Substrate transfer apparatus, method of transferring substrate, and method of manufacturing electro-optical device

A substrate transfer apparatus transfers substrates stored in a first substrate storage case, which has support grooves in its inner wall, along the support grooves to substrate storage surfaces included in a second substrate storage case. The substrate transfer apparatus includes a first-substrate-storage-case placement section in which the first substrate storage case is placed, a second-substrate-storage-case placement section in which the second substrate storage case is placed, a substrate transfer mechanism that holds the substrates stored in the first substrate storage case so as to draw out the substrates from the first substrate storage case, and transfers the substrates to a substrate placement section of a substrate placing mechanism, a substrate holding mechanism that holds the substrates placed in the substrate placement section at hold positions, and discharges the substrates at discharge positions so as to dispose the substrates on the substrate storage surfaces of the second substrate storage case, and a transport mechanism that transports the substrate holding mechanism from the hold positions to the discharge positions.

BACKGROUND

1. Technical Field

The present invention relates to a substrate transfer apparatus which transfers substrates between substrate storage cases, to a method of transferring a substrate, and to a method of manufacturing an electro-optical device using the method of transferring a substrate.

2. Related Art

In general, a liquid crystal display device is manufactured such that a plurality of liquid crystal display devices are formed on a pair of glass substrates to cut out a single liquid crystal display device (hereinafter, referred to as a single product) from the glass substrates. The glass substrate, which is used in such a manufacturing method, has sides each having a length of several hundreds of millimeters or more.

On the other hand, the liquid crystal display device may be manufactured by bonding a plurality of counter glass substrates, each of which has a diagonal size of about two inches or less corresponding to the single product, to a large glass substrate in advance, and cutting out a single liquid crystal display device. This manufacturing method is performed in order to avoid a risk of miscombination at the time of bonding the counter glass substrates or to control a gap between the glass substrates with high precision. In this case, a method of manufacturing a liquid crystal display device has a process of transporting the counter glass substrates each having a size corresponding to the single product. As an example of such a process, a process of drawing out the counter glass substrates stored upright in a substrate storage case one by one and transferring the counter glass substrates to a different palette-shaped substrate storage case side by side can be exemplified.

However, an apparatus for transferring a small counter glass substrate, which can be applied to the above-described process, had not been suggested yet. At present, the counter glass substrates are transferred by human hands. There is a possibility for problems to occur when transferred by human hands, such as the substrate may be damaged, a transfer position may be misaligned, yield is lowered due to an error in a storage direction of the substrate or the like, the number of workers needed is increased, or it takes too much time for a worker to become proficient.

SUMMARY

According to a first aspect of the invention, a substrate transfer apparatus for transferring a substrate stored in a first substrate storage case, which has support grooves in its inner wall, along the support grooves to substrate storage surfaces included in a second substrate storage case includes a first-substrate-storage-case placement section in which the first substrate storage case is placed, a second-substrate-storage-case placement section in which the second substrate storage case is placed, a substrate transfer mechanism that holds the substrates stored in the first substrate storage case so as to draw out the substrates from the first substrate storage case, and transfers the substrates to a substrate placement section of a substrate placing mechanism, a substrate holding mechanism that holds the substrates placed in the substrate placement section at hold positions, and discharges the substrates at discharge positions so as to dispose the substrates onto the substrate storage surfaces of the second substrate storage case, and a transport mechanism that transports the substrate holding mechanism from the hold positions to the discharge positions.

In such a substrate transfer apparatus, after the substrate transfer mechanism transfers the substrates from the first substrate storage case to the substrate placement section, the substrate holding mechanism holds the substrates. Subsequently, in this state, the transport mechanism transports the substrate holding mechanism to the discharge positions. Finally, the substrate holding mechanism stores the substrates in the second substrate storage case. As such, as one of the effects to be obtained from this configuration, the substrates including glass substrates each having a diagonal size of two-inches or less can be transferred to the second substrate storage case from the first substrate storage case, without human hands.

In the substrate transfer apparatus according to the first aspect, the substrate placing mechanism may have a moving mechanism that moves the substrate placement section to a plurality of positions including a first position and a second position, and the substrates placed in the substrate placement section disposed at the first position may be substantially parallel to the substrates stored in the first substrate storage case on the first-substrate-storage-case placement section. According to this configuration, the substrates drawn out from the first substrate storage case by the substrate transfer mechanism are substantially parallel to the substrate placement section disposed at the first position. Accordingly, it is not necessary to adjust the angles of the substrates at the time of transferring the substrates, and thus transferring of the substrates can be easily performed. Further, according to the above-described configuration, the substrates are stored in the first substrate storage case in a state of being inclined with respect to a vertical plane. Accordingly, the substrates lean against the support grooves by self-weight to have stable postures. Further, if the support grooves are arranged at constant intervals, the substrates are disposed at constant intervals. For this reason, the substrate transfer mechanism can easily hold the substrates.

In the substrate transfer apparatus according to the first aspect of the invention, the substrates placed in the substrate placement section disposed at the second position may be substantially parallel to the substrate storage surfaces included in the second substrate storage case, and the substrate holding mechanism may hold, at the hold positions, the substrates placed in the substrate placement section disposed at the second position. According to this configuration, the substrate holding mechanism can hold the substrates with good balance and can store the substrates on the substrate storage surfaces included in the second substrate storage case by parallel moving the substrates.

In the substrate transfer apparatus according to the first aspect of the invention, preferably, the moving mechanism has a rotating mechanism that rotates a part including the substrate placement section around a substantially horizontal axis. By using the rotating mechanism, the moving mechanism can easily move the substrate placement section between the first position where the placed substrates are inclined from horizontal states and the second position where the placed substrates are substantially in the horizontal states.

In the substrate transfer apparatus according to the first aspect of the invention, the substrate holding mechanism may have an absorbing mechanism that absorbs and holds the substrates. According to this configuration, the substrate holding mechanism can absorb one plane of each substrate, such that the substrate can be held in a state in which an end surface of the substrate is free. The free state indicates that the end surface of the substrate does not come into contact with any foreign substances. If all end surfaces of the substrate are free, even when the second substrate storage case has partition walls guiding the end surfaces of the substrate, the substrate holding mechanism can easily discharge the substrate to the second substrate storage case.

