Title of Invention

A PROCESSING METHOD FOR SUBSTRATES AND APPARATUS THEREFOR.

Abstract In a processing method, a substrate consisting of a plurality of individual substrates and a photo-curable adhesive layer interposed there between is irradiated by a curing light, and the deflection of the substrate is controlled by controlling the temperature while the individual substrates are bonded together by photo-curing the adhesive layer. The step for controlling the deflection includes a step of finding the temperature difference ¨7EHWZHHQWKHWHPSHUDWXUH7Kof a mounting table and the temperature Td of the substrates before curing ; a step of finding deflection difference ¨;EHWZHHQWKHdeflection X of the substrates after curing and the target deflection setting value Xt; a step of finding the temperature Tc by Tc = ¨7– M x ¨;E\XVLQJWKHFRQVWDQWRISURSRUWLRQDOLW\0GHWHUPLQHGE\WKHcorrelation between the temperature difference ¨7DQG the deflection X; and a step in which at least one of the substrates before curing and the mounting table are temperature controlled according to the temperature Tc such that Tc = Th - Td.
Full Text BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a method and apparatus for processing,
substrates while controlling the deflection (amount of warping or tilt angle) that occurs in
the substrates during bonding of the individual substrates of, for example, optical disc
substrates so as to attain a desired deflection.
Priority is claimed on Japanese Patent Application No. 2003-433599, filed
December 26, 2003, the content of which is incorporated herein by reference.
Description of Related Art
An optical disc for a DVD is known wherein two individual substrates having a
recording layer, or one individual substrate having a recording layer and one individual
substrate not having a recording layer, or an individual substrate having a recording layer
and a sheet film, or one individual substrate and another individual substrate (here, these
are also referred to as "individual substrates") are bonded together by having interposed a
photo-curable adhesive layer therebetween (for example, refer to Japanese Unexamined
Patent Application, First Publication No. Hei 5-20714).
To read the data recorded on an optical disc or to record the data on an optical
disc, the optical disc is irradiated externally by a laser while the optical disc is rotated,
and the laser irradiates the recording layer by penetrating the transparent substrates of the
optical disc. Because the recording density of the optical disc is extremely high, the
laser must irradiate the recording layer with high precision. If the flatness of the optical
disc is substandard, naturally the flatness of the recording layer will also become
substandard. The laser will not be able to irradiate the recording layer in correct
alignment with a predetermined position, and errors will occur when writing and reading
the data. For this reason, when manufacturing the optical disc, generally there must not
be warping or distortion and that a high degree of flatness can be maintained.
Various inventions have been proposed as methods for decreasing such warping
during the manufacture of an optical disc. In one of these, a method is proposed in
which the heat of the substrates, whose temperature has risen due to the irradiation of the
curing light during the bonding of the individual substrates, is dissipated into the
mounting table on which the substrates is mounted. After the ambient temperature and
the temperature of the substrates have become substantially equal, the substrates are
removed from the mounting table. In this method, this mounting table is cooled by
using a cooling medium such as air or cooled water, and thereby the temperature of this
cooling medium is controlled (for example, refer Japanese Unexamined Patent
Application, First Publication No. Hei 10-199053).
Another method has been proposed wherein the mounting table on which the
substrates are mounted is cooled so as to maintain a constant temperature (for example,
refer to Japanese Unexamined Patent Application, First Publication No. 2003-99985).
In another invention that decreases the warping during the manufacturing of an
optical disc described above have been proposed. The invention includes a method has
been proposed wherein the temperature of at least one of the surfaces of the substrates is
controlled while the photo-curable adhesive layer interposed between the individual
substrates of the optical disc is being cured, and thereby the temperature of both surfaces
is controlled; a method has been proposed wherein the temperature of the substrates is
controlled, and thereby the temperature distribution in both directions of the substrates is
made uniform; and an apparatus has been proposed that provides a temperature control
device that can adjust the surface temperature of a mounting table (for example, refer to
Japanese Unexamined Patent Application, First Publication No. 2000-76710).
However, due to increasing the flatness of the optical disc because of
implementing the methods described above during manufacture of the optical disc, even
if the optical disc possesses the required flatness immediately after its manufacture,
during the subsequent storage, management, and distribution, the optical disc may warp
in a predictable manner. For example, warping may occur due to label printing after
bonding. In such a case, it is necessary to control the warping of the optical disc by
taking into account the warping of such an optical disc during the final usage, and
compensating warping must be intentionally applied to the optical disc so that almost no
warping is present during the final usage.
In consideration of the problems described above, it is an object of the present
invention to control the deflection (tilt angle) of the optical disc during manufacture so as
to attain a target deflection.
SUMMARY OF THE INVENTION
In the processing method and processing apparatus for the substrates of the
present invention, the temperature difference AT°C (= Th - Td) is found between
measured temperature Td of the substrates consisting of a plurality of superposed
individual substrates after interposing an uncured photo-curable adhesive layer
therebetween and the measured temperature Th of a mounting table on which these
substrates are mounted, and at the same time the measured deflection X (deg) of the
substrates is found, and a plurality of these (AT and X) are plotted. The result thereof is
a straight line that represents a linear function, and the slope thereof is the constant of
proportionality M (°C/deg).
Using this constant of proportionality M, when one or both of a mounting table
and the substrates are temperature controlled using the control temperature found by
calculating according to the equation (Th - Td) - Mx(DX or DX") or the equation Th -
Mx(DX or DX"), it is possible to obtain substrates having a desired warping. Xt is the
target deflection for the substrates and X is the measured deflection. In addition,
DX=Xt - X, and DX" is the compensated value obtained by compensating DX. This
compensation is carried out by taking into account the tendency of DX or the like, for
example, whether or not the direction of the increase or decrease is increasing or
decreasing according to a linear, second order, or a higher order curve.
According to the substrate processing method and processing apparatus of the
present invention, it is possible to provide a substrate consisting of bonded individual
substrates having a desired deflection (tilt angle).
Accordingly, the present invention provides a processing method for
substrates, comprising : a step in which substrates before curing are mounted on a
mounting table, said substrates having a plurality of individual substrates and an
uncured photo-curable adhesive layer interposed between these individual
substrates ; a step in which substrates after curing are obtained wherein, while said
substrates before curing are mounted on said mounting table, said individual
substrates are bonded together by photo-curing said adhesive layer by irradiating
said substrates before curing with photo-curing Jight ; and a step in which the
deflection of said substrates after curing is controlled by controlling at least one of
said substrates before curing and said mounting table ; the step in which said
deflection is controlled comprises : a step in which the temperature difference DT
between the temperature Th of said mounting table and the temperature Td of said
substrates before curing is found ; a step in which the deflection difference DX
between the deflection X of said substrates after curing and the target deflection
setting value Xt is found ; a step in which the temperature Tc is found by Tc = DT -
M x DX by using the constant of proportionality M determined by the correlation
between said temperature difference DT and said deflection X ; and a step in which
at least one of said substrates before curing and said mounting table are
temperature controlled according to said temperature Tc such that Tc = Th - Td.
The present invention also provides a processing apparatus for substrates,
comprising : a mounting table for mounting substrates before curing, said
substrates consisting of pair of individual substrates having a photo-curable
adhesive layer interposed therebetween ; an irradiating device that irradiates said
substrates before curing with a curing light while the substrates before curing are
mounted on said mounting table ; and a control device for controlling the deflection
of the substrates after curing by carrying out temperature control of at least one of
the substrates before curing and said mounting table while said individual
substrates are bonded together by photo-curing said adhesive ; said control device
comprises : a device that calculates the temperature difference DT between the
temperature Th of said mounting table and the temperature Td of said substrates
before curing ; a device that finds the deflection difference AX between the
deflection X of said substrates after curing and the target deflection setting value
Xt; a device that finds the temperature Tc by calculating Tc = DT - M x DX by using
the constant of proportionality M determined by the correlation between said
temperature difference DT and said deflection X ; and a device that carries out
temperature control of at least one of said substrates before curing and said
mounting table according to said temperature Tc such that Tc = Th - Td.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Fig. 1 is a drawing for explaining the insight on which the present invention is
based, and shows the method for finding the constant of proportionality M (°C/deg).
Fig. 2 is a drawing showing the relationship between Th - Td, and the deflection
X of the substrates, where Th is the temperature of the mounting table for the substrates
and Td is the temperature of the substrates.
Fig. 3 is a drawing for explaining the basic conception of the present invention.
Fig. 4 is a drawing showing part of the bonding line 100 of the optical disc
substrates that is an embodiment of the present invention.
Fig. 5 is a drawing showing the basic arrangement of the structure for
controlling the deflection of the substrates.
Fig. 6 is a drawing for explaining the temperature control according to an
embodiment of the present invention.
Fig. 7 is a drawing for explaining the temperature control apparatus used in an
embodiment of the present invention
Fig. 8 is a drawing showing a flowchart of the operation of an embodiment of
the present invention.
Fig. 9 is a drawing showing the relationship between the flowchart in Fig. 7 and
(deflection X of the substrates - time).
Fig. 10 is a drawing showing the bonding line 200 of the optical disc substrates
that is another embodiment of the present invention.
Fig. 11A and Fig. 11B are drawings showing an example of the mounting table
used in the present invention.
Fig. 12 is a cross-sectional drawing of the substrates showing the definition of
the deflection.
DETAILED DESCRIPTION OF THE INVENTION
First, the new insight on which the present invention is based will be explained
before explaining a first embodiment of the preferred configuration for implementing the
present invention.
As shown in Fig. 1, the inventors of the present invention (a) measured the
