LCD panels take only a few seconds for alignment work, so there is almost no temperature rise. Therefore, when the alignment of the first liquid crystal panel is completed (when the above standard coordinates are stored), the position of the alignment mark of the liquid crystal panel in the thermally expanded state is stored. On the other hand, when aligning the second and subsequent liquid crystal panels, the liquid crystal panel hardly expands. Therefore, in the second and subsequent LCD panels, the liquid crystal panels that are not thermally expanded are aligned based on the standard coordinates obtained at the time of thermal expansion. .

  In the future, as the size of liquid crystal panels and backlights increase in brightness, the effects of the above-mentioned thermal expansion will increase. For example, if the size of the liquid crystal panel is 50 to 60 and the backlight brightness is 30,000 candela (about 8,000 candela for a conventional personal computer liquid crystal panel), the influence of thermal expansion becomes considerably large. As a result, during the lighting inspection of the second and subsequent liquid crystal panels, lighting failure due to misalignment (alignment failure) between the electrodes of the liquid crystal panel and the probe of the inspection device occurs particularly on the long side of the liquid crystal panel. Is starting to do.

By the way, in the field of inspection devices using probes, a technique described in the following Patent Document 2 is known as a technique for avoiding alignment failure due to thermal expansion.
JP-A-7-58167

  This patent document 2 discloses a technique for accurately aligning the bumps of the probe card and the electrode pads of the wafer. In the high temperature test, even if the heated probe card is thermally expanded, the thermal expansion is taken into consideration. Can be aligned. Specifically, in the probe card, when the bumps are arranged in the X direction and the Y direction, scales are formed in parallel to the bump arrangement, that is, in the X direction and the Y direction. By photographing the scale expansion / contraction state with an imaging device, the actual thermal expansion amount of the probe card can be grasped, and thereby the expansion / contraction state of the probe card bump arrangement can be understood. Based on this, the bump and the electrode pad of the wafer are aligned.

  This Patent Document 2 considers the influence of the thermal expansion of the probe card, not the object to be inspected. A scale is provided on the probe card, and the expansion / contraction amount of the scale is read by the imaging device. Therefore, in order to use this technique, it is necessary to form scales in advance in the X and Y directions of the probe card.

  The present invention has been made to solve the above-described problems. The purpose of the present invention is to provide a difference in expansion / contraction due to thermal expansion between liquid crystal panels when a plurality of liquid crystal panels having the same specifications are inspected for lighting. However, it is an object of the present invention to provide an alignment method capable of aligning a liquid crystal panel in consideration of the difference and a liquid crystal panel lighting inspection apparatus for carrying out the method. Another object of the present invention is to provide an alignment method that does not require the provision of a scale for measuring the amount of expansion and contraction due to thermal expansion, and a liquid crystal panel lighting inspection device for implementing the method.

  The alignment method of the liquid crystal panel lighting inspection apparatus according to the present invention includes the following steps (a) to (g). (A) A rectangular liquid crystal panel, wherein a first alignment mark and a second alignment mark which are formed at a distance from each other along the first side of the rectangle, and a second perpendicular to the first side The first alignment mark and the third alignment mark formed at a distance from each other along the side, and a first electrode group comprising a plurality of electrodes formed side by side along the first side; A panel preparation step of preparing a liquid crystal panel including a second electrode group including a plurality of electrodes formed side by side along the second side. (A) An inspection device preparation stage for preparing a liquid crystal panel lighting inspection device comprising the following (a) to (c). (A) An inspection stage that can hold the liquid crystal panel and shine light on the back surface of the liquid crystal panel. (B) a first probe group that can contact the first electrode group, a second probe group that can contact the second electrode group, the first alignment mark, the second alignment mark, and the A probe stage including a first camera, a second camera, and a third camera, each capable of observing a third alignment mark. (C) A driving mechanism capable of moving the inspection stage in the X direction and the Y direction perpendicular to the probe stage and rotating around the Z axis perpendicular to the XY plane. (C) Place the first liquid crystal panel on the inspection stage so that the first side is parallel to the Y direction and the second side is parallel to the X direction. First panel setting stage to set. (D) The inspection stage is moved relative to the probe stage in the X and Y directions and rotated around the Z axis, using the first camera, the second camera, and the third camera. The first alignment mark, the second alignment mark, and the third alignment mark are observed, and the first probe group and the second probe group with respect to the first electrode group and the second electrode group are observed. , The XY coordinates of the first alignment mark with respect to the reference point of the first camera are stored as first standard coordinates (x1a, y1a), and the reference of the second camera is confirmed. XY coordinates of the second alignment mark relative to a point are stored as second standard coordinates (x2a, y2a), and the second alignment mark relative to the reference point of the third camera is stored. The XY coordinates of the alignment marks third standard coordinate (x3a, y3a) as the standard coordinate storage step of storing the at least X-coordinate (x3a). (E) The first liquid crystal panel is removed from the inspection stage, and the second liquid crystal panel having the same specifications as the first liquid crystal panel is placed with the first side parallel to the Y direction. And a second panel setting step of setting the inspection stage so that the second side is parallel to the X direction. (F) The inspection stage is moved relative to the probe stage in the X direction and the Y direction and rotated about the Z axis, and the first camera and the second camera are used to One alignment mark and the second alignment mark are observed, and the XY coordinates of the first alignment mark and the XY coordinates of the second alignment mark are the first standard coordinates (x1a, y1a) and the second alignment marks, respectively. Temporary positioning step of positioning the second liquid crystal panel so as to be closest to the standard coordinates (x2a, y2a). (G) After the provisional positioning step is completed, the third alignment mark of the second liquid crystal panel is observed using the third camera, and the third alignment mark with respect to the reference point of the third camera is observed. A temporary coordinate storage step of storing the X coordinate of the three alignment marks as a temporary coordinate (x3b). (H) A deviation calculating step of calculating a deviation (Δx) of the temporary coordinate (x3b) with respect to the X coordinate (x3a) of the third standard coordinate. (G) Final positioning for positioning the second liquid crystal panel by shifting the inspection stage by a half of the deviation (Δx) in the direction opposite to the deviation (Δx) in the X direction. Stage.