In the substrate transfer apparatus according to the first aspect of the invention, the substrate holding mechanism may have a rotating unit that rotates the absorbing mechanism around a substantial vertical axis. Such a substrate holding mechanism can rotate the substrates around the vertical axis in a state in which the substrates are absorbed by the absorbing mechanism. Accordingly, the substrate transfer apparatus can transfer the substrates along the partition walls of the substrate storage surfaces.

The substrate transfer apparatus according to the first aspect of the invention may further include a first detecting mechanism that detects the direction of the substrate placed in the substrate placement section. In the substrate transfer apparatus having this configuration, when the first detecting mechanism detects that the direction of the substrate placed in the substrate placement section is rotated by 180 degrees from a predetermined state in the same plane, for example, the direction of the substrate can be corrected to the predetermined state by causing the substrate holding mechanism to rotate the absorbing mechanism, which holds the substrate, by 180 degrees, and then the substrate can be transferred. Further, in the substrate transfer apparatus, when the first detecting mechanism detects that the substrate placed in the substrate placement section is turned over from the predetermined state, for example, by stopping the apparatus, the substrate can be prevented from being transferred in a state of being turned over.

The substrate transfer apparatus according to the first aspect of the invention may further include a second detecting mechanism that detects damages of the substrates placed in the substrate placement section. In the substrate transfer apparatus having this configuration, when the second detecting mechanism detects that the substrate is damaged, for example, by stopping the apparatus, the damaged substrate can be prevented from being transferred.

The substrate transfer apparatus according to the first aspect of the invention may further include a third detecting mechanism that detects positions of end surfaces of the substrates held by the substrate holding mechanism, a fourth detecting mechanism that detects positions of partition walls of the substrate storage surfaces provided in the second substrate storage case, and a processing unit that calculates the discharge positions from the positions of the end surfaces detected by the third detecting mechanism and the positions of the partition walls detected by the fourth detecting mechanism, and transmits information of the discharge positions to the transport mechanism. In the substrate transfer apparatus having this configuration, by calculating the discharge positions of the substrates from the positions of the end surfaces of the substrates held by the substrate holding mechanism and the positions of the partition walls of the second substrate storage case in advance, the substrates can be stored on the substrate storage surfaces with high precision.

According to a second aspect of the invention, a substrate transfer apparatus for transferring substrates stored on substrate storage surfaces included in a second substrate storage case to a first substrate storage case, which has support grooves in its inner wall, includes a second-substrate-storage-case placement section in which the second substrate storage case is placed, a first-substrate-storage-case placement section in which the first substrate storage case is placed, a substrate holding mechanism that holds the substrates placed on the substrate storage surfaces of the second substrate storage case at hold positions, and discharges the substrates at discharge positions so as to dispose the substrates in a substrate placement section of a substrate placing mechanism, a transport mechanism that transports the substrate holding mechanism from the hold positions to the discharge positions, and a substrate transfer mechanism that holds the substrates placed in the substrate placement section, and transfers the substrates to the first substrate storage case. As one of the effects obtained from this configuration, the substrates can be transferred in a direction opposite to the above-described direction. Specifically, the substrates can be transferred from the substrate storage surfaces included in the second substrate storage case to the first substrate storage case.

According to a third aspect of the invention, there is provided a method of transferring a substrate stored in a first substrate storage case, which has support grooves in its inner wall, along the support grooves to substrate storage surfaces included in a second substrate storage case. The method of transferring a substrate includes causing a substrate transfer mechanism to hold the substrates stored in the first substrate storage case on a first-substrate-storage-case placement section so as to draw out the substrates from the first substrate storage case, and to transfer the substrates to a substrate placement section of a substrate placing mechanism, causing a substrate holding mechanism to hold the substrates placed in the substrate placement section at hold positions, causing a transport mechanism to transport the substrate holding mechanism from the hold positions to discharge positions, and causing the substrate holding mechanism to discharge the substrates at the discharge positions and to dispose the substrates onto the substrate storage surfaces of the second substrate storage case placed in a second-substrate-storage-case placement section.

As one of the effects obtained from the above-described method, the substrates including glass substrates each having a diagonal size of two inches or less can be transferred from the first substrate storage case to the second substrate storage case, without human hands.

The method for transferring a substrate according to the third aspect of the invention may further include, prior to the causing the substrate transfer mechanism to hold and transfer the substrates, causing a moving mechanism included in the substrate placing mechanism to move the substrate placement section to the first position. In this case, the substrates placed in the substrate placement section disposed at the first position may be substantially parallel to the substrates stored in the first substrate storage case on the first-substrate-storage-case placement section. According to this method, the substrates drawn out from the first substrate storage case by the substrate transfer mechanism are substantially parallel to the substrate placement section disposed at the first position. Accordingly, it is not necessary to adjust the angles of the substrates at the time of transferring the substrates, such that transferring of the substrates can be easily performed. Further, according to the above-described method, the substrates are stored in the first substrate storage case in a state of being inclined with respect to the vertical plane. Accordingly, the substrates lean against the support grooves by self-weight to have stable postures. Further, if the support grooves are arranged at constant intervals, the substrates are disposed at constant intervals. For this reason, the substrate transfer mechanism can easily hold the substrates.

The method of transferring a substrate according to the third aspect of the invention may further include, after the causing the substrate transfer mechanism to hold and transfer the substrates, causing a moving mechanism included in the substrate placing mechanism to move the substrate placement section to the second position. Further, the causing the substrate holding mechanism to hold the substrates may have causing the substrate holding mechanism to hold, at the hold positions, the substrates placed in the substrate placement section disposed at the second position. In this case, the substrates placed in the substrate placement section disposed at the second position may be substantially parallel to the substrate storage surfaces included in the second substrate storage case. According to this method, the substrate holding mechanism can hold the substrates with good balance and can store the substrates on the substrate storage surfaces included in the second substrate storage case by parallel moving the substrates.