temperature Td of the optical disc substrates (below, referred to as the "substrates")
before being mounted on the mounting table, where the substrates consisting of a
plurality of individual substrates superposed after interposing an uncured photo-curable
adhesive layer therebetween. In addition, the inventors (b) measured the temperature
Th of the mounting table on which the substrates are mounted before irradiating a curing
light such as UV light. As shown in Fig. 1, the inventors (c) found the temperature
difference DT (°C) (=Th-Td) between the temperature Td and the temperature Th, and (d)
found the deflection X (deg) of the substrates D after curing when the temperature has
substantially fallen to room temperature after curing the photo-curable adhesive layer by
irradiating a curing light on the substrates before curing. Note that, as shown in Fig. 12,
the deflection (tilt angle) denotes the angle 0 formed by the normal that is perpendicular
to the recording surface of the substrates and the axis of the optical system.
The basic insight was attained that, for a plurality of substrates, as shown in Fig.
2, the results of (e) plotting of the deflection X (deg) and the plurality of temperature
differences AT (°C) show that the relationship between the deflection X and the
temperature difference AT fits a linear function M", which is a substantially proportional
relationship. The slope of this linear function M" serves as the constant of
proportionality M (°C/deg). Based on many experimental results, a section of the linear
function M" changes depending on the condition of the warping of the bonded individual
substrates, but the slope, that is, the constant of proportionality M, is substantially
unchanged. Therefore, it was confirmed that by using the constant of proportionality M
and the linear function M", when controlling the difference between the temperature of a
mounting table and temperature of the substrates, the deflection (tilt angle) of the
substrates can attain a desired value by using this temperature difference. In particular,
by using a constant of proportionality M within a range from 15 (°C/deg) to 40 (°C/deg),
that is, 15 (°C/deg) a desired value in a short period of time.
Embodiment 1
The basic embodiment of the processing method and processing apparatus for
the substrates according to the present invention will be explained with reference to Fig.
3 to Fig. 7. Fig. 3 is a drawing for explaining the basic conception of the present
invention. Fig. 4 is a drawing showing the optical disc bonding device 100 according to
an embodiment for explaining the control of the deflection X of the substrates, and Fig. 5
shows a schematic drawing of the mechanism that controls the deflection of the bonded
substrates which, in the present embodiment, are substrates consisting of a plurality of
individual substrates that have been bonded together. Fig. 6 is a drawing for explaining
basic arrangement of a preferable example of the temperature control apparatus that
controls the warping of the substrates, and Fig. 7 is a drawing that shows the block
structure of the temperature control apparatus that controls the deflection of the
substrates.
The basic conception of the present invention will be explained with reference to
Fig. 3. Assuming that the deflection of a substrates is XI when the measured
temperature of the mounting table is Thl and the measured temperature of the substrates
is Td1, then Thl - Td1 = DT1, and as shown in Fig. 3, the point (XI, DT1) on the linear
function M" is shown by Ml.
In order for the deflection X1 of the substrates to be made equal to a desired
target deflection Xt, as shown by the dashed line, it is sufficient that the temperature Th2
of the mounting table and the temperature Td2 of the substrates satisfy the temperature
difference DT2 = (Th2 - Td2), which corresponds to point M2 on the linear function M"
at the target deflection Xt of the substrates. At this time, the difference (DT1 - DT2)
between DT1 and DT2 becomes M (Xt - X1). Expressed as an equation, this becomes
(DT1 - DT2) = M (Xt - X1). From this equation, it can finally be deduced that (Th2 -
Td2) = (Thl - Td1) - M (Xt - X1). (Thl - Td1) denotes the temperature difference DT1,
which is obtained by subtracting the measured temperature Tdl of the substrates from the
measured temperature Th1 of the mounting table, and X1 denotes the deflection of the
substrates after curing at that time, and thus each of these are a known numerical value at
the point in time that they are measured.
Therefore, it is understood that it is sufficient that either one or both of the
temperature Th2 of the mounting table and the temperature Td2 of the substrates are
controlled so as to satisfy the principal equation (Th2 - Td2) = (Th1 - Td1) - M (Xt - X1).
When expressed by the temperature Th of the mounting table and the temperature Td of
the substrates, this function can be simplified to (Th - Td) = Tc = DT - M x (DX or DX").
Below, this function will serve as the principal function. Here, AT denotes the
temperature difference between the temperature Th of a mounting table and the
temperature Td of the substrates measured when finding the point Ml, and AX denotes
the difference between the desired target deflection Xt and the measured deflection X.
As described above, DX" is the compensated value obtained by compensating DX. This
compensation takes into account whether or not the tendency of DX, for example, the
direction of increase or decrease, increases or decreases as a linear, a second order, or a
higher order curve. In embodiment 1, only the temperature of the mounting table is
controlled.
As shown in Fig. 4, two individual substrates (not illustrated) are superposed
having a photo-curable adhesive layer interposed therebetween, and by eliminating the
excess photo-curable adhesive by a spinner apparatus 1, the superposed substrates d
having uncured adhesive interposed therebetween are obtained. While the substrates d
are being transferred to the turntable 3 from the spinner apparatus 1, the temperature Td
of the substrates is measured by a general method in which a substrate temperature
measuring device such as an infrared light temperature sensor (not illustrated) is used.
The substrates d are mounted on the mounting table 5a among the plurality of mounting
tables 5a to 5j, which are disposed in sequence at fixed intervals on the turn table 3.
The turntable 3 rotates intermittently in the direction of the arrow (clock) at a constant
speed.
The measurement of the temperature Th of each of the mounting tables when
located at the position of mounting table 5a is carried out by using a general method,
such as an infrared light temperature sensor (not illustrated), or a mounting table
temperature measuring device such as a thermocouple (not illustrated). The substrates d
are mounted on the mounting table 5a, and the individual substrate among the substrates
d that is on the side in contact with the mounting table 5a expands or contracts due to the
temperature Th of the mounting table. While the adhesive between the individual
substrates is uncured, it is possible to change the shape of the individual substrates on the
side in contact with the mounting table 5 a comparatively freely. Note that here 5 a to 5j
are considered to be the mounting tables positioned at mounting position.
At the mounting tables 5a to 5j, a cooling and heating mechanism 7 that serves
as the temperature control device of the mounting tables 5 is provided. At the mounting
positions 5h, 5i, 5j, 5a, and 5b in the temperature adjustment area 6, adjustment of the
temperature of a mounting table is carried out so as to adjust the difference between the
temperature of the mounting table and the temperature of the substrates. Next, the
temperature adjustment of a mounting table will be explained.
The uncured photo-curable adhesive layer of the substrates d is irradiated by a
curing light such as ultraviolet light from a curing light irradiating apparatus 9 and
photo-cured to make the bonded substrates D, in which the individual substrates are
completely bonded. When the temperature has fallen to room temperature, the
necessary tests are carried out on substrates D by a testing apparatus 11. One among the
tests is the measurement of the deflection X of the substrate D.
An example of the basic preferable arrangement of the temperature control
apparatus 13 will be explained with reference to Fig. 6. The temperature control
apparatus 13 calculates the target deflection Xt of the input substrates D and the
deflection X of the substrates D found by carrying out the warping tests, and finds the
deflection difference DX, which is the difference therebetween. This deflection
difference DX is compensated by the compensating device 13k. A compensating device
13k that employs a widely used PID control method is explained as a preferable example.
This PID control method outputs a compensated value DX". The DX" is a value
compensated by a device k1 that carries out proportional control action, in which an
output signal is output that is proportional to the deviation between the target value and
the measured value; a device k2 that carries out integral control action, in which an
output signal is output that is proportional to the time integral of the deviation; and a
device k3 that carries out derivative control action, in which an output signal is output
that is proportional to the rate of change of the deviation as a function of time, depending
on whether the tendency of the deflection difference DX described above is, for example,
is a linear function that is a function of time, a second order function that is a function of
time, or another function. The calculation of Tc = DT - MxDX" described above is
carried out by the calculating unit 13m of the temperature control apparatus 13, and
temperature adjustment of the cooling and heating mechanism 7 is carried out such that
the deflection X of the substrates smoothly and quickly approaches the target deflection
Xt.
Note that in the above explanation, the compensation device 13k compensated
the deflection difference AX by PID control, but other suitable control methods besides
PID control can be used.
A detailed example of the temperature control apparatus 13 will be explained
with reference to Fig. 7. The deflection X that has been input into the temperature
control apparatus 13 is input into a first deflection calculating unit 13B via a gate C1 of a
gate unit 13A, and calculated. The first deflection calculating unit 13B finds the pure
average value of the deflection X of a predetermined number of substrates D or the
average value of the deflection X within an allowable range (below, these are referred to
as the average deflection Xa).
In addition, a desired target deflection Xt is input into the deflection setting unit
13C of the temperature control apparatus 13 as a reference value, and set. This desired
target deflection Xt is determined taking into consideration that this deflection in the
finished disc is zero or lies within an allowable range. Next, in the deflection
calculation and determination unit 13D of the temperature control apparatus 13, a
calculation is carried out to find the deflection difference AX, which is the difference
between the average deflection Xa described above and the desired target deflection Xt
described above. Preferably, this deflection difference AX is compensated by the
compensation device as described above, but because compensation is not always
necessary, the compensation device has been omitted in the temperature compensation
device 13 shown in Fig- 7. However, of course during calculation of the temperature Tc,
this compensated value DX" can be used instead of the deflection difference DX.
In the proportionality constant setting unit 13E of this temperature control
apparatus 13, the constant of proportionality M found as described above is registered.
It should be possible to select the constant of proportionality M within a range of 15
(°C/deg) = M = 40 (°C/deg) or should be set to a suitable value within the range of 15
(°C/deg) = M = 40 (°C/deg), for example, the substantially intermediate values 27 or 28
(°C/deg).
When describing the constant of proportionality M, in the case of a constant of
proportionality M within the range 15 (°C/deg) = M = 40 (°C/deg), the deflection X of
the substrates D can be controlled so as to attain a target deflection Xt in a short period of
