Abstract:
A supporting module is used to support a substrate in an alignment apparatus for aligning the substrate. The supporting module includes one or more supporting bodies, each supporting body having a hole on an upper portion of the supporting body. A supporting ball is partially inserted into the hole such that an exposed portion of the supporting ball makes contact with the substrate supported by the supporting module. As the substrate is laterally translated, static friction between the substrate and the supporting ball causes the supporting ball to rotate. An auxiliary ball is also provided in the supporting body to make contact with the supporting ball. The auxiliary ball rotates using a friction between the supporting ball and the auxiliary ball. This arrangement prevents scratching, cracking or other damage that would be caused to the substrate by dynamic friction between the substrate and a non-rotatable supporting module.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     The present application claims priority from Korean Patent Application No. 2004-14031, filed on Mar. 2, 2004, the disclosure of which is hereby incorporated herein by reference in its entirety.  
       BACKGROUND  
       [0002]     1. Field of the Invention  
         [0003]     The present invention relates to a supporting module for supporting a substrate and an alignment apparatus for aligning the substrate. More particularly, the present invention relates to a supporting module for supporting a substrate for a liquid crystal display (LCD) apparatus and an alignment apparatus for aligning a substrate, which has the supporting module.  
         [0004]     2. Description of the Related Art  
         [0005]     An LCD apparatus, in general, is manufactured by performing a plurality of manufacturing processes on a substrate. The manufacturing processes of the LCD apparatus are typically automated to increase the efficiency of the manufacturing process. In a predetermined unit process, the substrate may be unloaded using an unloading unit so that the unloaded substrate is in a cassette, and the substrate in the cassette is transported to another apparatus for another unit process.  
         [0006]     When the unloaded substrate is in the cassette, the substrate is aligned using an alignment apparatus for aligning the substrate. In addition, prior to the transportation of the substrate in the cassette, the substrate is also aligned using the alignment apparatus for aligning the substrate.  
         [0007]     The alignment apparatus for aligning the substrate includes a supporting module that contacts and supports the substrate for the LCD apparatus, and an aligning module that aligns the substrate for the LCD apparatus. When the substrate for the LCD apparatus is aligned, the aligning module moves the substrate relative to the supporting module. As the substrate is moved by the aligning module, the dynamic friction between the supporting module and the substrate for the LCD apparatus may result in scratching or cracking of the surface of the substrate for the LCD apparatus. Therefore, the substrate for the LCD apparatus may be damaged.  
       SUMMARY  
       [0008]     In accordance with the present invention, a supporting module for supporting a substrate for a liquid crystal display (LCD) apparatus is provided.  
         [0009]     In accordance with the present invention, an alignment apparatus for aligning a substrate and having the above-mentioned supporting module is also provided.  
         [0010]     A supporting module in accordance with an exemplary embodiment of the present invention includes a supporting body, a supporting ball and an auxiliary ball. The supporting module supports the substrate. The supporting body has a hole on an upper portion of the supporting body. The supporting ball is partially inserted into the hole such that the supporting ball is partially exposed through the hole. During operation, the exposed portion of the supporting ball makes contact with the substrate. The friction between the substrate and the supporting ball causes the supporting ball to rotate as the substrate is moved relative to the supporting module. The rotation of the supporting ball helps to prevent damage to the substrate caused by static friction between the two moving parts. The auxiliary ball is rotatably contained in the supporting body such that the auxiliary ball makes contact with the supporting ball. As the supporting ball rotates due to the movement of the substrate, the auxiliary ball also rotates as a result of the friction between the supporting ball and the auxiliary ball.  
         [0011]     An alignment apparatus for aligning a substrate in accordance with an exemplary embodiment of the present invention includes a supporting module and an aligning module. The supporting module comprises a supporting body, a supporting ball and an auxiliary ball. The supporting body supports the substrate, as described above. The aligning module aligns the loaded substrate, which is supported by the supporting module.  