  As described above, according to the present invention, after the liquid crystal panel is temporarily positioned based on the first alignment mark and the second alignment mark, the above-described deviation Δx is obtained with respect to the third alignment mark, and the liquid crystal panel is only half of that. Shifted in the X direction. Thereby, the alignment of the probe and the electrode on the second side becomes more accurate than before. As a result, even when a large liquid crystal panel is illuminated with a high-brightness backlight, lighting defects due to poor alignment can be avoided.

  The liquid crystal panel lighting inspection apparatus according to the present invention is for inspecting lighting of the liquid crystal panel shown in the following (A), and includes the following (A) to (SA). (A) A rectangular liquid crystal panel, wherein a first alignment mark and a second alignment mark which are formed at a distance from each other along the first side of the rectangle, and a second perpendicular to the first side The first alignment mark and the third alignment mark formed at a distance from each other along the side, a first electrode group comprising a plurality of electrodes arranged side by side along the first side, A liquid crystal panel comprising: a second electrode group including a plurality of electrodes arranged side by side along the second side. (A) The liquid crystal panel lighting inspection device is an inspection stage that can hold the liquid crystal panel and shine light on the back surface of the liquid crystal panel. (C) a first probe group that can contact the first electrode group, a second probe group that can contact the second electrode group, the first alignment mark, the second alignment mark, and the A probe stage including a first camera, a second camera, and a third camera, each capable of observing a third alignment mark. (D) A drive mechanism that can move the inspection stage in the X direction and the Y direction perpendicular to the probe stage and can rotate around the Z axis perpendicular to the XY plane. (E) The first liquid crystal panel is placed on the inspection stage so that the first side is parallel to the Y direction and the second side is parallel to the X direction. First panel setting means that can be set. (F) The inspection stage is moved relative to the probe stage in the X direction and the Y direction, and rotated around the Z axis, using the first camera, the second camera, and the third camera. The first alignment mark, the second alignment mark, and the third alignment mark are observed, and the first probe group and the second probe group with respect to the first electrode group and the second electrode group are observed. , The XY coordinates of the first alignment mark with respect to the reference point of the first camera are stored as first standard coordinates (x1a, y1a), and the reference of the second camera is confirmed. XY coordinates of the second alignment mark relative to a point are stored as second standard coordinates (x2a, y2a), and the second alignment mark relative to the reference point of the third camera is stored. The XY coordinates of the alignment marks third standard coordinate (x3a, y3a) as the standard coordinate storage means for storing at least X coordinates (x3a). (G) The first liquid crystal panel is removed from the inspection stage, and the second liquid crystal panel having the same specifications as the first liquid crystal panel is arranged with the first side parallel to the Y direction. And second panel setting means that can be set on the inspection stage such that the second side is parallel to the X direction. (H) The inspection stage is moved relative to the probe stage in the X direction and the Y direction and rotated around the Z axis, and the first camera and the second camera are used to One alignment mark and the second alignment mark are observed, and the XY coordinates of the first alignment mark and the XY coordinates of the second alignment mark are the first standard coordinates (x1a, y1a) and the second alignment marks, respectively. Temporary positioning means for positioning the second liquid crystal panel so as to be closest to the standard coordinates (x2a, y2a). (K) The third alignment mark of the second liquid crystal panel is observed using the third camera, and the X coordinate of the third alignment mark with respect to the reference point of the third camera is set as a temporary coordinate (x3b ) As temporary coordinate storage means. (G) Deviation calculation means for calculating a deviation (Δx) of the temporary coordinate (x3b) with respect to the X coordinate (x3a) of the third standard coordinate. (C) Final positioning for positioning the second liquid crystal panel by shifting the inspection stage by a half of the deviation (Δx) in the direction opposite to the deviation (Δx) in the X direction. means.