time. However, the constant of proportionality M is a constant that converts the
deflection X of the substrates D to a temperature, and when this constant of
proportionality M deviates from the optimal value by becoming smaller, the response of
the convergence to the target deflection Xt deteriorates. Contrariwise, when the
constant of proportionality becomes large, the response of the convergence to this target
deflection Xt becomes rapid, but oscillation occurs easily, and convergence takes time.
In the present embodiment, in the case that the constant of proportionality M is smaller
than 15 (°C/deg), the deflection X of the substrates D slowly approaches the target
deflection Xt by using temperature control, and thus a long time is required to reach the
target deflection Xt, making this constant of proportionality difficult to use in an actual
bonding line. In addition, in the case that the constant of proportionality M is larger
than 40 (°C/deg), the deflection X of the substrates D approaches the target deflection Xt
in a short time, but the target deflection Xt oscillates vertically off the center, a long time
is required to converge on the target deflection Xt, making this constant of
proportionality difficult to use in an actual bonding line.
At the same time, in the temperature difference calculation unit 13F of the
temperature control apparatus 13, the measured value Th of the mounting table 5a and
the measured temperature Td of the substrates d before being mounted on the mounting
table are input, the temperature difference calculating unit 13F carries out the calculation
of (Th - Td), and the signal for the temperature difference AT, which is the result of this
calculation, is output. The temperature control calculating unit 13G that finds the
temperature Tc, which changes the deflection X so as to attain the target deflection Xt,
carries out the calculation of (DT -Mx DX) by the function described above by using the
constant of proportionality M from the proportionality constant setting unit 13E, the
temperature difference DX from the deflection calculation and determination unit 13D,
and the temperature difference DT from the temperature difference calculating unit 13F,
and finds the temperature Tc, which is the difference between the temperature Th of a
mounting table and the temperature Td of the substrates d. A temperature command
directing whether to raise, lower, or maintain a temperature at a certain °C depending on
this temperature Tc is sent to the cooling and heating mechanism 7. This temperature
command directs how many °C to change the temperature command currently provided.
The cooling and heating mechanism 7 provides an electricity-temperature
conversion element (not illustrated) such as a Peltier element on the surface of each of
the mounting tables under the substrates, and the temperature adjustment can be carried
out by using the electrical signal. The temperature adjustment of a mounting table 5
shown in Fig. 5 is carried out according to the temperature control amount Tc described
above in the temperature adjustment area 6, which includes the mounting positions 5h, 5i,
5j, 5a, and 5b, as shown in Fig. 4. The reason that five mounting tables are present in
the temperature adjustment area 6 is due to taking into consideration the speed of the
temperature change of a mounting table 5 and the time required for a mounting table 5 to
transit the temperature adjustment area 6. In the case that the time-lag of the
temperature adjustment of a mounting table 5 is a minor problem, one or two mounting
tables may be present in the temperature adjustment area 6.
By adjusting the temperature of a mounting table in this manner, the control of
the temperature difference DT between the temperature Th of a mounting table 5 and the
temperature Td of the substrates d is carried out and thereby the deflection of the
substrates D is controlled. The relationship between the warping of the substrates D
and the temperature is that when the temperature of the substrates d rises, the warping of
the substrates D becomes concave, and when the temperature of the substrates d falls, the
warping of the substrates D becomes convex. That is, when the temperature of the
substrates d changes, the deflection and direction change.
The operation will be explained with reference again to Fig. 4. A temperature
adjustment area 10 is provided downstream of the curing light irradiating apparatus 9 for
making the temperature of the substrates D equal to room temperature. This
temperature adjustment area 10 is also provided in other generally used bonding
apparatuses for individual substrates, and will not be explained in detail. However, in a
cooling and heating mechanism that uses an electricity-heat conversion element or the
like, the cooling time per unit temperature requires about 2.5 more time than the heating
time, and thus the method of cooling adjusts the temperature difference DT so as to attain
a predetermined value in a short period of time such that the temperature of the substrates
D in this temperature adjustment area 10 attains room temperature or a temperature that
is somewhat lower than the control temperature of the cooling and heating mechanism 7
at that time.
The substrates D are discharged before being conveyed to the temperature
adjustment area 10 or discharged at the mounting position as shown in the figure and
naturally cooled at a cooling position (not illustrated). While the temperature has fallen
to room temperature, the substrates D are tested by the testing apparatus 11. The data
for the deflection X found by the testing apparatus 11 is sent to the temperature control
apparatus 13, as described above, and an operation such as that described above is
repeated. The term "room temperature" denotes the ambient temperature of the
substrates D, and indicates the temperature of the room when the substrates D are in the
atmosphere of a room or indicates the temperature of the atmosphere when the substrates
D are surrounded by the atmosphere in an apparatus.
According to embodiment 1, the deflection of the bonded substrates D after
adhesive curing can attain a desired value by controlling the temperature of a mounting
table 5 as described above, adjusting the difference between the temperature of a
mounting table 5 and the temperature of the substrates d, and controlling the deflection of
the superposed substrates d by this adjusted temperature difference.
Embodiment 2
A second embodiment will be explained with reference to Fig. 5 to Fig. 1 IB.
Fig. 5, Fig. 6 and Fig. 7 have been described above, and their explanation will be omitted.
Fig. 8 is a drawing showing a flowchart for explaining the control of the deflection X of
substrates. Fig. 9 is a drawing showing the relationship between the change in warping
of the substrates and time. Fig. 10 is a drawing sowing the optical disc bonding
apparatus 200 according to another embodiment of the present invention. Figs. 11A and
11B show an example of the mounting table which can be used in the optical disc
bonding apparatus shown in Figs. 4 and 10. The steps S1 to S9 described below
correspond to steps S1 to S9 in the flowchart in Fig. 8.
In activating the bonding line for the substrates, first in step S1 the target
deflection Xt, which is the warping target value for the substrates D, is input into the
temperature control apparatus 13, and set in the deflection setting unit 13C. At the
same time, the initial temperature of a mounting table 5 is set in the temperature control
unit 13H. Past values close to room temperature, for example, are used as this initial
temperature.
In step S2, the cooling and heating mechanism 7 is controlled so as to maintain
this initial temperature, and then the temperature of a mounting table 5 has stabilized at
the initial temperature, the bonding line for the substrates is activated as shown in Fig. 10.
This stand-by time is, for example, about 10 to 30 seconds. After passage of the
stand-by time, as described in embodiment 1, the substrates d superposed at the spinner
apparatus 1 are held by suction to a single transfer arm 15 that carries out a left to right
turning operation, and then they are conveyed from the spinner apparatus 1 to a mounting
table 5. In the case that it is necessary to measure the temperature Td of the substrates d,
the temperature Td of the substrates d is measured during the conveyance of the
substrates d by a substrate temperature measuring device 17 such as an infrared
temperature sensor provided on the transfer arm 15.
A mounting table 5 has the structure shown, for example, in Fig. 11A and Fig.
11B. A duct or passage 5Y zigzags through the interior of a mounting table 5, and
substantially uniformly cools or heats a mounting table 5. A temperature adjusting
medium, such as air or water, that adjusts the temperature flows through the duct 5 Y due
to a temperature adjusting unit (not illustrated) in the cooling and heating mechanism 7.
Although not illustrated, a mounting table temperature measuring device such as an
infrared sensor or thermocouple is provided on the bottom surface side of a mounting
table 5 to measure the temperature thereof.
The substrates d mounted on a mounting table 5 are conveyed up to the curing
light irradiation apparatus 9 by a conveyance mechanism 19, such as a 1-axis robot,
along with the mounting table 5. The adhesive between the individual substrates in the
pair of substrates d is cured by irradiation of a curing light such as ultraviolet light, and
the substrates d become bonded substrates D. The substrates D are returned to the
position shown in the figure along with the mounting table 5 by the conveyance
mechanism 19. At the position shown in the drawing, the substrates D are conveyed to
a static eliminating mechanism 23 by a second transfer arm 21. The static eliminating
mechanism 23 blows air having positive or negative ions onto the substrates D, the static
electricity on the substrates D is neutralized, and at the same time, cooling is carried out.
Subsequently, the substrates D are conveyed to the testing apparatus 11 by the third
transfer arm 25.
In step S3, number n of substrates D is tested by the testing apparatus 11, and in
sequence, the results are input into the first deflection calculation unit 13B after passing
through the gate Cl of the gate unit 13A shown in Fig. 7. Temperature control is
carried out at the initial temperature described above until the deflection X of the n
substrates D has been measured. When the initial temperature is set in the temperature
control unit 13H, a signal (not illustrated) is sent to the deflection calculation and
determination unit 13D, this deflection calculation and determination unit 13D receives
this signal, and closes the gate Cl of the gate unit 13A. At this time, the gate C2 is
opened. That is, gates C1 and C2 operate at opposite phases.
In step S4, the first deflection calculation unit 13B finds the average deflection
Xa of the deflection X of the n substrates D sent through the gate C1. This average
deflection Xa is the average value of the deflection X within a predetermined allowable
range, and a deflection X that falls outside this range is ignored.
In step S5, the average deflection Xa of the deflection X of the n substrates D is
sent to the deflection calculation and determination unit 13D, and the deflection
calculation and determination unit 13D determines whether or not the average deflection
Xa falls within the target range of the target deflection Xt ±a. a is selected from among
values equal to or less than 0.1°, and preferably equal to or less then 0.05°.
In step S6, if the average deflection Xa does not fall within the target range of
the target deflection Xt ±a, then the deflection calculation and determination unit 13D
sends the deflection difference DX, which is the difference between the average
deflection Xa and the target deflection Xt, to the temperature control amount calculation
unit 13G, and the temperature control amount calculation unit 13G carries out the
calculation according to the function described above (DT - M x DX or the compensated
value DX" thereof) from the deflection difference DX (or the compensated value DX"
thereof), the constant of proportionality M (°C/deg) set by the proportionality constant
setting device 13E, the measured temperature Th of the input mounting table, and the