In the method of transferring a substrate according to the third aspect of the invention, it is preferable that, in the causing the moving mechanism to move the substrate placement section to the first position or in the causing the moving mechanism to move the substrate placement section to the second position, the moving mechanism having a rotating mechanism for rotating a part including the substrate placement section around a substantial horizontal axis move the substrate placement section. Due to the rotating mechanism, the moving mechanism can easily move the substrate placement section between the first position where the placed substrates are inclined from the horizontal states and the second position where the placed substrates are substantially in the horizontal states.

In the method of transferring a substrate according to the third aspect of the invention, the causing the substrate holding mechanism to hold the substrates may have causing the substrate holding mechanism to absorb and hold the substrates. According to this method, the substrate holding mechanism can absorb and hold one plane of each substrate, such that the substrate can be held in a state in which an end surface of the substrate is free. If all end surfaces of the substrate are free, even when the second substrate storage case has partition walls guiding the end surfaces of the substrate, the substrate holding mechanism can easily discharge the substrate to the second substrate storage case.

The method of transferring a substrate according to the third aspect of the invention may further include, after the causing the substrate transfer mechanism to hold and transfer the substrates, causing a first detecting mechanism to detect the directions of the substrates placed in the substrate placement section. According to this method of transferring a substrate, when the first detecting mechanism detects that the direction of the substrate placed in the substrate placement section is rotated by 180 degrees from a predetermined state in the same plane, for example, the direction of the substrate can be corrected to the predetermined state by causing the substrate holding mechanism to rotate the absorbing mechanism, which holds the substrate, by 180 degrees, and then the substrate can be transferred. In addition, according to this method of transferring a substrate, when the first detecting mechanism detects that the substrate placed in the substrate placement section is turned over from the predetermined state, for example, by stopping the apparatus, the substrate can be prevented from being transferred in a state of being turned over.

The method of transferring a substrate according to the third aspect of the invention may further include, after the causing the substrate transfer mechanism to hold and transfer the substrates, causing a second detecting mechanism to detect damages of the substrates placed in the substrate placement section. According to this method of transferring a substrate, when the second detecting mechanism detects that the substrate is damaged, for example, by stopping the apparatus, the damaged substrate can be prevented from being transferred.

The method of transferring a substrate according to the third aspect of the invention may further include, after the causing the substrate holding mechanism to hold the substrates, causing a third detecting mechanism to detect positions of end surfaces of the substrates held by the substrate holding mechanism, after the causing the third detecting mechanism to detect the positions of the end surfaces of the substrates, causing a fourth detecting mechanism to detect positions of partition walls of the substrate storage surfaces provided in the second substrate storage case, and, after the causing the fourth detecting mechanism to detect the positions of the partition walls of the substrate storage surfaces, causing a processing unit to calculate the discharge positions from the positions of the end surfaces detected by the third detecting mechanism and the positions of the partition walls detected by the fourth detecting mechanism, and to transmit information of the discharge positions to the transport mechanism. According to this method of transferring a substrate, by calculating the discharge positions of the substrates from the positions of the end surfaces of the substrates held by the substrate holding mechanism and the positions of the partition walls of the second substrate storage case in advance, the substrates can be stored on the substrate storage surfaces with high precision.

According to a fourth aspect of the invention, there is provided a method of transferring substrates stored on substrate storage surfaces included in a second substrate storage case to a first substrate storage case, which has support grooves in its inner wall. The method of transferring substrates includes causing a substrate holding mechanism to hold the substrates stored on the substrate storage surfaces included in the second substrate storage case on a second-substrate-storage-case placement section at hold positions, causing a transport mechanism to transport the substrate holding mechanism from the hold positions to discharge positions, causing the substrate holding mechanism to discharge the substrates at the discharge positions and to place the substrates in a substrate placement section of a substrate placing mechanism, and causing a substrate transfer mechanism to hold the substrate placed in the substrate placement section and to transfer the substrates to the first substrate storage case placed in a first-substrate-storage-case placement section. As one of the effects obtained from this method, the substrates can be transferred in a direction opposite to the above-described direction. Specifically, the substrates can be transferred from the substrate storage surfaces included in the second substrate storage case to the first substrate storage case.

According to a fifth aspect of the invention, there is provided a method of manufacturing an electro-optical device by transferring a substrate in a first substrate storage case, which has support grooves in its inner wall, along the support grooves to substrate storage surfaces included in a second substrate storage case. The method of manufacturing an electro-optical device includes causing a substrate transfer mechanism to hold the substrates stored in the first substrate storage case on a first-substrate-storage-case placement section so as to draw out the substrates from the first substrate storage case, and to transfer the substrates to a substrate placement section of a substrate placing mechanism, causing a substrate holding mechanism to hold the substrates placed in the substrate placement section at hold positions, causing a transport mechanism to transport the substrate holding mechanism from the hold positions to discharge positions, and causing the substrate holding mechanism to discharge the substrates at the discharge positions and to dispose the substrates onto the substrate storage surfaces of the second substrate storage case placed in a second-substrate-storage-case placement section. This method has a method of transferring a substrate which can transfer the substrates, without human hands, and thus the electro-optical device can be manufactured with high yield.

DESCRIPTION OF EXEMPLARY EMBODIMENTS

A. Configuration of Substrate Transfer Apparatus

FIG. 1is a schematic view showing the configuration of a substrate transfer apparatus1according to this embodiment. The substrate transfer apparatus1has a substrate transfer mechanism10, a substrate-storage-case placement section50serving as ‘first-substrate-storage-case placement section’, a rotary pocket20serving as ‘substrate placing mechanism’, a substrate holding mechanism30, a transport mechanism40, cameras91,92,93, and94, and a palette placement section60serving as ‘second-substrate-storage-case placement section. The substrate transfer apparatus1is an apparatus which transfers glass substrates5serving as ‘substrate’ in a substrate storage case51placed in the substrate-storage-case placement section50to a palette61placed in the palette placement section60. Hereinafter, a direction from the substrate storage case51toward the palette61in a horizontal plane, that is, a direction in which the glass substrates5are transferred, is referred to as an X axis, a direction perpendicular to the X axis on the horizontal plane is referred to as a Y axis, and a vertical upward direction is referred to as a Z axis. Hereinafter, the above-described parts will be described with reference toFIG. 1.