  According to the present invention, when a plurality of liquid crystal panels having the same specifications are inspected for lighting, even if there is a difference in expansion / contraction due to thermal expansion between the liquid crystal panels, the liquid crystal panels can be aligned in consideration of the difference. . As a result, even when a large liquid crystal panel is illuminated with a high-brightness backlight, lighting defects due to poor alignment can be avoided. In addition, since only three existing alignment marks are used, there is no need to provide a special scale for measuring the amount of expansion / contraction due to thermal expansion.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. FIG. 1 is a plan view of a main part of an example of a liquid crystal panel lighting inspection apparatus to which the alignment method of the present invention is applied. This liquid crystal panel lighting inspection apparatus includes a probe stage having a probe and an inspection stage for holding the liquid crystal panel, and the inspection stage is below the probe stage. FIG. 1 shows the main part of the probe stage as viewed from above, and the liquid crystal panel 10 placed on the inspection stage can be seen. The probe stage includes a first probe base 12 and a second probe base 14. The first probe base 12 extends in the Y direction, and the second probe base 14 extends in the X direction. The X direction and the Y direction are orthogonal to each other. The liquid crystal panel 10 is rectangular, and one short side 28 (first side) is called a gate side, and one long side 30 (second side) adjacent to the short side 28 is called a data side. Many gate line electrodes of the matrix cell are arranged on the gate side of the liquid crystal panel, and many data line electrodes are arranged on the data side. Hereinafter, the first probe base 12 is referred to as a gate-side probe base, and the second probe base 14 is referred to as a data-side probe base.

  A gate side probe unit 16 is mounted on the gate side probe base 12. A plurality of gate side probe blocks 18 are fixed to the gate side probe unit 16. A plurality of gate-side probes 20 are attached to each gate-side probe block 18. All the gate-side probes 20 attached to the gate-side probe base 12 constitute a first probe group.

  A data side probe unit 22 is mounted on the data side probe base 14. A plurality of data side probe blocks 24 are also fixed to the data side probe unit 22. A plurality of data side probes 26 are attached to each data side probe block 24. All the data-side probes 20 attached to the data-side probe base 14 constitute a second probe group.

  In FIG. 1, two gate-side probe blocks 18 and three data-side probe blocks 24 are shown for ease of understanding, but in an actual liquid crystal panel lighting inspection apparatus, more probe blocks are shown. Is used. In addition, although several probes 20 and 26 are shown in the probe blocks 18 and 24, more probes are actually provided.

  The gate side probe unit 16 is provided with a first camera 32 and a second camera 34 in the vicinity of both ends thereof. On the other hand, a third camera 36 is disposed in the data side probe unit 22 near the end portion away from the gate side probe unit 16.

  2 is a cross-sectional view taken along line 2-2 of FIG. An inspection stage 40 is disposed below the probe stage 38. The inspection stage 40 includes an X drive table 42, a Y drive table 44, a Z drive table 46, and a θ rotation table 48. The liquid crystal panel 10 can be held on the upper surface of the inspection stage 40. The X drive base 42 can move the upper surface of the inspection stage in the X direction (direction perpendicular to the paper surface of FIG. 2). The Y drive base 44 can move the upper surface of the inspection stage in the Y direction. The Z drive base 46 can move the upper surface of the inspection stage in the Z direction (vertical direction). The θ rotation table 48 can rotate the upper surface of the inspection stage around the Z axis (axis extending in the vertical direction).

  In FIG. 2, the first camera 32, the second camera 34, the gate-side probe block 18 and the gate-side probe 20 are clearly shown. A first origin mark 50 is disposed directly below the optical axis of the first camera 32, and a second origin mark 52 is disposed directly below the optical axis of the second camera 34. These origin marks 50 and 52 are attached to the gate side probe unit 16 and serve as reference points for the two cameras 32 and 34. Similarly, a third origin mark is also arranged just below the optical axis of the third camera 36 in FIG. The third origin mark is attached to the data side probe unit 22 and serves as a reference point for the third camera 36.