measured temperature Td of the substrates d, calculates the temperature Tc, and sends a
signal corresponding to the temperature Tc to the temperature control unit 13H.
The temperature Tc indicates the current temperature control amount, in this
case, how much the initial temperature described above is changed. The temperature
control unit 13H controls the cooling and heating mechanism 7 using a command
temperature that combines the initial temperature that has been set and the temperature
Tc. When the temperature Tc is positive, the set initial temperature is increased, and
when the temperature Tc is negative, the set initial temperature is decreased.
In step S7, a mounting table 5 is controlled so as to attain this command
temperature until the temperature of the mounting table 5 stabilizes at this command
temperature, without changing the control. When stabilized at the command
temperature, the control operation described above is again carried out.
If the newly found average deflection Xa does not fall within the target range of
the target deflection Xt ±a, the temperature control calculating unit 13G again carries out
the calculation according to the equation described above (DT - M x DX or the
compensated value DX" thereof) from the deflection difference DX, which is the
difference between the newly found average deflection Xa and the target deflection Xt,
the constant of proportionality M set by the proportionality constant setting unit 13E, the
measured temperature Th of the input mounting table 5, and the measured temperature
Td of the substrates d, calculates the temperature Tc, and controls the cooling and heating
mechanism 7 using the new command temperature, which is a combination of the
command temperature described above and the temperature Tc. This control is
maintained, and when the mounting table stabilizes at this new command temperature,
control operation is again carried out as described above, and a new average deflection
Xa is calculated again.
In step S8, if the newly calculated average deflection Xa falls within a target
range (Xt - a = Xa = Xt + a) of the target deflection Xt ±a, the deflection calculation and
determination unit 13D does not output a signal to the temperature control amount
calculating unit 13G. Therefore, because the temperature control amount calculation
unit 13G does not send the temperature Tc to the temperature control unit 13H, the
temperature control amount calculation unit 13G maintains the new command
temperature, and as long as the new average deflection Xa falls within the target range of
the target deflection Xt ±a, the cooling and heating mechanism 7 is controlled using the
new command temperature.
In step S9, in addition, when Xt - a = Xa = Xt + a, the deflection calculation
and determination unit 13D switches from gate Cl in the gate unit 13A to gate C2, closes
gate C2, and the second deflection calculation unit 131 finds the moving average value
Xa by calculating the deflection X of the n substrates sent through gate C2. Here, the
moving average value denotes the average value Xa of the deflection X, which is in a
predetermined allowable range, among the deflections of the most recent n substrates
after curing.
While the average value Xa of this deflection X is Xt - a = Xa = Xt + a, the
command temperature is not changed, and the previous command temperature is
maintained.
However, when the calculation and determination unit 13D determines that the
most recent moving average deflection Xa does not fall within the target range of the
target deflection Xt ±a, the processing returns to the operation of steps S6 ? S7 ? S3 in
the flowchart shown in Fig. 8, and then the operations of steps S4, S5 and after are
carried out.
In this manner, the temperature control of a mounting table 5 is carried out, and
the difference between the temperature Th of a mounting table 5 and the temperature Td
of the substrates d, that is, the temperature control amount Tc, is found, the temperature
of only a mounting table 5 is controlled, and the temperature difference Tc between a
mounting table 5 and the substrates d is made equal to Tc. Thereby, the deflection of
the superposed substrates d is controlled, and it is possible to make the deflection of the
bonded substrates D after curing of the adhesive equal to a desired value.
Fig. 9 shows the state in which the deflection X of the substrates d falls within
the target range of the target deflection Xt ±a as a function of time, and approaches the
set value Xt. S1 to S9 in the figure correspond to steps S1 to S9 in the flowchart shown
in Fig. 8. Steps S3 and S7 in the figure shows the stand-by time, and the arrows at step
S6 show that the deflection (tilt angle) X has largely changed in the direction of the target
deflection Xt.
Embodiment 3
In an actual bonding line for individual substrates, the individual substrates are
conveyed to the bonding environment, the bonding requires a predetermined amount of
time or greater, and the temperature of the bonding environment is maintained
substantially constant (for example, 25°C). Thus, frequently the temperature of the
substrates d that are superposed with the adhesive interposed therebetween can be
considered to be constant.
Therefore, in this case, in the principal equation (Th2 - Td2) = (Th1 - Td1) - M
(Xt - X1), the temperature of the substrates d is considered to be Td2 = Td1, and thus the
equation can be rewritten as Th2 = Thl - M (Xt - XI) = Thl - M • DX. From this
equation, simply by subtracting M • AX from the temperature Thl of a mounting table
when finding the constant of proportionality M, it is possible to find the temperature Th2
of a mounting table. In addition, by using a compensated value AX", which is the
deflection difference AX that has been compensated as described above, it is possible to
find the temperature Th2 of a mounting table simply by subtracting M • DX" from the
temperature Th1 of a mounting table.
As described above, the present inventors confirmed that a constant of
proportionality M is preferably a numerical value within a range from 15 (°C/deg) to 40
(°C/deg), and if a constant of proportionality M having a numerical value within this
range is used, then the temperature Th1 of the mounting table is known when finding the
constant of proportionality M. Thus, in the actual bonding line, both the temperature
measurement of a mounting table and a temperature measurement of the substrates
becomes unnecessary, and simply by measuring the deflection X of the substrates D and
carrying out the calculation according to the above equation, the temperature of a
mounting table can be controlled so as to attain any temperature.
In this embodiment, for example, the cooling capacity of the cooling and heating
mechanism 7 is 2 sec/°C, the constant of proportionality M is 28.5°C/deg, and the
measured value X of the substrates D is 0.2 deg smaller than the setting value Xt. In
this case, from the equation Th2 = Th1 - M (Xt - X1), Th2 = Th1 - 5.7°C. Therefore, it
is understood that Th2 should be about 6°C lower than the temperature Thl found when
calculating the constant of proportionality M. For example, if Thl is 26°C, then Th2
should be about 20°C. Because the cooling capacity of the cooling and heating
mechanism 7 shown in Fig. 4 and Fig. 10 is 2 sec/°C, the time at this point is about 12
seconds, the temperature of a mounting table will be substantially stabilized after the
passage of about 12 seconds, and thus the bonding line can be operated. In this case,
the stand-by time is approximately 12 seconds.
In addition, conventionally, when curing the adhesive in the curing light
irradiation system, there has been the problem that the temperature of a mounting table
increases due to the curing heat generated while the adhesive layer is being cured.
However, in the case that the embodiment 3 is realized by the apparatus shown in Fig. 10,
Fig. 11 A, and Fig. 11B, temperature control of a mounting table is carried out even
during the irradiation by the curing light. Thus, there are the effects that it is possible to
limit increases in the temperature of a mounting table, make the temperature fluctuation
of a mounting table small, and at the same time, make temperature increases in the
substrates small.
In the above explanation, the case that the temperature of the substrates d was
considered to be Td2 = Td1, but there are also cases in which the temperature Th of the
mounting table can also be considered to be Th2 = Th1. In this case, in the principal
equation described above, (Th2 - Td2) = (Th1 - Td1) - M (Xt - X1), the temperature of a
mounting table can be considered to be Th2 = Thl, and thus this equation can be
rewritten as Td2 = Tdl + M (Xt - X1) = Td1 + M • DX. From this equation, simply by
adding M • DX to the temperature Tdl of the substrates when finding the constant of
proportionality M, the temperature Td2 of the substrates can be found. In addition,
when the compensated value DX", which is the compensated deflection difference DX as
described above, simply by adding M • DX" to the temperature Tdl of the substrates, it is
possible to find a more preferable temperature Td2 for the substrates.
Embodiment 4
In the embodiment described above, a configuration was described in which the
constant of proportionality M was appropriately selected from constants of
proportionality in a range from 15 (°C/deg) to 40 (°C/deg), that is 15 (°C/deg) = M = 40
(°C/deg). However, as described in Embodiment 1 and Embodiment 2, there cases in
which, in an actual production line (not illustrated), the temperature sensor that measures
the temperature Th of a mounting table and a temperature sensor that measures the
temperature Td of the substrates are provided and the measured temperature data thereof
is obtained. Thus, a calculating device that calculates the constant of proportionality M
is provided in the processing apparatus of the substrates, and a constant of proportionality
M suitable for the processing conditions at this time can be found.
In this embodiment, the temperature difference AT between the temperature Td
of the substrates and the temperature of Th of a mounting table is found, and at the same
time, the deflection X of the substrates D after irradiation by curing light is measured.
The constant of proportionality M is found from the slope of the straight line found from
a combination (X, DT) of at least two points of the temperature difference AT and the
deflection X, a combination (X, DT) of each of the substrates is added as available, and
the constant of proportionality M is updated. For example, if the straight line (a straight
line identical to the straight line represented by the linear function M" described above)
as described above is found from twenty combinations (X, DT) of the temperature
difference DT and the deflection X and the constant of proportionality M is found from
the slope of this line, when the twenty-fifth temperature difference DT and deflection X
are found, the constant of proportionality M is found from the twenty points of the sixth
through twenty-fifth temperature difference DT and deflection X. When the
twenty-sixth temperature difference DT and deflection X are found, the constant of
proportionality M is found from the twenty points between the seventh and the
twenty-sixth temperature difference DT and deflection T.
In this manner, while finding the constant of proportionality M by taking into
account the combinations (X, DT) of the temperature difference DT and the deflection X
for each of the substrates, the temperature Tc is found by carrying out the calculation of
(DT - M x DX or the compensated value DX" thereof) by using the found constant of
proportionality M, as explained in embodiments 1 and 2 or embodiment 3. Thus, one or
both of the temperature Th of a mounting table and the temperature Td of the substrates
can be controlled such that Tc = Th - Td.
According to the present invention, the appropriate control temperature is found
while finding sequentially the constant of proportionality M by the measured temperature
data for each of the mounting tables and each of the substrates and the measured
deflection data for each of the substrates. Thus, depending on the conditions at the time,
it is possible to automatically select a suitable constant of proportionality M from a range
of 15 (°C/deg) = M = 40 (°C/deg).
Embodiment 5