         [0012]     Therefore, when the substrate is transported, the supporting ball that makes contact with the substrate rotates in a direction substantially parallel with a direction of translation of the substrate so that the friction between the supporting module and the substrate is decreased, thereby preventing damage of the substrate. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]     The above and other advantages of the present invention will become more apparent by describing in detail exemplary embodiments thereof with reference to the accompanying drawings, in which:  
         [0014]      FIG. 1  is a cross-sectional view showing an apparatus for manufacturing an LCD apparatus in accordance with an exemplary embodiment of the present invention;  
         [0015]      FIG. 2  is a perspective view showing an alignment apparatus for aligning a substrate in a loader or an unloader of  FIG. 1 ;  
         [0016]      FIG. 3  is a cross-sectional view showing a supporting module of  FIG. 2 ; and  
         [0017]      FIGS. 4A and 4B  are cross-sectional views showing a method of aligning the substrate using the alignment apparatus of  FIG. 2 .  
     
    
     DETAILED DESCRIPTION  
       [0018]     It should be understood that the exemplary embodiments of the present invention described below may be varied and modified in many different ways without departing from the inventive principles disclosed herein, and the scope of the present invention is therefore not limited to these particular embodiments. Rather, these embodiments are provided so that this disclosure will be through and complete, and will fully convey the invention to those skilled in the art by way of example and not of limitation.  
         [0019]     Hereinafter, embodiments present invention will be described in detail with reference to the accompanying drawings.  
         [0020]      FIG. 1  is a cross-sectional view showing an apparatus for manufacturing an LCD apparatus in accordance with an exemplary embodiment of the present invention.  
         [0021]     Referring to  FIG. 1 , the apparatus for manufacturing the LCD apparatus includes a plurality of in-line devices IE 1 , IE 2 , . . . for performing a plurality of manufacturing processes, respectively. For example, a substrate  10  for the LCD apparatus is processed in a first in-line device IE 1 , and the substrate  10  for the LCD apparatus is then transported to a second in-line device IE 2  that is adjacent to the first in-line device IE 1 . The substrate  10  for the LCD apparatus is then transported from the second in-line device IE 2  to a third in-line device (not shown) adjacent to the second in-line device IE 2 . The above-mentioned processes may be repeated using the in-line devices.  
         [0022]     The first in-line device IE 1  includes a first processing part TP 1 , a first loading part LP 1  and a first unloading part ULP 1 . The first processing part TP 1  performs a predetermined unit process on the substrate  10  for the LCD apparatus. The first loading part LP 1  loads the substrate  10  for the LCD apparatus onto the first processing part TP 1 . The first unloading part ULP 1  unloads the substrate  10  for the LCD apparatus from the first processing part TP 1 . The first processing part TP 1  has a plurality of processing chambers C 1 , C 2 , . . . , Cn- 1 , Cn. In this exemplary embodiment, the number of the processing chambers C 1 , C 2 , . . . , Cn- 1 , Cn in the first processing part is ‘n’, wherein ‘n’ is a whole number.  
         [0023]     The substrate  10  for the LCD apparatus, which is processed in the first in-line device IE 1 , is aligned before being transported to the second in-line device IE 2  by the first unloading part ULP 1  or after being transported to a second loading part UP 2  of the second in-line device. That is, the first unloading part ULP 1  or the second loading part UP 2  includes an alignment apparatus  100  shown in  FIG. 2  for aligning the substrate  10  for the LCD apparatus.  
         [0024]      FIG. 2  is a perspective view showing an alignment apparatus for aligning a substrate in a loader or an unloader of  FIG. 1 .  FIG. 3  is a cross-sectional view showing a supporting module in the alignment apparatus of  FIG. 2 .  
         [0025]     Referring to  FIGS. 2 and 3 , the alignment apparatus  100  for aligning the substrate  10  for the LCD apparatus includes a first supporting module  111 , a second supporting module  112 , a third supporting module  113 , a fourth supporting module  114 , an elevator  120 , a first aligning module  130  and a second aligning module  140 . The first to fourth supporting modules  111 ,  112 ,  113  and  114  support the substrate  10  for the LCD apparatus. The elevator  120  controls a vertical movement of the first to fourth supporting modules  111 ,  112 ,  113  and  114 . The first and second aligning modules  130  and  140  align the substrate  10  for the LCD apparatus.  
         [0026]     The first to fourth supporting modules  111 ,  112 ,  113  and  114  include a first supporting ball  111   b , a second supporting ball  112   b , a third supporting ball  113   b  and a fourth supporting ball  114   b , respectively. The first to fourth supporting balls  111   b ,  112   b ,  113   b  and  114   b  make contact with a lower surface of the substrate  10  for the LCD apparatus. The first to fourth supporting balls  111   b ,  112   b ,  113   b  and  114   b  may rotate. In this exemplary embodiment, the first to fourth supporting balls  111   b ,  112   b ,  113   b  and  114   b  rotate in a direction substantially parallel with a transportation direction of the substrate  10  for the LCD apparatus. Each of the first to fourth supporting balls  11   b ,  112   b ,  113   b  and  114   b  may comprise a ceramic, a synthetic resin, etc.  