  FIG. 3 is a plan view showing the positional relationship between the liquid crystal panel 10 and the probe stage 38. As for the probe stage 38, the gate side probe unit 16 is shifted to the left in the figure from the original position, and the data side probe unit 22 is shifted from the original position in the upper direction in the figure. Thereby, the whole liquid crystal panel 10 below the probe stage 38 can be shown. A plurality of gate electrodes 54 are arranged along the side 28 on the first side 28 of the liquid crystal panel 10. The gate electrode 54 is grouped for each predetermined block. A group of gate-side probes 20 belonging to one gate-side probe block 18 corresponds to the group of gate electrodes 54 described above. All the gate electrodes 54 formed on the first side 28 constitute a first electrode group. Therefore, the first probe group (comprising a plurality of gate-side probes 20) corresponds to the first electrode group (comprising a plurality of gate electrodes 54). A first alignment mark 56 and a second alignment mark 58 are formed near both ends of the first side 28 of the liquid crystal panel 10. These alignment marks 56 and 58 are formed along the first side 28 so as to be spaced from each other.

  A plurality of data electrodes 60 are arranged along the side 30 on the second side 30 of the liquid crystal panel 10. The data electrode 60 is also grouped for each predetermined block. A group of data side probes 26 belonging to one data side probe block 24 corresponds to the group of data electrodes 60 described above. All the data electrodes 60 along the second side 30 constitute a second electrode group. Therefore, the second probe group (comprising a plurality of data-side probes 26) corresponds to the second electrode group (comprising a plurality of data electrodes 60). The first alignment mark 56 described above exists near the left end of the second side 30 of the liquid crystal panel 10, and the third alignment mark 62 is formed near the right end of the second side 30. The first alignment mark 56 and the third alignment mark 62 are formed along the second side 30 so as to be spaced from each other.

  The first camera 32 and the second camera 34 attached to the gate side probe unit 16 can observe the first alignment mark 56 and the second alignment mark 58, respectively. The third camera 36 attached to the data side probe unit 22 can observe the third alignment mark 62.

  FIG. 4 is an enlarged view of a part of the electrodes and alignment marks of the liquid crystal panel 10. To describe the enlarged data side, the data electrode 60 is elongated in the Y direction, and is arranged side by side along the second side 30 (that is, in the X direction). The third alignment mark 62 has a cross shape. As for the gate side as well, the gate electrode 54 extends in the X direction and is arranged along the first side 28 (that is, in the Y direction). The first alignment mark 56 and the second alignment mark 58 are also cross-shaped. Since these electrodes 54, 60 and alignment marks 56, 58, 62 are formed using a common mask or the like, the positional relationship between them is accurately determined.

  Next, an outline of the alignment procedure of the liquid crystal panel will be described. When inspecting lighting of liquid crystal panels of the same specification one after another, the following is performed. First, for the first LCD panel, use a microscope to check that all the probes on the probe stage are securely in contact with all the electrodes on the LCD panel. At that time, the position of the alignment mark on the LCD panel and the camera reference The positional relationship with the position is registered as standard coordinates. In the second and subsequent liquid crystal panels, the liquid crystal panels are basically aligned so that the position of the alignment mark coincides with the standard coordinates described above with respect to the reference position of the camera. In the present invention, the thermal expansion amount of the liquid crystal panel during the alignment operation of the first liquid crystal panel is different from the thermal expansion amount of the liquid crystal panel during the alignment operation of the second and subsequent liquid crystal panels. However, the alignment procedure has been improved to minimize the effects of these differences. Hereinafter, the alignment procedure will be described in detail.

  The first liquid crystal panel 10 is placed on the upper surface of the inspection stage 40 shown in FIG. A backlight is incorporated in the inspection stage 40, and this backlight is turned on in advance. By moving the X drive table 42, Y drive table 44, and θ rotation table 48 of the inspection stage 40, the three alignment marks 56, 58, 62 of the liquid crystal panel 10 shown in FIG. To enter. In addition, since the origin marks (two of which are indicated by reference numerals 50 and 52 in FIG. 2) are visible in the field of view of the three cameras 32, 34, and 36, these origin marks are visible. Move the inspection stage so that each alignment mark matches as much as possible. This operation is automatically performed by pattern matching by image processing.

  Next, the Z drive base 46 of the inspection stage shown in FIG. 2 is raised, and the electrode of the liquid crystal panel is brought into contact with the probe of the probe stage. Then, whether or not the gate electrode 54 and the data electrode 60 of the liquid crystal panel 10 shown in FIG. 3 are all in contact with all of the gate-side probe 20 and the data-side probe 26 of the probe stage is confirmed using a microscope. Confirm. If it is found that the positions of the electrodes and the probe are shifted, after confirming the shift amount, the Z drive base 46 is lowered, and then the X drive base 42 of the inspection stage 40 is equivalent to the shift amount described above. Then, the position of the liquid crystal panel 10 is finely adjusted by moving the Y drive base 44 and the θ rotation base 48. Then, after the liquid crystal panel 10 is raised again, it is confirmed whether or not the electrodes 54 and 60 of the liquid crystal panel 10 and the probes 20 and 26 are in reliable contact using a microscope. If it is confirmed that they are in contact with each other, the coordinate positions of the three alignment marks with respect to the reference points of the three cameras are stored as standard coordinates. Next, with the probe in contact with the electrodes of the liquid crystal panel, a predetermined voltage is applied to the probe to turn on the liquid crystal panel completely, and the operator visually checks for the presence of lighting defects. The work so far takes, for example, about 10 to 30 minutes. Most of the time is spent on the work to determine the standard coordinates described above.