In embodiment 4, the constant of proportionality M (°C/deg) is updated for each
of the mounting tables and each of the substrates, but in this embodiment, the measured
temperature of a predetermined number (for example, 10) substrates is extracted each
time the number of the processed substrates reaches a predetermined number, for
example, 500 or 1000, and thereby the average temperature Td1 thereof is found.
Similarly, the measured temperature of the substrates for the next predetermined number
(for example, 10) is extracted, and the average temperature Td2 thereof is found. At the
same time, the measured temperature of a mounting table on which the predetermined
number of substrates has been mounted is extracted, and the average temperature Th1
thereof is found. Similarly, the measured temperature of the mounting tables on which
the next predetermined number of substrates has been mounted is extracted, and the
average temperature Th2 thereof is found.
In addition, for the deflection of the substrates, the deflection data for a
predetermined number of substrates after curing, which are the object for extraction of
the measured temperature, is extracted, the pure average thereof or the average of the
deflections within an allowable range is found, and the result serves as the deflection X
of the substrates. As described above, the deflection difference AX that expresses the
difference between the deflection X and the target deflection Xt, is found. Or, as
described above, the compensated value DX", which is the compensated value of the
deflection difference DX, is found.
As explained in embodiment 4, the constant of proportionality M at the time can
be found from the principal equation described above. In this embodiment, the constant
of proportionality M is found for each of the predetermined number of substrates, and
until the constant of proportionality M for the next predetermined number is found, this
found constant of proportionality M is used in order to carry out and temperature control
of either or both of each of the mounting tables or each of the substrates. Thus, like
embodiment 4, it is possible to select automatically the constant of proportionality
suitable for the various conditions at the time from a range of 15 (°C/deg) = M = 40
(°C/deg).
In embodiment 4 and embodiment 5, like embodiment 3, the temperature of the
substrates is substantially room temperature, and if the room temperature is constant, the
temperature of the substrates is also constant. Thus, it is possible to measure only the
temperature of the mounting table to carry out control the temperature of a mounting
table according to temperature Tc. There is not need to measure the temperature of the
substrates. Thereby, the control can be simplified.
Embodiment 6
In the above embodiments, control is carried out by using the constant of
proportionality M (°C/deg), finding the temperature Tc, which controls the warping of
the substrates D according to Tc = DT - M x (DX or DX"), so as to approach and match
the target deflection Xt, and finding the moderating temperature difference for the
temperature difference between the present temperature of the a mounting table and the
temperature of the substrates. However, control can be carried out by finding the
temperature difference using the linear function M" shown in Fig. 2 and Fig. 3.
In this case, as is clear from Fig. 2 and Fig. 3, the linear function M" has a
slope of M when Th - Td is DT, and thus can be expressed by the equation DT = MX + a.
The constant value a is the value of DT (ordinate) when the deflection X (abscissa) of the
substrates is zero, and is determined by the combination of the warping of two bonded
individual substrates, such as the deflection X of individual substrates to be bonded and
the direction of warping or the like.
By inputting beforehand the linear function M" (DT = MX + a) into a personal
computer, microcontroller, or the like, or by inputting a plurality of linear functions
having predetermined constant values al, a2, a3, ..., an that correspond to a variety of
conditions, it is possible to select either depending on the conditions. By inputting the
target setting value Xt into this linear function, it is possible to control one or both of a
mounting table or the substrates so that the sought temperature difference DT between a
mounting table and the substrates can be found automatically and the temperature
difference between the mounting table and the substrates becomes DT.
In this embodiment, it is always possible to carry out control by using an
optimal linear function M" even if the deflection of the substrates fluctuates due to the
occurrence of variation in the deflection of individual substrates caused by variation in
moulding and sputter technologies, fluctuations in the ambient temperature or the like.
For example, when control is carried out using DT1=MxXt + a1,...(1) based on the
linear function M" in order to make the deflection of the substrates equal to a target
deflection Xt and the deflection X is controlled so as to attain the target deflection Xt and
be constant, in the case that the deflection X deviates from the set range due to some
cause (the segment a changes but the slope of the linear function M" does not), the
following operation is carried out by a deflection determining device (not illustrated)
outputting a signal.
First, the current deflection X of the measured substrates is substituted into the
linear function M", and the temperature difference DT2 {= M x X + a2,..., (2)} between the
present temperature of a mounting table and the temperature of the substrates is calculated.
Because the difference between the temperature of a mounting table and the temperature of the
substrates is controlled so as to be constant, DT1 = AT2, and from equation (1) and equation (2),
a2 = M (Xt - X) + al is obtained. Therefore, by carrying out control by updating the segment al
of equation (1) to a2, it is possible to adjust the deflection X.
In the embodiment described above, only the temperature of a mounting table is
controlled, but by controlling only the temperature of the substrate or controlling the
temperatures of both the mounting table and the substrates, it is possible to realize the
present invention, and it is possible to make the deflection of the substrates equal to the
warping value equal to the target deflection Xt. Of course, the deflection can be made
equal to zero.
In addition, the embodiment described above was explained in which the
substrate was an substrate, but the present invention can be similarly implemented for
other substrates that are bonded having an adhesive interposed therebetween, such as a
glass sheet, a synthetic resin sheet, or the like.
The effect of the present invention according to each of the aspects is as follows:
1. According to the invention in aspect 1, it is possible to obtain automatically a
substrate consisting of bonded individual substrates having a desired deflection (tilt
angle).
2. According to the invention in aspect 2,it is possible to obtain automatically a
substrate consisting of bonded individual substrates having a desired deflection (tilt
angle) more smoothly and in a shorter period of time by using a compensated value DX"
for the deflection X of the substrates.
3. According to the invention in aspect 3, it is possible to obtain simply and
automatically a substrate consisting of bonded individual substrates presenting a desired
deflection (tilt angle) without measuring the temperature of the substrates.
4. According to the invention in aspect 4, it is possible to obtain automatically a
substrate consisting of bonded individual substrates presenting a desired deflection (tilt
angle) more smoothly and in a shorter period of time without measuring the temperature
of the substrates by using a compensated value DX" for the deflection X of the substrates
and making the temperature of the substrates substantially constant.
5. According to the invention in aspect 5, it is possible to obtain simply and
automatically a substrate consisting of bonded individual substrates presenting a desired
deflection (tilt angle) by making the temperature of a mounting table substantially
constant without measuring the temperature of a mounting table.
6. According to the invention in aspect 6, it is possible to obtain automatically a
substrate consisting of bonded individual substrates presenting a desired deflection (tilt
angle) more smoothly and in a shorter period of time by using a compensated value DX"
for the deflection X of the substrates and making the temperature of the substrates
substantially constant.
7. According to the invention in aspect 7, it is possible to obtain simply and
automatically a substrate consisting of bonded individual substrates presenting a desired
deflection (tilt angle) in an actual bonding step by finding a constant of proportionality M
(°C/deg), which is the basic insight of the present invention.
8. According to the invention in aspect 8, it is possible to obtain simply and
automatically a substrate consisting of bonded individual substrates presenting a desired
deflection (tilt angle) while obtaining a constant of proportionality M that suits the
conditions during bonding, without finding a constant of proportionality M (°C/deg),
which is the basic insight of the present invention.
9. According to the invention in aspect 9, it is possible to specify a preferable range for
the constant of proportionality M and select and use the constant of proportionality M.
10. According to the invention in aspect 10, a more preferable warping adjustment of
the substrates becomes possible because it is possible to compensate the deflection X of
the substrates by using PID control.
11. According to the invention in aspect 11, it is possible do decrease the influence of
variation in the warping and carry out stable temperature control because the average
deflection of n substrates after curing is found, the temperature is calculated using the
average deflection, and temperature control of a mounting table is carried out by using
this temperature Tc.
12. According to the invention in aspect 12, it is possible to decrease further the
influence of variation in the warping and carry out stable temperature control because the
amount of the noise is decreased.
13. According to the invention in aspect 13, it is possible to maintain the temperature of
a mounting table within a set range easily.
14. According to the invention in aspect 14, it is possible to carry out temperature
control of a mounting table stably by using the averages of new deflection data.
15. According to the invention in aspect 15, it is possible to return to a set range in a
short time period without hunting in the case that the average deflection Xa of the
substrates falls outside the set range.
16. According to the invention in aspect 16, it is possible to find the temperature
difference DT between a mounting table and the substrates simply by substituting the
target deflection Xt into a predetermined linear function and carry out temperature
control simply.
17. According to the invention in aspect 17, it is possible to present a processing
apparatus for substrates that can automatically obtain bonded substrates having a desired
deflection (tilt angle).
18. According to the invention in aspect 18, it is possible to present an automatic
processing apparatus for substrates that can obtain in a shorter period of time and more
smoothly bonded substrates having a desired deflection (tilt angle).
19. According to the invention in aspect 19, it is possible to obtain simply and
automatically a substrate consisting of bonded individual substrates that present a desired
deflection (tilt angle) without measuring the temperature of the substrates.
20. According to the invention in aspect 20, it is possible to obtain automatically a
substrate consisting of individual bonded substrates presenting a desired deflection (tilt
angle) without measuring the temperature of the substrates by using the compensated
value DX" of the deflection X of the substrates and making the temperature of the
substrates substantially constant.
21. According to the invention in aspect 21, it is possible to obtain simply and
automatically substrates consisting of bonded individual substrates presenting a desired
deflection (tilt angle) by making the temperature of a mounting table constant, without