         [0027]     Therefore, the friction between the substrate  10  for the LCD apparatus and each of the first to fourth supporting balls  111   b ,  112   b ,  113   b  and  114   b  is decreased to prevent scratching, cracking or other damage to the substrate  10 .  
         [0028]     Referring to  FIG. 3 , the first supporting module  111  includes a first supporting body  111   a , a first supporting ball  111   b  and a first auxiliary ball  111   c . The first to fourth supporting modules  111 ,  112 ,  113  and  114  have substantially similar shapes to one another, and any further explanation of the second to forth supporting modules  112 ,  113  and  114  will be omitted.  
         [0029]     An upper portion of the first supporting body  111   a  is positioned adjacent to the substrate  10  for the LCD substrate. A hole  111   e  is formed at the upper portion of the first supporting body  111   a . An engaging recess  111   d  is formed at a lower portion of the first supporting body  111   a  so that the first supporting body  111   a  is coupled with a first connecting rod  125   a . In this exemplary embodiment, the first supporting body  111   a  comprises a threaded bore that receives a threaded first connecting rod  125   a  mounted to the plate  125 . Thus, a height of the first supporting body  111   a  relative to the plate  125  may be controlled using an axial rotation of the first connecting rod  125   a.    
         [0030]     The first supporting ball  111   b  is inserted into the hole  111   e , and the first supporting ball  111   b  is partially exposed through the hole  111   e  so that the exposed portion of the first supporting ball  111   b  makes contact with the substrate  10  for the LCD apparatus. When the substrate  10  for the LCD apparatus is translated relative to the first supporting module  111 , the friction between the bottom surface of the substrate  10  and the first supporting ball  111   b  causes the first supporting ball  111   b  to rotate. This rotation reduces or eliminates the amount of dynamic friction between the substrate  10  and the first supporting module  111 , thereby preventing damage to the substrate  10  for the LCD apparatus. The first auxiliary ball  111   c  is in the first supporting body  111   a , and makes contact with the first supporting ball  111   b . The first auxiliary ball  111   c  rotates using a friction between the first supporting ball  111   b  and the first auxiliary ball  111   c  so that the first supporting ball  111   b  may easily rotate. The first auxiliary ball  111   c  reduces the rotational resistance of the first supporting ball  111   b . In this exemplary embodiment, two pieces having recesses are combined each other to form the supporting body  111   a , and the first auxiliary ball  111   c  is inserted into the recesses of the pieces before the pieces are combined. Alternatively, the first auxiliary ball  111   c  may inserted into a recess of the supporting body  111   a , and the recess may be partially covered so that the auxiliary ball  111   c  is in the supporting body  111   a.    
         [0031]     Referring again to  FIG. 2 , the elevator  120  is connected to a plate  125  to control vertical movement of the plate  125 . The first to fourth supporting modules  111 ,  112 ,  113  and  114  are coupled to the plate  125  through the first connecting rod  125   a , a second connecting rod  125   b , a third connecting rod  125   c  and a fourth connecting rod  125   d , respectively. The elevator  120  controls the vertical movement of the plate  125  with respect to the substrate  10  for the LCD apparatus to control vertical movements of the first to fourth supporting modules  111 ,  112 ,  113  and  114 .  
         [0032]     When the substrate  10  for the LCD apparatus is loaded on the alignment apparatus  100  for aligning the substrate  10 , the elevator  120  elevates the plate  125  so that the first to forth supporting modules  111 ,  112 ,  113  and  114  are elevated. When the substrate  10  for the LCD apparatus is unloaded from the alignment apparatus  100  for aligning the substrate, the elevator  120  lowers the plate  125  so that the first to fourth supporting modules  111 ,  112 ,  113  and  114  are lowered.  
         [0033]     The first and second aligning modules  130  and  140  are positioned adjacent to a first end portion  10   a  and a second end portion  10   b  of the substrate  10  for the LCD apparatus, which is supported by the first to fourth supporting modules  111 ,  112 ,  113  and  114 . In this exemplary embodiment, the second end portion  10   b  is opposite to the first end portion  10   a.    