  FIG. 5A schematically shows the positions of the three alignment marks when the above-described standard coordinates are obtained. The coordinates (x1a, y1a) (hereinafter referred to as first standard coordinates) of the center position of the first alignment mark 56 are obtained with reference to the center point of the cross-shaped origin mark 50 in the field of view of the first camera. Similarly, the coordinates (x2a, y2a) (hereinafter referred to as second standard coordinates) of the center position of the second alignment mark 58 are obtained with reference to the center point of the cross-shaped origin mark 52 in the field of view of the second camera. It is done. The coordinates (x3a, y3a) (hereinafter referred to as third standard coordinates) of the center position of the third alignment mark 62 are obtained with reference to the center point of the cross-shaped origin mark 64 in the field of view of the third camera. These three coordinates become the standard coordinates of each alignment mark. As will be described later, since only the X coordinate x3a is important for the third standard coordinate, it is necessary to store at least the X coordinate x3a.

  By the way, during the alignment work for 10 to 30 minutes, the temperature of the liquid crystal panel rises upon receiving illumination light from the backlight. For example, the panel temperature rises from room temperature 20 ° C. to 40 ° C. For this reason, the liquid crystal panel expands thermally. In a large liquid crystal panel (for example, 50 type), when the length of the long side is about 1 m and the temperature rises by 20 ° C., the thermal expansion amount is about 40 μm, for example. Therefore, the standard coordinates described above are actually obtained for a thermally expanded liquid crystal panel.

  Next, the first liquid crystal panel is removed from the inspection stage, and a second liquid crystal panel having the same specifications as the first liquid crystal panel is placed on the inspection stage. As shown in FIG. 5B, the center position of the first alignment mark 56 is as close as possible to the first standard coordinates (x1a, y1a) described above with reference to the first origin mark 50, and The liquid crystal panel 10b is moved in the X direction and the Y direction so that the center position of the second alignment mark 58 is as close as possible to the second standard coordinates (x2a, y2a) described above with reference to the second origin mark 52. At the same time, it rotates θ around the Z axis. This operation is the same as the conventional method of positioning the liquid crystal panel using two alignment marks. At this time, the coordinates of the center position of the first alignment mark 56 are (x1b, y1b) (hereinafter referred to as first intermediate coordinates), and the coordinates of the center position of the second alignment mark 58 are (x2b, y2b) (hereinafter referred to as “x1b, y1b”). , Referred to as second intermediate coordinates). The X coordinate x1b of the first intermediate coordinate and the X coordinate x2b of the second intermediate coordinate can be made equal to the X coordinate x1a of the first standard coordinate and the X coordinate x2a of the second standard coordinate, respectively. On the other hand, the Y coordinate y1b of the first intermediate coordinate and the Y coordinate y2b of the second intermediate coordinate cannot necessarily match the Y coordinate y1a of the first standard coordinate and the Y coordinate y2a of the second standard coordinate. This is because the first liquid crystal panel was thermally expanded, whereas the second liquid crystal panel was hardly thermally expanded. Since the second liquid crystal panel 10b does not perform the alignment confirmation work using a microscope, the time during which the liquid crystal panel is placed on the inspection stage is very short. Accordingly, the second liquid crystal panel 10b has little temperature rise and little thermal expansion compared to the first liquid crystal panel 10a. If y1b matches y1a, y2b moves away from y2a. Conversely, if y2b matches y2a, y1b moves away from y1a. Therefore, in the actual positioning control, the position in the Y direction of the liquid crystal panel is controlled so that the intermediate position between y1a and y2a coincides with the intermediate position between y2a and y2b. In other words, control is performed so that y1b-y1a = y2a-y2b.

  The positioning work so far is the same as the conventional method. When the LCD panel is relatively small and the backlight luminance is not so high, the second and subsequent LCD panels can be inspected without problems by the alignment work so far. However, when a large liquid crystal panel such as a 50-60 type is used and the backlight is also bright, the amount of thermal expansion of the liquid crystal panel increases, causing a displacement between the data electrode and the data probe. As a result, line defects in the lighting inspection are generated. This point will be described in detail below.

  FIG. 6 is an explanatory diagram for explaining the positional deviation in the X direction between the data side probe and the data electrode. The upper part of FIG. 6 schematically shows the X-direction positions of the first origin mark 50 and the third origin mark 64 and the plurality of data side probes 26 therebetween. Although the actual number of data side probes 26 is larger, only a small number of data side probes 26 are shown for easy understanding.