measuring the temperature of the mounting table.
22. According to the invention in aspect 22, it is possible to obtain simply and
automatically substrates consisting of bonded individual substrates presenting a desired
deflection (tilt angle) by using the compensated value DX" of the deflection X of the
substrates and making the temperature of the mounting table substantially constant.
23. According to the invention in aspect 23, it is possible to obtain simply and
automatically a substrate consisting of bonded individual substrates having a desired
deflection (tilt angle) in an actual bonding step by finding a constant of proportionality M
(°C/deg), which is the basic insight of the present invention.
24. According to the invention in aspect 24, it is possible to obtain automatically a
substrate consisting of bonded individual substrates having a desired deflection (tilt
angle) while obtaining a constant of proportionality M suitable to the conditions during
bonding without finding a constant of proportionality M (°C/deg), which is the basic
insight of the present invention.
25. According to the invention in aspect 25, it is possible to specify a preferable range
for the constant of proportionality M, select and use this constant of proportionality M,
and thereby simplify the apparatus.
26. According to the invention in aspect 26, it is possible to present an apparatus in
which a more preferable warping adjustment of the substrates is possible because the
deflection X of the substrates can be compensated by using PID control.
27. According to the invention in aspect 27, it is possible do decrease the influence of
variation in the warping and carry out stable temperature control because the average
deflection of n substrates after curing is found, the temperature is calculated using the
average deflection, and temperature control of a mounting table is carried out by using
this temperature Tc.
28. According to the invention in aspect 28, it is possible to decrease further the
influence of variation in the warping and carry out stable temperature control.
29. According to the invention in aspect 29, it is possible to maintain the temperature of
a mounting table within a set range easily.
30. According to the invention in aspect 30, it is possible to carry out temperature
control of a mounting table stably by using the newest average of the deflection data.
31. According to the invention in aspect 31, it is possible to return to a set range in a
short time period without hunting in the case that the average deflection Xa of the
substrates falls outside the set range.
32. According to the invention in aspect 32, it is possible to find the temperature
difference DT between a mounting table and the substrates simply by substituting the
target deflection Xt into a predetermined linear function and carry out temperature
control simply.
While preferred embodiments of the invention have been described and
illustrated above, it should be understood that these are exemplary of the invention and
are not to be considered as limiting. Additions, omissions, substitutions, and other
modifications can be made without departing from the spirit or scope of the present
invention. Accordingly, the invention is not to be considered as being limited by the
foregoing description, and is only limited by the scope of the appended claims.
WE CLAIM :
1. A processing method for substrates, comprising:
a step in which substrates before curing are mounted on a mounting table,
said substrates having a plurality of individual substrates and an uncured photo-
curable adhesive layer interposed between these individual substrates;
a step in which substrates after curing are obtained wherein, while said
substrates before curing are mounted on said mounting table, said individual
substrates are bonded together by photo-curing said adhesive layer by irradiating
said substrates before curing with photo-curing light; and
a step in which the deflection of said substrates after curing is controlled by
controlling at least one of said substrates before curing and said mounting table;
the step in which said deflection is controlled comprises:
a step in which the temperature difference AT between the temperature Th
of said mounting table and the temperature Td of said substrates before curing is
found;
a step in which the deflection difference AX between the deflection X of said
substrates after curing and the target deflection setting value Xt is found;
a step in which the temperature Tc is found by Tc = AT - M x DX by using
the constant of proportionality M determined by the correlation between said
temperature difference DT and said deflection X; and
a step in which at least one of said substrates before curing and said
mounting table are temperature controlled according to said temperature Tc such
that Tc = Th - Td.
2. A processing method for substrates as claimed in claim 1, involving a step in
which the compensated value DX", which is said deflection difference DX that has
been compensated according to conditions that have the tendency of said
deflection difference DX, is found, and where this compensated value DX1 serves as
the value of said deflection difference DX, said temperature Tc is found.
3. A processing method for substrates, comprising :
a step in which substrates before curing are mounted on a mounting table,
said substrates having a plurality of individual substrates and an uncured photo-
curable adhesive layer interposed between these individual substrates ;
a step in which substrates after curing are obtained wherein, while said
substrates before curing are mounted on said mounting table, said individual ¦
substrates are bonded together by photo-curing said adhesive layer by irradiating
said substrates before curing with photo-curing light; and
a step in which the deflection of said substrates after curing is controlled by
controlling at least one of said substrates before curing and said mounting table ;
the step in which said deflection is controlled comprises :
a step in which the temperature Th of said mounting table is found ;
a step in which the deflection difference DX between the target deflection
setting value Xt and said deflection X is found ;
a step in which the temperature Tc is found by carrying out calculation of Tc
= Th - M x DX by using the constant of proportionality M determined by the
correlation between said the temperature Th of said mounting table and said
deflection X ; and
a step in which the temperature control of said mounting table is carried out
according to said temperature Tc.
4. A processing method for substrates as claimed in claim 3, comprising a step
in which the compensated value DX", which is said deflection difference DX that has
been compensated according to conditions that have the tendency of said
deflection difference DX, is found, and where this compensated value DX" serves as
the value of said deflection difference DX, said temperature Tc is found.
5. A processing method for substrates comprising :
a step in which substrates before curing are mounted on a mounting table,
said substrates having a plurality of individual substrates and an uncured photo-
curable adhesive layer interposed between these individual substrates ;
a step in which substrates after curing are obtained wherein, while said
substrates before curing are mounted on said mounting table, said individual
substrates are bonded together by photo-curing said adhesive layer by irradiating
said substrates before curing with photo-curing light; and
a step in which the deflection of said substrates after curing is controlled by
controlling at least one of said substrates before curing and said mounting table ;
a step in which said deflection is controlled comprises ;
a step in which the temperature Td of said substrates before curing is
found ;
a step in which the target deflection Xt and said deflection X are calculated,
and the deflection difference DX is found ;
a step in which temperature Tc is found by carrying out the calculation of Tc
= Td + M x DX by using the constant of proportionality M determined by the
correlation between the temperature Td of said substrates before curing and said
deflection X; and
a step in which temperature control of the temperature of said substrates
before curing is carried out according to temperature Tc.
6. A processing method for substrates as claimed in claim 5, comprising a step
in which the compensated value DX", which is said deflection difference DX that has
been compensated according to conditions that have the tendency of said
deflection difference DX, is found, and where this compensated value DX" serves as
the value of said deflection difference DX, said temperature Tc is found.
7. A processing method for substrates as claimed in any of claims 1, 3 or 5,
wherein :
said constant proportionality M (°C/deg) is a constant of proportionality
expressing the slope of a straight line found from a plurality of combinations (X, DT)
of the temperature difference DT between the temperature Th of said mounting
table and the temperature Td of said substrates before curing and the deflection X
of the substrates after curing by irradiation of a curing light, and is found in
advance.
8. A processing method for substrates as claimed in any of claims 1, 3 and 5,
wherein :
said constant of proportionality M (°C/deg) is a constant of proportionality
expressing the slope of a straight line found from a plurality of combinations (X, DT)
of the temperature difference DT between the temperature Th of said mounting
table and the temperature Td of said substrates before curing and the deflection X
of the substrates after curing by irradiation of a curing light, and the warping of said
substrates is adjusted while finding said constant of proportionality M by updating
said combination (x, DT) as necessary.
9. A processing method for substrates as claimed in any of claims 1, 3 and 5,
wherein said constant of proportionality M is 15 to 40 (°C/deg).
10. A processing method for substrates as claimed in any of claims 2, 4, and 6,
wherein said deflection difference DX is compensated by carrying out PID control.
11. A processing method for substrates as claimed in any of claims 1, 3, and 5,
wherein said deflection X is an average deflection Xa that expresses the average
value of a predetermined number n of said substrates after curing.
12. A processing method of substrates as claimed in claim 11, wherein said
average deflection Xa of said substrates after curing is a value obtained by
averaging deflections within a predetermined allowable range among the
deflections X of a predetermined number n of substrates after curing.
13. A processing method for substrates as claimed in claim 11, wherein said
temperature of said rnounting table and said substrates before curing is maintained
without change while the average deflection Xa of said substrates after curing is
within a predetermined deflection range (Xt ± an arbitrary numerical value a).
14. A processing method for substrates as claimed in claim 11, wherein a
moving average value (average value of the n most recent substrates) of the
predetermined number n of said substrates after curing is found while the average
deflection Xa of said substrates after curing is within a predetermined deflection
range (Xt ± an arbitrary numerical value a).
15. A processing method for substrates as claimed in claim 11, wherein, when
the average deflection Xa of said substrates after curing is outside a predetermined
deflection range ( Xt ± an arbitrary numerical value a), said temperature of said
mounting table and said substrates before curing is calculated and temperature
control of said mounting table and said substrates before curing is carried out at
this calculated temperature, and the measurement of the deflection of the
predetermined number n substrates after curing is newly carried out, and until this
measurement is completed, temperature control of said mounting table and said
substrates before curing is carried out using said calculated temperature.
16. A processing method for substrates, comprising :
a step in which substrates before curing are mounted on a mounting table,
said substrates having a plurality of individual substrates and an uncured photo-
curable adhesive layer interposed between these individual substrates ;
a step in which substrates after curing are obtained wherein, while said