A1. Substrate Transfer Mechanism

A substrate transfer mechanism10has a hand11, a hand moving mechanism12, and a hand moving mechanism base section13. In the hand moving mechanism base section13, the substrate-storage-case placement section50, in which the substrate storage case51is placed, is provided. The substrate-storage-case placement section50has a shape in which a plurality of containers configured to place the substrate storage case51are connected. In the substrate storage case51, the glass substrates5, which are to be transferred by the substrate transfer apparatus1, are stored.

FIG. 2is a schematic perspective view of the substrate storage case51. The substrate storage case51is a plastic container which has support grooves52formed at constant intervals so as to support the glass substrates5in its inner wall. In the substrate storage case51, the glass substrates5are arranged and stored in a direction along the support grooves52.

Here, each glass substrate5is a member which constitutes a counter substrate82(seeFIG. 11A) of a liquid crystal display device100(seeFIG. 11B). On one surface of the glass substrate5, excluding an outer edge, transparent electrodes and an alignment film coated to overlap the transparent electrodes are formed. At one point close to the outer edge of the glass substrate5, a mark for judging a direction thereof is given. Further, the glass substrate5has a rectangular surface having a diagonal size of 1.3 inches, and has a thickness of 1.1 mm.

Of the hand moving mechanism base section13, a surface on which the substrate-storage-case placement section50is provided is an inclined surface which is inclined by a predetermined angle from the horizontal plane. Accordingly, the substrate-storage-case placement section50and the substrate storage case51are also provided at the angle with respect to the horizontal plane. At this time, the glass substrate5is stored in a state of being inclined with respect to a vertical plane in the substrate storage case51and leans against the support groove52by its weight, such that the glass substrate5has a stable posture. As a result, all glass substrates5leans against the support grooves52, and thus the glass substrates are stored in the substrate storage case51at constant intervals.

The above-described parts of the substrate transfer mechanism10are assembled to one another as follows. The hand moving mechanism12is mounted on the hand moving mechanism base section13, and the hand11is mounted on the hand moving mechanism12. Among these, the hand moving mechanism12has an arm portion121. The hand moving mechanism12has a movable range in an ascending and descending direction of the inclined surface of the hand moving mechanism base section13, and has a movable range in a direction perpendicular to the inclined surface. That is, the hand moving mechanism12can move in a direction within an X-Z plane. The hand11has a pair of parallel gripping fingers at an adjustable gap therebetween. The hand11is mounted on the arm portion121of the hand moving mechanism12so as to have a movable range in a direction parallel to the arm portion121, that is, in the Y axis direction.

The hand11can grip the glass substrate5by making the gap between the grip fingers narrow at a position capable of gripping the glass substrate5and holding the end surface of the glass substrate5. Here, as described above, since the glass substrates5are stably stored in the substrate storage case51at constant intervals, the hand11can easily grip the glass substrate5. The substrate transfer mechanism10, which has gripped the glass substrate5by the hand11, suitably moves the hand moving mechanism12and the hand11in the movable range so as to move the glass substrate5to the periphery of a pocket21disposed at a first position described below. In this state, by opening the gap of the grip fingers of the hand11wide so as to release the glass substrate5, the substrate transfer mechanism10can place the glass substrate5in the pocket21. At this time, the glass substrate5is placed with its surface, on which the transparent electrodes and the alignment film are not formed, turned toward the pocket21. Therefore, when the glass substrate5is placed, its surface, on which the alignment film is formed, is rarely contaminated.

As described above, the substrate transfer mechanism10can draw out the glass substrate5stored in the substrate storage case51and can place the glass substrate5in the pocket21.

A2. Substrate Placing Mechanism

As shown inFIG. 1, the rotary pocket20serving as ‘substrate placing mechanism’ has the pocket21serving as ‘substrate placement section’, a pocket base section22, and a moving mechanism23. The pocket21is fixed to the pocket base section22, and the pocket base section22is attached to the moving mechanism23.

Here, the arrangement and operation of the parts of the rotary pocket20will be described in detail with reference toFIGS. 3 and 4. As shown inFIG. 3, the pocket base section22has substantially a regular octagonal prism in which eight surfaces are arranged in a ring shape so as to provide the pocket21, and is attached to the moving mechanism23such that a pair of surfaces from the eight surfaces is substantially parallel to the moving mechanism23. The pocket base section22is formed of a metal. On one surface inclined by +45 degrees with respect to the horizontal plane of the eight surfaces, the pocket21is provided. Hereinafter, the position of the pocket21is referred to as ‘first position’. In the pocket21disposed at the first position, the glass substrate5can be placed by the substrate transfer mechanism10.

The pocket21is a metal part capable of placing the glass substrate5therein, and has partition walls211a,211b, and211cfor defining the position of the end surface of the glass substrate5and an absorbing hole212. Moreover, the surface of the pocket21may be coated with fluorocarbon resin so as to prevent the glass substrate5from being damaged. The absorbing hole212has a negative pressure with respect to outside air so as to absorb outside air or an object in the periphery of the absorbing hole. The partition wall211abecomes relatively higher than the partition walls211band211c. According to this configuration, the glass substrate5released from the above-described hand11to the pocket21disposed at the first position is temporarily supported by the partition wall211a, leans against the pocket21by its weight and the negative pressure generated in the absorbing hole212, and is placed in the pocket21. The glass substrate5placed in the pocket21is fixed to the pocket21by suction force of the absorbing hole212and the partition walls211a,211b,211c.

Moreover, the glass substrate5placed in the pocket21disposed at the first position is substantially parallel to the glass substrate5stored in the above-described substrate storage case51and the glass substrate5gripped by the hand11. That is, the glass substrate5gripped by the hand11and moved to the periphery of the pocket21is placed in the pocket21with no substantial change in the angle. According to this configuration, the above-described substrate transfer mechanism10can easily place the glass substrate5in the pocket21.