  The state A in FIG. 6 is the state of FIG. 5A, that is, the alignment of the first liquid crystal panel, and the two alignment marks 56 and 62 and the plurality of data electrodes 60 between them. The position in the X direction is shown. The X coordinate of the center position of the first alignment mark 56 is x1a (X coordinate of the first standard coordinate) with the first origin mark 50 as a reference. The X coordinate of the center position of the third alignment mark 62 is x3a (X coordinate of the third standard coordinate) with the third origin mark 64 as a reference. In this state, it has been confirmed that all the data electrodes 60 can contact all the data-side probes 26 using a microscope.

  The state B of FIG. 6 is the first alignment in the state of FIG. 5B, that is, the state in which the second liquid crystal panel having the same specifications is aligned using the first alignment mark 56 and the second alignment mark 58. The positions of the mark 56 and the third alignment mark 62 and the plurality of data electrodes 60 between them in the X direction are shown. At this time, the X coordinate x1b of the center position of the first alignment mark 56 is equal to the X coordinate x1a of the first standard coordinate. On the other hand, the X coordinate x3b of the center position of the third alignment mark 62 is shifted by a deviation Δx compared to the X coordinate x3a of the third standard coordinate. The reason is that in the A state, the first liquid crystal panel was thermally expanded and extended in the X direction, whereas in the B state, the second liquid crystal panel was hardly thermally expanded. The shift amount Δx is substantially equal to the thermal expansion amount between the two alignment marks 56 and 62 in the first liquid crystal panel. In the B state, it is difficult to say that all the data electrodes 60 can contact all the data side probes 26. Depending on the magnitude of the deviation Δx and the degree of variation in the arrangement of the probes 26, any data electrode 60 may not contact the corresponding data-side probe 26. As a matter of fact, when a large liquid crystal panel is inspected for lighting using a high-brightness backlight, in the inspection of the second and subsequent liquid crystal panels, one of the data side probes does not come into contact with the data electrode. A lighting failure (line defect) has occurred.

  Therefore, in the present invention, after obtaining the above-described deviation Δx for the second and subsequent liquid crystal panels, as shown in the state C in FIG. 6, the direction of the deviation (left in FIG. 6) is half the deviation Δx. The liquid crystal panel is shifted in the opposite direction (right direction in FIG. 6). Since x3b is shifted by a deviation Δx in the left direction in FIG. 6 with respect to x3a, the liquid crystal panel is shifted in the right direction by Δx / 2. As a result, the center position in the X direction of the first liquid crystal panel coincides with the center position in the X direction of the second and subsequent liquid crystal panels. As a result, the positions of the plurality of data-side probes 26 and the positions of the plurality of data electrodes 60 are best matched. By the way, if the amount of thermal expansion of the first liquid crystal panel becomes very large, there may be a situation in which any of the data side probes 26 cannot contact the data electrode 60 even if the shift is performed as described above. In such a case, even with the present invention, it becomes impossible to eliminate the lighting failure caused by the contact failure, and another countermeasure needs to be considered.

  The lower part of FIG. 6 shows mathematical formulas for obtaining the X coordinate x1c of the first alignment mark and the X coordinate x3c of the third alignment mark for the second and subsequent liquid crystal panels finally positioned. Equation (1) is an equation for obtaining the deviation Δx. Δx is obtained by subtracting the X coordinate x3a of the third alignment mark in the A state from the X coordinate x3b of the third alignment mark in the B state. Expression (2) is an expression for obtaining the final X coordinate x1c of the first alignment mark. This x1c is obtained by subtracting Δx / 2 from the X coordinate x1b of the first alignment mark in the B state. Expression (3) is an expression for obtaining the final X coordinate x3c of the third alignment mark. This x3c is also obtained by subtracting Δx / 2 from the X coordinate x3b of the third alignment mark in the B state.

  FIG. 5C shows a state in which the liquid crystal panel is shifted from the state of FIG. 5B by Δx / 2 in the X direction in the direction opposite to the deviation Δx (that is, in the direction of the arrow 66). That is, it corresponds to the state C in FIG. In this state, the center of the thermally expanded liquid crystal panel 10a (first liquid crystal panel) coincides with the center of the liquid crystal panel 10b (second and subsequent liquid crystal panels) that hardly undergoes thermal expansion. .

  By the way, by shifting the liquid crystal panel in the X direction from the state of FIG. 5B to the state of FIG. 5C, the first alignment mark 56, the second alignment mark 58, the first origin mark 50, the second The alignment state with the origin mark 52 is shifted in the X direction. However, since the gate electrode is elongated in the X direction, the gate side probe does not come off the gate electrode even when the liquid crystal panel is shifted in the X direction.