         [0034]     The first aligning module  130  includes a first alignment plate  132  and a first control member  131 . The first alignment plate  132  is adjacent to the first end portion  10   a  of the substrate  10  for the LCD apparatus. The first control member  131  controls horizontal movement of the first alignment plate  132 . The second aligning module  140  includes a second alignment plate  142  and a second control member  141 . The second alignment plate  142  is adjacent to the second end portion  10   b  of the substrate  10  for the LCD apparatus. The second control member  141  controls horizontal movement of the second alignment plate  142 .  
         [0035]     When the substrate  10  for the LCD apparatus is supported by the first to fourth supporting modules  111 ,  112 ,  113  and  114 , the first and second aligning modules  130  and  140  align the substrate  10  by using the first and second control members  131  and  141  to move the first and second alignment plates  132  and  142  toward the substrate  10  for the LCD apparatus. The first and second alignment plates  132  and  142  then make contact with the first and second end portions  10   a  and  10   b  of the substrate  10  for the LCD apparatus, respectively, so that the substrate  10  for the LCD apparatus is aligned with respect to the alignment apparatus  100  for aligning the substrate  10  for the LCD apparatus.  
         [0036]      FIGS. 4A and 4B  are cross-sectional views showing a method of aligning the substrate using the alignment apparatus for aligning the substrate of  FIG. 2 .  FIGS. 4A and 4B  are cross-sectional views taken along a line I-I′ of  FIG. 2 .  
         [0037]     Referring to  FIG. 4A , the substrate  10  for the LCD apparatus is supported by the first, second, third and fourth supporting modules  111 - 114  (only the first and second supporting modules  111  and  112  are shown in  FIG. 4A ), and the substrate  10  is misaligned with respect to a first aligning line AL 1  and a second aligning line AL 2  that is spaced apart from the first aligning line AL 1  by a horizontal width of the substrate  10  for the LCD apparatus. The first and second aligning lines AL 1  and AL 2  represent the desired horizontal position of the substrate  10 . The misaligned substrate  10  for the LCD apparatus is aligned using the first and second aligning modules  130  and  140 .  
         [0038]     Referring to  FIG. 4B , the first control member  131  translates the first alignment plate  132  toward the substrate  10  for the LCD apparatus in a first direction D 1  so that the first alignment plate  132  is aligned with the first aligning line AL 1 . In addition, the second control member  141  translates the second alignment plate  142  toward the substrate  10  for the LCD apparatus in a second direction D 2  so that the second alignment plate  142  is aligned with the second aligning line AL 2 .  
         [0039]     As the second control member  141  translates the second alignment plate  142  in the second direction D 2  towards the second aligning line AL 2 , the second alignment plate  142  makes contact with the second end portion  10   b  of the substrate  10  for the LCD apparatus. Therefore, the second alignment plate  142  transports the substrate  10  for the LCD apparatus in the second direction D 2  so that the first and second end portions  10   a  and  10   b  are aligned with the first and second aligning lines AL 1  and AL 2 , respectively. The substrate  10  for the LCD apparatus is thus aligned with respect to the first aligning line AL 1  and the second aligning line AL 2 .  
         [0040]     As the substrate  10  is moved by the first and second aligning modules  130  and  140 , the first supporting ball  111   b  of the first supporting module  111  and the second supporting ball  112   b  of the second supporting module  112  rotate in substantially equal directions to each other. Therefore, the friction between the substrate  10  for the LCD apparatus and each of the first and second supporting modules  111  and  112  is decreased to prevent scratching or cracking of the substrate  10  for the LCD apparatus.  
         [0041]     In accordance with embodiments of the present invention, when the substrate is transported, the supporting ball that makes contact with the substrate rotates using the friction between the substrate and the supporting ball. In addition, the auxiliary ball that makes contact with the supporting ball rotates with the supporting ball so that the supporting ball may easily rotate.  
         [0042]     Therefore, the supporting ball rotates in a direction substantially parallel with the transportation direction to decrease a friction between the supporting module and the substrate, thereby preventing scratching or cracking of the substrate.  
         [0043]     This invention has been described with reference to the exemplary embodiments. It is evident, however, that many alternative modifications and variations will be apparent to those having skill in the art in light of the foregoing description. Accordingly, the present invention embraces all such alternative modifications and variations as fall within the spirit and scope of the appended claims.