The moving mechanism23can rotate the pocket base section22around a rotational shaft24parallel to the Y axis shown inFIG. 3with a rotating mechanism (not shown) provided therein.FIG. 4shows a state in which the moving mechanism23rotates the pocket base section22such that the pocket21is in a vertical upward direction. Hereinafter, the position of the pocket21is referred to as ‘second position’. A substrate holding mechanism30described below can hold the glass substrate5placed in the pocket21disposed at the second position. The moving mechanism23can rotate the pocket base section22in any direction by an arbitrary rotation amount, and thus the pocket21can be returned from a second state to a first state.

Moreover, in this embodiment, the pocket21is provided on one of the eight surfaces of the pocket base section22, but other pockets21may be simultaneously provided on other surfaces. For example, if pockets, which can store glass substrates having different sizes, are individually provided on the surfaces, by suitably rotating the pocket base section22, the glass substrates having different sizes can be transferred.

Further, as shown inFIG. 1, the entire rotary pocket20is configured to move in the X axis direction. More specifically, the rotary pocket20can move between a position at which the hand11can place the glass substrate5in the pocket21disposed at the first position (a position indicated by a two-dot-chain line inFIG. 1), and a position at which an absorption collect31described below can hold the glass substrate5from the pocket21disposed at the second position (a position indicated by a solid line inFIG. 1). Hereinafter, the former is referred to as ‘third position’, and the latter is referred to as ‘fourth position’. The movement of the rotary pocket20is realized by a driving device (not shown) in the moving mechanism23.

This can be specifically described in view of the transport of the glass substrate5. That is, when the pocket21is disposed at the first position, and the entire rotary pocket20is disposed at the third position, the hand11can place the glass substrate5in the pocket21. Further, when the pocket21is disposed at the second position, and the entire rotary pocket20is disposed at the fourth position, the absorption collect31can hold the glass substrate5from the pocket21.

As described above, the rotary pocket20serving as the substrate placing mechanism can place the glass substrate5in the pocket21and can move the placed glass substrate5between the predetermined positions.

A3. Substrate Holding Mechanism and Transport Mechanism

As shown inFIG. 1, the substrate holding mechanism30has the absorption collect31serving as ‘absorbing mechanism’ at a lower end in the Z axis direction. An upper end of the substrate holding mechanism30is attached to the transport mechanism40. Further, to the substrate holding mechanism30, a camera94is fixed in a vertical downward direction.

The absorption collect31has a rectangular ring-shaped absorbing section which can absorb an object by a negative pressure. The rectangular ring-shaped absorbing section is constantly parallel to an X-Y plane, and its shape corresponds to an outer circumference of the glass substrate5. Accordingly, the absorption collect31faces and absorbs the glass substrate5, such that the absorption collect31can be brought into contact with only the outer circumference of the glass substrate5and can hold the glass substrate5. The alignment film is not disposed at the outer circumference of the glass substrate5, and thus the absorption collect31can hold the glass substrate5, without contaminating the alignment film. Moreover, the substrate holding mechanism30can rotate the absorption collect31around the Z axis. Hereinafter, the rotation angle is represented by θ.

The transport mechanism40can transport the substrate holding mechanism30including the absorption collect31. More specifically, the substrate holding mechanism30can be vertically moved in the Z axis direction, and can parallel move in the X-Y plane.

With the above-described operation of the substrate holding mechanism30including the absorption collect31and the transport mechanism40, the substrate holding mechanism30can hold the glass substrate5placed in the pocket21disposed at the second position and can discharge the glass substrate5so as to be stored on the substrate storage surface62of the palette61.

Here, the palette61is a metal substrate storage case, which is placed on the palette placement section60in a horizontal state.FIG. 5is a schematic perspective view of the palette61. The palette61has pallet partition walls63, which are formed by cutting and bending a metal plate. The palette partition walls63are formed to fit to the size of the glass substrate5. On the substrate storage surfaces62divided by the palette partition walls63,20glass substrates5in total are stored.

Moreover, since the palette61and the pocket21disposed at the second position can place the glass substrate5in the horizontal states, after temporarily holding the glass substrate5, the substrate holding mechanism30can store the glass substrate5on the substrate storage surface62, without adjusting the elevation angle of the glass substrate5.

Hereinafter, a position of the substrate holding mechanism30when the substrate holding mechanism30holds the glass substrate5placed in the pocket21is referred to as ‘hold position’, and a position of the substrate holding mechanism30when the substrate holding mechanism30discharges the glass substrate5to the substrate storage surface62is referred to as ‘discharge position’. According to this configuration, the transport mechanism40transports the substrate holding mechanism30between the hold position and the discharge position.

The discharge position is a position at which, when the substrate holding mechanism30discharges the glass substrate5, the glass substrate5is stored on the substrate storage surface62. Therefore, the end surfaces of the glass substrate5held by the substrate holding mechanism30at the discharge position need to be aligned with the end surfaces of the palette partition walls63corresponding to the substrate storage surface62with high precision, on which the glass substrate5is to be stored. With the functions of the cameras93and94described below, the transport mechanism40can move the substrate holding mechanism30to the discharge position satisfying such a condition. The substrate holding mechanism30, which has moved to the discharge position, discharges the glass substrate5, thereby storing the glass substrate5on the substrate storage surface62.

The absorption collect31of the substrate holding mechanism30absorbs one plane of the glass substrate5and holds the glass substrate5, and thus all the end surfaces of the glass substrate5are not brought into contact with any foreign substance. For this reason, even if the palette61has the palette partition walls63, the substrate holding mechanism30can easily discharge the glass substrate5to the substrate storage surface62, without being brought into contact with the palette partition walls63.

As shown inFIG. 1, in the substrate transfer apparatus1, at one point of the movable range of the substrate holding mechanism30, the camera93is disposed in a direction opposite to the substrate holding mechanism30, that is, in a vertical upward direction. In addition, as described above, to the substrate holding mechanism30, the camera94is fixed in a vertical downward direction. The camera93is connected to a processing unit71through a substrate end surface judging unit97(seeFIG. 6). Further, similarly, the camera94is connected to the processing unit71through a palette partition wall end surface judging unit98(seeFIG. 6).