  It takes about several seconds to align the second and subsequent liquid crystal panels. To explain this, in order to make the second and subsequent liquid crystal panels into the state shown in FIG. 5B, the first alignment mark 56 and the second alignment mark 58 are set to the first standard coordinates (x1a, y1a) as much as possible. The inspection stage is moved so as to coincide with the second standard coordinates (x2a, y2b). This work is based on pattern matching by image processing of the alignment mark and the origin mark, and it takes about a few seconds. When this alignment operation is completed, the liquid crystal panel is raised, the electrode of the liquid crystal panel is brought into contact with the probe, a predetermined voltage is applied from the probe to the electrode, and the operator visually inspects the lighting state of the liquid crystal panel. The time required for the inspection is about one minute at most. In the meantime, the liquid crystal panel is illuminated by the backlight and slightly rises in temperature, causing some thermal expansion. However, once the tip of the probe comes into contact with the electrodes of the liquid crystal panel, the tip of the probe remains in contact with the electrodes even if the liquid crystal panel expands slightly and the electrode position shifts slightly. The probe does not come off the electrode.

  The description of the above embodiment is based on the premise that the optical axis of the camera and the Z axis of the inspection stage are completely coincident. If the optical axis of the camera is slightly tilted with respect to the Z axis of the inspection stage, it is necessary to correct the alignment mark coordinates. Such a correction method is described in Patent Document 1 described above, for example. The alignment method of the present invention can also be combined with such a correction method.

It is a top view of the principal part of an example of the liquid crystal panel lighting test | inspection apparatus to which the alignment method of this invention is applied. FIG. 2 is a sectional view taken along line 2-2 of FIG. It is a top view which shows the positional relationship of a liquid crystal panel and a probe stage. This is an enlarged view of a part of an electrode and an alignment mark of a liquid crystal panel. It is a top view which shows typically the standard position of the 1st liquid crystal panel, and the intermediate position and final position of the 2nd liquid crystal panel. It is a top view explaining the position shift of the X direction between a data side probe and a data electrode.

Explanation of symbols

10 Liquid crystal panel 12 First probe base (gate side probe base)
14 Second probe base (data side probe base)
16 Gate-side probe unit 18 Gate-side probe block 20 Gate-side probe (first probe group)
22 Data-side probe unit 24 Data-side probe block 26 Data-side probe (second probe group)
28 First side 30 Second side 32 First camera 34 Second camera 36 Third camera 38 Probe stage 40 Inspection stage 42 X drive base 44 Y drive base 46 Z drive base 48 θ rotary base 50 First origin mark 52 Second origin mark 54 Gate electrode (first electrode group)
56 First alignment mark 58 Second alignment mark 60 Data electrode (second electrode group)
62 Third alignment mark 64 Third origin mark

Claims (2)