substrates before curing are mounted on said mounting table, said individual
substrates are bonded together by photo-curing said adhesive layer by irradiating
said substrates before curing with photo-curing light; and
a step in which the deflection of said substrates after curing is controlled by
controlling at least one of said substrates before curing and said mounting table ;
said step in which said deflection is controlled comprises :
a step in which the relationship (Th - Td = M x X + a) is found, where the
constant of proportionality determined by the correlation of at least two
combinations of the temperature difference DT between the temperature Th of said
mounting table and the temperature Td of said substrates before curing and said
deflection X is denoted M, the temperature difference DT between the temperature
Th of said mounting table and the temperature Td of said substrates before curing
when the deflection X of said substrates after curing is zero is denoted a ; and
a step in which the temperature control of at least one of said substrates
after curing and said mounting table is carried out such that (Th - Td = M x Xt + a),
where the deflection setting value is denoted Xt.
17. A processing apparatus for substrates, comprising :
a mounting table (5) for mounting substrates before curing, said substrates
consisting of pair of individualsubstrates having a photo-curable adhesive layer
ihterposed therebetween;
an irradiating device (9) that irradiates said substrates before curing with a
curing light while the substrates before curing are mounted on said mounting table ;
and
a control device (13) for controlling the deflection of the substrates after
curing by carrying out temperature control of at least one of the substrates before
curing and said mounting table while said individual substrates are bonded together
by photo-curing said adhesive ;
said control device comprises :
a device (13F) that calculates the temperature difference DT between the
temperature Th of said mounting table and the temperature Td of said substrates
before curing ;
a device (13D) that finds the deflection difference DX between the deflection
X of said substrates after curing and the target deflection setting value Xt;
a device (13G) that finds the temperature Tc by calculating Tc = DT - M x
AX by using the constant of proportionality M determined by the correlation
between said temperature difference DT and said deflection X ; and
a device (13H) that carries out temperature control of at least one of said
substrates before curing and said mounting table according to said temperature Tc
such that Tc = Th-Td.
18. A processing apparatus for substrates as claimed in claim 17, comprising a
compensating device (13K) that finds the compensated value DX", which is said
deflection difference DX that has been compensated according to conditions that
have the tendency of said deflection difference DX, and where this compensated
value DX" serves as the value of said deflection difference DX, finds said
temperature Tc.
19. A processing apparatus for substrates, comprising :
a mounting table for mounting substrates before curing, said substrates
consisting of a paid of individual substrates having a photo-curable adhesive layer-
interposed therebetween ;
an irradiating device that irradiates said substrates before curing with a
curing light while the substrates before curing are mounted on said mounting table;
and
a control device for controlling the deflection of the substrates after curing by
carrying out temperature control of at least one of the substrates before curing and
said mounting table while said individual substrates are bonded together by photo-
curing said adhesive ;
said control device comprises :
a device that finds temperature Th of said mounting table ;
a device that finds the deflection difference AX by calculating the target
deflection setting value Xt and said deflection X ;
a device that finds that temperature Tc by calculating Tc = Th - M x DX by
using the constant of proportionality M determined by the correlation between at
least two combinations of the temperature Th of said mounting table and said
deflection X; and
a device that carries out temperature control of said mounting table
according to said temperature Tc.
20. A processing apparatus for substrates as claimed in claim 19, comprising a
device that finds the compensated value DX", which is said deflection difference DX
that has been compensated according to conditions that have the tendency of said
deflection difference DX, and finds said temperature Tc using the compensated
value DX" as the value of said deflection difference DX.
21. A processing apparatus for substrates, comprising :
a mounting table for mounting substrates before curing, said substrates
consisting of a pair of individual substrates having a photo-curable adhesive layer
interposed therebetween ;
an irradiating device that irradiates said substrates before curing with a
curing light while the substrates before curing are mounted on said mounting table ;
and
a control device for controlling the deflection of the substrates after curing by
carrying out temperature control of at least one of the substrates before curing and
said mounting table when said individual substrates are bonded together by photo-
curing said adhesive ;
said control device comprises :
a device that finds temperature Td of said substrates before curing ;
a device that finds the deflection difference DX by calculating the target
deflection setting value Xt and said deflection X ;
a device that finds the temperature Tc by calculating Tc = Td + M x DX by
using the constant of proportionality M determined by the correlation between at
least two combinations of the temperature Td of said substrates before curing and
said deflection X ; and
a device that carries out temperature control of said substrates before curing
according to said temperature Tc.
22. A processing apparatus for substrates as claimed in claim 21, comprising :
a compensating device that finds the compensated value DX", which is said
deflection difference DX that has been compensated according to conditions that
have the tendency of said deflection difference DX, and finds said temperature Tc
by using the compensated value DX" as the value of said deflection difference DX.
23. A processing apparatus for substrates as claimed in any of claims 19, 19
and 21, wherein :
said constant of proportionality M (°C/deg) is a constant of proportionality
expressing the slope of a straight line found from the temperature difference DT
between the temperature Th of said mounting table and the temperature Td of said
substrates before curing, and the deflection X after curing by irradiation of a curing
light, and is found in advance.
24. A processing apparatus for substrates as claimed in any of claims 17, 19
and 21, wherein said constant of proportionality M (°C/deg) is a constant of
proportionality expressing the slope of a straight line found from a plurality of
combinations (X,DAT) of the temperature difference AT between the temperature Th
of said mounting table and the temperature Td of said substrates before curing and
the deflection X of the substrates after curing by irradiation of a curing light, and the
warping of said substrates is adjusted while finding said constant of proportionality
M by updating said combination (X, DT) as necessary.
25. A processing apparatus for substrates as claimed in any of claims 17, 19
and 21, wherein same constant of proportionality M is 15 to 40(°C/deg).
26. A processing apparatus for substrates as claimed in any of claims 18, 20
and 22, wherein said deflection difference AX is compensated by carrying out PID
control.
27. A processing apparatus for substrates as claimed in any of claims 17, 19
and 21, wherein said deflection X is the average deflection Xa expressing the
average number of a predetermined number n of said substrates after curing.
28. A processing apparatus for substrates as claimed in claim 27, wherein said
average deflection Xa of said substrates after curing is a value obtained by
averaging deflections within a predetermined allowable range among the
deflections X of a predetermined number n of substrates after curing.
29. A processing apparatus for substrates as claimed in claim 27, wherein said
temperature of said mounting table and said substrates before curing is maintained
without change while the average deflection Xa of said substrates after curing is
within a predetermined deflection range (Xt ± an arbitrary numerical value a).
30. A processing method for substrates as claimed in claim 27, wherein a
moving average value (average value of the n most recent substrates) of the
deflection X of the predetermined number n of said substrates after curing is found
while the average deflection Xa of said substrates after curing is within a
predetermined deflection range (Xt ± an arbitrary numerical value a).
31. A processing method for substrates as claimed in claim 27, wherein, when
the average deflection Xa of said substrates after curing is outside a predetermined
deflection range (Xt ± an arbitrary numerical value a), said temperature of said
mounting table and said substrates before curing is calculated and temperature
control of said mounting table and said substrates before curing is carried out at
this calculated temperature, the measurement of the deflection of the
predetermined number n substrates after curing is newly carried out, and until this
measurement is completed, temperature control of said mounting table and said
substrates before curing is carried out using said calculated temperature.
32. A processing apparatus for substrates, comprising :
a mounting table for mounting substrates before curing, said substrates consisting
of a pair of individual substrates having a photo-curable adhesive layer interposed
therebetween ;
an irradiating device that irradiates said substrates before curing with a curing light
while the substrates before curing are mounted on said mounting table and
a control device for controlling the deflection of the substrates after curing by
carrying out temperature control of at least one of the substrates before curing and said
mounting table while said individual substrates are bonded together by photo-curing said
adhesive ;
said control device comprises :
a device that finds the relationship (Th - Td = M x X + a), where the constant of
proportionality determined by the correlation of at least two combinations of the
temperature difference DT between the temperature Th of said mounting table and the
temperature Td of said substrates before curing and said deflection X is denoted M, the
temperature difference DT between the temperature Th of said mounting table and the
temperature Td of said substrates before curing when the deflection X of said substrates
after curing is zero is denoted a ; and
a device that carries out the temperature control of at least one of said substrates
after curing and said mounting table such that (Th - Td = M x Xt + a), where the
deflection setting value is denoted Xt.
33. A process method for substrates, substantially as herein described, particularly
with reference to the accompanying drawings.
34. A processing apparatus for substrates, substantially as herein described,
particularly with reference to the accompanying drawings.
In a processing method, a substrate consisting of a plurality of individual
substrates and a photo-curable adhesive layer interposed therebetween is irradiated by a
curing light, and the deflection of the substrate is controlled by controlling the
temperature while the individual substrates are bonded together by photo-curing the
adhesive layer. The step for controlling the deflection includes a step of finding the
temperature difference DT between the temperature Th of a mounting table and the
temperature Td of the substrates before curing; a step of finding defection difference DX
between the deflection X of the substrates after curing and the target deflection setting
value Xt; a step of finding the temperature Tc by Tc = DT - M x DX by using the constant
of proportionality M determined by the correlation between the temperature difference
DT and the deflection X; and a step in which at least one of the substrates before curing
and the mounting table are temperature controlled according to the temperature Tc such
that Tc = Th - Td.