The cameras93and94are cameras having image-capturing elements, which use CCDs (Charge Coupled Devices). The camera93captures images of the end surfaces of the glass substrate5held by the substrate holding mechanism30, and transmits data of the captured images to the substrate end surface judging unit97. The substrate end surface judging unit97detects the positions and angles of the end surfaces of the glass substrate5from the received data, and transmits the detection information to the processing unit71. On the other hand, the camera94captures images of the ends surfaces of the palette partition walls63of the substrate storage surface62, on which the glass substrate5held by the substrate holding mechanism30is to be stored, and transmits data of the captured images to the palette partition wall end surface judging unit98. The palette partition wall end surface judging unit98detects the positions and angles of the end surfaces of the palette partition walls63from the received data, and transmits the detection information to the processing unit71.

Here, the camera93and the substrate end surface judging unit97correspond to ‘third detecting mechanism’ of the invention, and the camera94and the palette partition wall end surface judging unit98correspond to ‘fourth detecting mechanism’ of the invention.

The processing unit71receives the information of the positions and angles of the end surfaces of the glass substrate5and the end surfaces of the palette partition walls63from the substrate end surface judging unit97and the palette partition wall end surface judging unit98, and calculates a suitable discharge position of the substrate holding mechanism30from the data. And then, the processing unit71transmits information, which is required for moving the substrate holding mechanism30and the absorption collect31to the discharge position, to the transport mechanism40and the substrate holding mechanism30. The required information is movement amounts of the substrate holding mechanism30in the X, Y, and Z directions, and the rotation angle θ of the absorption collect31. The former is transmitted to the transport mechanism40, and the latter is transmitted to the substrate holding mechanism30. The transport mechanism40moves the substrate holding mechanism30on the basis of the received information. Further, the substrate holding mechanism30rotates the absorption collect31on the basis of the received information. By doing so, the substrate holding mechanism30including the absorption collect31is moved to the discharge position at which the glass substrate5can be suitably discharged to the substrate storage surface62.

In the substrate transfer apparatus1, the cameras91and92are further disposed. The cameras91and92are disposed at a point of the movable range of the rotary pocket20so as to face the pocket21at the second position, that is, in a vertical downward direction. The camera91is connected to the processing unit71through a direction judging unit95(seeFIG. 6). Further, the camera92is connected to the processing unit71through a damage judging unit96(seeFIG. 6).

Like the cameras93and94, the camera91is also a camera having an image-capturing element, which uses a CCD. The camera91captures an image of a direction judging mark of the glass substrate5placed in the pocket21, and transmits data of the captured image to the direction judging unit95. The direction judging unit95detects and judges the direction of the glass substrate5from the received data. Specifically, if the direction judging mark exists at a predetermined position, it is judged that the direction of the glass substrate5is normal. Further, if the direction judging mark exists on a side opposite to the predetermined position, that is, at a point-symmetrical position with respect to the center of the glass substrate5, it is judged that the direction of the glass substrate5is misaligned by 180 degrees. In addition, if the position of the direction judging mark does not come under the above-described cases, it is judged that abnormal placing including the turnover of the glass substrate5, other than the above-described cases, is performed. Next, the direction judging unit95transmits information regarding the direction of the glass substrate5to the processing unit71. The processing unit71does not perform a special operation when the direction is normal. Further, if the direction is misaligned by 180 degrees, when the substrate holding mechanism30holds the glass substrate5, the processing unit71transmits a signal for rotating the substrate holding mechanism30in the θ direction by 180 degrees to the transport mechanism40. In addition, if the direction is turned over, the entire substrate transfer apparatus1stops. Moreover, the camera91and the direction judging unit95correspond to ‘first detecting mechanism’ of the invention.

Like the cameras93and94, the camera92is also a camera having an image-capturing element, which uses a CCD. The camera92captures images of the end surfaces of the glass substrate5placed in the pocket21, and transmits data of the captured images to a damage judging unit96. The damage judging unit96detects and judges presence/absence of cracks or fragments in the glass substrate5from the received data. Specifically, when contrast is changed due to the damages, such as cracks or fragments in the captured images of the end surfaces, it is judged that the glass substrate5is damaged. And then, the damage judging unit96transmits information regarding presence/absence of the damage in the glass substrate5to the processing unit71. When the glass substrate5is not damaged, the processing unit71does not perform a special operation. Further, when the damage exists, the entire substrate transfer apparatus1stops. Moreover, the camera92and the damage judging unit96correspond to ‘second detecting mechanism’ of the invention.

With the functions of the cameras91and92, only the undamaged glass substrate5can be transferred to the substrate storage surface62of the palette61in a predetermined direction.

The substrate transfer apparatus1having the above-described configuration can transfer the glass substrate5from the substrate storage case51onto the substrate storage surface62of the palette61without human hands.

B. Method of Transferring Substrate

The electrical configuration of the substrate transfer apparatus1will now be described with reference toFIG. 6. And then, on the basis of this description, a method of transferring a substrate according to this embodiment will be described with reference toFIGS. 7 to 9C.

FIG. 6is a block diagram showing the electrical configuration of the substrate transfer apparatus1. As shown inFIG. 6, the processing unit71is connected to the hand moving mechanism12, the hand moving mechanism base section13, the moving mechanism23, the direction judging unit95, the damage judging unit96, the substrate end surface judging unit97, the palette partition wall end surface judging unit98, the substrate holding mechanism30, the transport mechanism40, a recipe storage unit72, and an input unit73. The processing unit71receives and processes various kinds of information and signals from the above-described parts, and transmits various information and signals to the above-described parts. The substrate transfer apparatus1is an apparatus which transfers the substrates by causing the processing unit71to transmit the signals for driving the substrate transfer mechanism10, the rotary pocket20, the substrate holding mechanism30, the transport mechanism40, and the like at predetermined timing, thereby sequentially driving these parts so as to transfer the substrates.

The recipe storage unit72receives and stores recipe information input from the input unit73through the processing unit71. Here, the recipe information includes the size of the glass substrate5, the number of glass substrates5stored in the substrate storage case51, the pitch of the support groove52, the position of the direction judging mark, and the arrangement of the substrate storage surfaces62of the palette61(the number of rows and columns).