An alignment method for a liquid crystal panel lighting inspection apparatus comprising the following steps.
(A) A rectangular liquid crystal panel, wherein a first alignment mark and a second alignment mark which are formed at a distance from each other along the first side of the rectangle, and a second perpendicular to the first side The first alignment mark and the third alignment mark formed at a distance from each other along the side, and a first electrode group comprising a plurality of electrodes formed side by side along the first side; A panel preparation step of preparing a liquid crystal panel including a second electrode group including a plurality of electrodes formed side by side along the second side.
(A) An inspection device preparation stage for preparing a liquid crystal panel lighting inspection device comprising the following (a) to (c).
(A) An inspection stage that can hold the liquid crystal panel and shine light on the back surface of the liquid crystal panel.
(B) a first probe group that can contact the first electrode group, a second probe group that can contact the second electrode group, the first alignment mark, the second alignment mark, and the A probe stage including a first camera, a second camera, and a third camera, each capable of observing a third alignment mark.
(C) A driving mechanism capable of moving the inspection stage in the X direction and the Y direction perpendicular to the probe stage and rotating around the Z axis perpendicular to the XY plane.
(C) Place the first liquid crystal panel on the inspection stage so that the first side is parallel to the Y direction and the second side is parallel to the X direction. First panel setting stage to set.
(D) The inspection stage is moved relative to the probe stage in the X and Y directions and rotated around the Z axis, using the first camera, the second camera, and the third camera. The first alignment mark, the second alignment mark, and the third alignment mark are observed, and the first probe group and the second probe group with respect to the first electrode group and the second electrode group are observed. , The XY coordinates of the first alignment mark with respect to the reference point of the first camera are stored as first standard coordinates (x1a, y1a), and the reference of the second camera is confirmed. XY coordinates of the second alignment mark relative to a point are stored as second standard coordinates (x2a, y2a), and the second alignment mark relative to the reference point of the third camera is stored. The XY coordinates of the alignment marks third standard coordinate (x3a, y3a) as the standard coordinate storage step of storing the at least X-coordinate (x3a).
(E) The first liquid crystal panel is removed from the inspection stage, and the second liquid crystal panel having the same specifications as the first liquid crystal panel is placed with the first side parallel to the Y direction. And a second panel setting step of setting the inspection stage so that the second side is parallel to the X direction.
(F) The inspection stage is moved relative to the probe stage in the X direction and the Y direction and rotated about the Z axis, and the first camera and the second camera are used to One alignment mark and the second alignment mark are observed, and the XY coordinates of the first alignment mark and the XY coordinates of the second alignment mark are the first standard coordinates (x1a, y1a) and the second alignment marks, respectively. Temporary positioning step of positioning the second liquid crystal panel so as to be closest to the standard coordinates (x2a, y2a).
(G) After the provisional positioning step is completed, the third alignment mark of the second liquid crystal panel is observed using the third camera, and the third camera mark relative to the reference point of the third camera is observed. A temporary coordinate storage step of storing the X coordinate of the three alignment marks as a temporary coordinate (x3b).
(H) A deviation calculating step of calculating a deviation (Δx) of the temporary coordinate (x3b) with respect to the X coordinate (x3a) of the third standard coordinate.
(G) Final positioning for positioning the second liquid crystal panel by shifting the inspection stage by a half of the deviation (Δx) in the direction opposite to the deviation (Δx) in the X direction. Stage. A liquid crystal panel lighting inspection apparatus for inspecting lighting of a liquid crystal panel shown in the following (a), comprising the following (a) to (sa).
(A) A rectangular liquid crystal panel, wherein a first alignment mark and a second alignment mark which are formed at a distance from each other along the first side of the rectangle, and a second perpendicular to the first side The first alignment mark and the third alignment mark formed at a distance from each other along the side, a first electrode group comprising a plurality of electrodes arranged side by side along the first side, A liquid crystal panel comprising: a second electrode group including a plurality of electrodes arranged side by side along the second side.
(A) The liquid crystal panel lighting inspection device is an inspection stage that can hold the liquid crystal panel and shine light on the back surface of the liquid crystal panel.
(C) a first probe group that can contact the first electrode group, a second probe group that can contact the second electrode group, the first alignment mark, the second alignment mark, and the A probe stage including a first camera, a second camera, and a third camera, each capable of observing a third alignment mark.
(D) A drive mechanism that can move the inspection stage in the X direction and the Y direction perpendicular to the probe stage and can rotate around the Z axis perpendicular to the XY plane.
(E) The first liquid crystal panel is placed on the inspection stage so that the first side is parallel to the Y direction and the second side is parallel to the X direction. First panel setting means that can be set.
(F) The inspection stage is moved relative to the probe stage in the X direction and the Y direction, and rotated around the Z axis, using the first camera, the second camera, and the third camera. The first alignment mark, the second alignment mark, and the third alignment mark are observed, and the first probe group and the second probe group with respect to the first electrode group and the second electrode group are observed. , The XY coordinates of the first alignment mark with respect to the reference point of the first camera are stored as first standard coordinates (x1a, y1a), and the reference of the second camera is confirmed. XY coordinates of the second alignment mark relative to a point are stored as second standard coordinates (x2a, y2a), and the second alignment mark relative to the reference point of the third camera is stored. The XY coordinates of the alignment marks third standard coordinate (x3a, y3a) as the standard coordinate storage means for storing at least X coordinates (x3a).
(G) The first liquid crystal panel is removed from the inspection stage, and the second liquid crystal panel having the same specifications as the first liquid crystal panel is arranged with the first side parallel to the Y direction. And second panel setting means that can be set on the inspection stage such that the second side is parallel to the X direction.
(H) The inspection stage is moved relative to the probe stage in the X direction and the Y direction and rotated around the Z axis, and the first camera and the second camera are used to One alignment mark and the second alignment mark are observed, and the XY coordinates of the first alignment mark and the XY coordinates of the second alignment mark are the first standard coordinates (x1a, y1a) and the second alignment marks, respectively. Temporary positioning means for positioning the second liquid crystal panel so as to be closest to the standard coordinates (x2a, y2a).
(K) The third alignment mark of the second liquid crystal panel is observed using the third camera, and the X coordinate of the third alignment mark with respect to the reference point of the third camera is set as a temporary coordinate (x3b ) As temporary coordinate storage means.
(G) Deviation calculation means for calculating a deviation (Δx) of the temporary coordinate (x3b) with respect to the X coordinate (x3a) of the third standard coordinate.
(C) Final positioning for positioning the second liquid crystal panel by shifting the inspection stage by a half of the deviation (Δx) in the direction opposite to the deviation (Δx) in the X direction. means.

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