Documents:

427-KOL-2004-CORRESPONDENCE.pdf

427-KOL-2004-FORM 27.pdf

427-KOL-2004-FORM-27.pdf

427-kol-2004-granted-abstract.pdf

427-kol-2004-granted-assignment.pdf

427-kol-2004-granted-claims.pdf

427-kol-2004-granted-correspondence.pdf

427-kol-2004-granted-description (complete).pdf

427-kol-2004-granted-drawings.pdf

427-kol-2004-granted-form 1.pdf

427-kol-2004-granted-form 18.pdf

427-kol-2004-granted-form 2.pdf

427-kol-2004-granted-form 3.pdf

427-kol-2004-granted-form 5.pdf

427-kol-2004-granted-letter patent.pdf

427-kol-2004-granted-pa.pdf

427-kol-2004-granted-priority document.pdf

427-kol-2004-granted-reply to examination report.pdf

427-kol-2004-granted-specification.pdf

427-kol-2004-granted-translated copy of priority document.pdf


Patent Number 219072
Indian Patent Application Number 427/KOL/2004
PG Journal Number 17/2008
Publication Date 25-Apr-2008
Grant Date 23-Apr-2008
Date of Filing 20-Jul-2004
Name of Patentee ORIGIN ELECTRIC COMPANY LIMITED.
Applicant Address 18-1, TAKADA 1-CHOME, TOSHIMA-KU, TOKYO
Inventors:
# Inventor's Name Inventor's Address
1 SUZUKI TAKAYUKI C/O. ORIGIN ELECTRIC COMPANY, LIMITED, 18-1, TAKADA 1-CHOME, TOSHIMA-KU, TOKYO
2 NAKAMURA MASAHIRO C/O. ORIGIN ELECTRIC COMPANY, LIMITED, 18-1, TAKADA 1-CHOME, TOSHIMA-KU, TOKYO
3 WAKAHIRA TSUYOSHI C/O. ORIGIN ELECTRIC COMPANY LIMITED, 18-1, TAKADA 1-CHOME, TOSHIMA-KU, TOKYO
4 KOBAYASHI HIDEO C/O. ORIGIN ELECTRIC COMPANY LIMITED, 18-1, TAKADA 1-CHOME, TOSHIMA-KU, TOKYO
PCT International Classification Number G03C 1/16
PCT International Application Number N/A
PCT International Filing date
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 2003-433599 2003-12-26 Japan