Next, the method of transferring a substrate according to this embodiment will be described with reference toFIG. 7 to 9C. As shown in a process view ofFIG. 7, the method of transferring a substrate according to this embodiment includes a process S1to a process S17. InFIG. 7, the respective processes are arranged and divided in a row direction for each target part, and arrows indicate the progress direction of the processes.FIGS. 8A to 9Care schematic views of the method of transferring a substrate according to this embodiment.

In the process S1, the rotary pocket20moves to the third position, and the pocket21moves to the first position. These movements are executed by causing the moving mechanism23to receive the driving signals sent from the processing unit71, and causing the moving mechanism23to parallel move the entire rotary pocket20on the basis of the signals and to rotate the pocket base section22around the rotational shaft24.

Next, in the process S2, the hand11of the substrate transfer mechanism10grips the glass substrate5stored in the substrate storage case51. More specifically, this process includes a step of parallel moving the hand11to a position capable of gripping the glass substrate5, and a step of causing the grip fingers of the hand11to hold the end surface of the glass substrate5and to grip the glass substrate5.

The movement of the hand11and gripping of the glass substrate5by the grip fingers are performed by the combination of the following operations. The processing unit71sends signals for the movement and gripping to the hand moving mechanism base section13and the hand moving mechanism12. The hand moving mechanism base section13moves the hand moving mechanism12on the basis of the signals. The hand moving mechanism12moves the hand11and the grip fingers of the hand11on the basis of the signals. The hand11is moved by the combination of these operations, and grips the glass substrate5. Moreover, the signals sent by the processing unit71is generated by the processing unit71on the basis of the size of the glass substrate5stored in the recipe storage unit72, the number of glass substrates5stored in the substrate storage case51, and information regarding the pitch of the support groove52of the substrate storage case51.

When the glass substrate5has been gripped by the hand11, the process S3is performed. In this process, as shown inFIG. 8A, the hand11of the substrate transfer mechanism10places the glass substrate5in the pocket21of the rotary pocket20. More specifically, this process includes a step of moving the hand11to a position at which the glass substrate5can be placed in the pocket21, and a step of causing the grip fingers of the hand11to release the glass substrate5such that the glass substrate5is placed in the pocket21.

The movement of the hand11and opening of the glass substrate5are performed by the combination of the following operations. The processing unit71sends signals for the movement and opening to the hand moving mechanism base section13and the hand moving mechanism12. The hand moving mechanism base section13moves the hand moving mechanism12on the basis of the signals. The hand moving mechanism12moves the hand11and the grip fingers of the hand11on the basis of the signals. The hand11is moved by the combination of these operations and opens the glass substrate5.

The processes S2and S3correspond to ‘causing the substrate transfer mechanism to hold and transfer the glass substrate’ of the invention.

Next, in the process S4, the pocket21of the rotary pocket20moves to the second position, and the rotary pocket20moves to a position at which the pocket21and the camera91face each other (seeFIG. 8B). The movements of the rotary pocket20and the pocket21are executed by causing the moving mechanism23to receive signals for the movements sent from the processing unit71, and causing the moving mechanism23to parallel move the entire rotary pocket20on the basis of the signals and to rotate the pocket base section22around the rotational shaft24.

When the movement of the rotary pocket20is completed, in the process S5, the direction of the glass substrate5placed in the pocket21is detected. This detection is performed by the cooperation of the camera91, the direction judging unit95, and the processing unit71. The judgment operation is as described above, and thus the description thereof will be omitted in order to avoid repeating.

When it is judged in the process S5that the glass substrate5is correctly placed or the glass substrate5is placed in a state of being rotated by 180 degrees, in the process S6, the rotary pocket20moves to a position at which the pocket21and the camera92face each other (seeFIG. 8C). The movement of the rotary pocket20is executed by causing the moving mechanism23to receive a signal for the movement sent from the processing unit71, and causing the moving mechanism23to parallel move the entire rotary pocket20on the basis of the signal.

When the movement of the rotary pocket20is completed, in the process S7, the damage of the glass substrate5placed in the pocket21is detected. This detection is performed by the cooperation of the camera92, the damage judging unit96, and the processing unit71. The judgment operation is as described above, and thus the description thereof will be omitted in order to avoid repeating.

Moreover, when it is judged in the process S5that the glass substrate5is placed in a state of being turned over, or when it is judged in the process S6that the glass substrate5is damaged, the process S17is performed. In this process, the processing unit71stops the substrate transfer apparatus. And then, a worker performs processing such as the removal of the glass substrate5or the like, and then the transfer of the glass substrate5restarts from the process S1.

When it is judged in the process S7that the glass substrate5is not damaged, in the process S8, the rotary pocket20moves to the fourth position. The movement of the rotary pocket20is executed by causing the moving mechanism23to receive a signal for the movement sent from the processing unit71, and causing the moving mechanism23to parallel move the entire rotary pocket20on the basis of the signal.

When the movement of the rotary pocket20is completed, the process S9is performed. In this process, as shown inFIG. 9A, the substrate holding mechanism30moves to the hold position, and the absorption collect31of the substrate holding mechanism30holds the glass substrate5placed in the pocket21. This process corresponds to ‘causing the substrate holding mechanism to hold the glass substrate’ of the invention.

The movement of the substrate holding mechanism30to the hold position is executed by causing the transport mechanism40to receive a signal for the movement sent from the processing unit71, and causing the transport mechanism40to move accompanied by the substrate holding mechanism30on the basis of the signal. Further, the absorption of the glass substrate5by the absorption collect31is executed by causing the substrate holding mechanism30to a signal for the absorption sent from the processing unit71, and causing the substrate holding mechanism30to perform the absorption operation of the absorption collect31on the basis of the signal. Moreover, when the absorption collect31absorbs the glass substrate5, the absorption of the glass substrate5by the absorbing hole212of the pocket21is not performed.

Here, when it is judged in the process S5that the glass substrate5is rotated by 180 degrees from a normal direction, the process S10is performed. In the process S10, the substrate holding mechanism30rotates the absorption collect31by 180 degrees in the θ direction. This rotation is executed by causing the substrate holding mechanism30to receive a signal for the rotation sent from the processing unit71, and causing the substrate holding mechanism30to rotate the absorption collect31on the basis of the signal. Through this process, the direction of the glass substrate5is corrected to the normal state.

When the process S10ends, or when, in the process S9, the substrate holding mechanism30holds the glass substrate5in the normal direction, the process S11is performed. In the process S11, the substrate holding mechanism30moves to a position at which the glass substrate5and the camera93face each other (seeFIG. 9B). The movement of the substrate holding mechanism30is executed by causing the transport mechanism40to receive a signal for the movement sent from the processing unit71, and causing the transport mechanism40to move accompanied by the substrate holding mechanism30on the basis of the signal.

Subsequently, in the process S12, the end surface of the glass substrate5is detected. This process is performed by the cooperation of the camera93, the substrate end surface judging unit97, and the processing unit71. The detection operation is as described above, and thus the description thereof will be omitted in order to avoid repeating.

Next, in the process S13, the substrate holding mechanism30moves to a position at which the camera94and the substrate storage surface62of the palette61face each other. As described above, the camera94is fixed to the substrate holding mechanism30, and thus the camera94moves along the movement of the substrate holding mechanism30.

In a state in which the camera94and the substrate storage surface62face each other in such a manner, in the process S14, the end surfaces of the palette partition walls63are detected. This process is performed by the cooperation of the camera94, the palette partition wall end surface judging unit98, and the processing unit71. The detection operation is as described above, and thus the description thereof will be omitted in order to avoid repeating.

When the detection of the end surfaces of the palette partition walls63ends, the process S15is performed. In this process, the substrate holding mechanism30moves to the discharge position (seeFIG. 9C). This process corresponds to ‘causing the transport mechanism to move the substrate holding mechanism to the discharge position’ of the invention.

In this process, the movement of the substrate holding mechanism30is performed as follows. In the processes S12and S14, the processing unit71receives the information of the positions and angles of the end surface of the glass substrate5and the end surfaces of the palette partition walls63from the substrate end surface judging unit97and the palette partition wall end surface judging unit98. The processing unit71calculates, from the data, information required for moving the glass substrate5held by the substrate holding mechanism30to a suitable position, and transmits the information to the transport mechanism40and the substrate holding mechanism30. The required information is the movement amounts of the substrate holding mechanism30in the X, Y, and Z directions, and the rotation angle θ of the absorption collect31. The former is transmitted to the transport mechanism40, and the latter is transmitted to the substrate holding mechanism30. Next, the transport mechanism40moves the substrate holding mechanism30on the basis of the received information. Further, the substrate holding mechanism30rotates the absorption collect31on the basis of the received information. By doing so, the substrate holding mechanism30including the absorption collect31moves to the suitable discharge position.

Subsequently, in the process S16, the absorption collect31of the substrate holding mechanism30discharges the glass substrate5, and the glass substrate5is stored in the substrate storage surface62of the palette61. This process corresponds to ‘causing the substrate holding mechanism to discharge and dispose the glass substrate’ of the invention.

This process is performed by causing the processing unit71to send a signal for discharging the glass substrate5to the substrate holding mechanism30. The substrate holding mechanism30, which receives the signal, stops the absorption operation of the absorption collect31so as to discharge the glass substrate5. The discharged glass substrate5is stored on the substrate storage surface62of the palette61in a state shown inFIG. 5.

Through the above-described processes, one glass substrate5is transferred from the substrate storage case51to the substrate storage surface62of the palette61. The time duration for a series of processes is about seven seconds. These processes are repeated by the number of glass substrates5stored in the substrate storage case51, which is stored in the recipe storage unit72. Similarly, the glass substrates5are stored in the palette61on the basis of the arrangement information (the number of rows and columns) of the substrate storage surfaces62of the palette61.

By doing so, all the glass substrates5stored in the substrate storage case51can be transferred to the palette61with high yield, without human hands. The inventors have examined that, when the glass substrates5are transferred by human hands, yield is about 75% due to damages, an error in storage direction, and the like. In contrast, the inventors have confirmed that, by using the substrate transfer apparatus1of this embodiment, these defects are reduced, and yield is improved to about 96%.

C. Method of Manufacturing Electro-Optical Device

A method of manufacturing a liquid crystal display device as ‘a method of manufacturing an electro-optical device’ including the method of transferring a substrate will now be described with reference toFIG. 10.FIG. 10is process view showing a manufacturing process of a liquid crystal display device of this embodiment. InFIG. 10, processes P11to P14are processes for manufacturing a composite element substrate, in which a plurality of element substrates81are integrally formed, and processes P21and P23are processes for manufacturing a counter substrate82. Processes P31to P35are processes for combining the composite element substrate and the counter substrate82so as to finish a liquid crystal panel80and a liquid crystal display device100. The processes P11to P14and the processes P21and P23are independently performed.

The process P11is a process for laminating and forming the parts including TFT elements, metal wiring lines, and transparent electrodes on a surface of a disc-shaped quartz glass substrate serving as the composite element substrate. In one quartz glass substrate, the parts corresponding to a plurality of liquid crystal display devices are formed. This process is performed, for example, by a photolithography method.

The process P12is a process for forming an alignment film formed of polyimide by a flexography method so as to overlap the parts formed in the process P11.

The process P13is a process for rubbing a surface of the alignment film formed in the process P12with a cloth, which is called a rubbing treatment. Through the rubbing process, the alignment film has a function of aligning liquid crystal to be brought into contact therewith along a rubbing direction.

The process P14is a process for forming a sealant on the surface subjected to rubbing in the process P13by a screen printing method. The sealant is formed on the outer circumference of a region to which the counter substrate82is bonded, excluding a part of an injection slot described below for injecting liquid crystal. Through the processes P11to P14, the composite element substrate is finished.

The process P21is a process for transferring the glass substrates5stored in the substrate storage case51to the substrate storage surfaces62of the palette61by using the substrate transfer apparatus1, and arranging the glass substrates5on the substrate storage surfaces62. This process includes the above-described processes S1to S17. These processes are as described above, and thus the descriptions thereof will be omitted in order to avoid repeating. Moreover, as described above, on one surface of the glass substrate5, the transparent electrodes and the alignment film are formed. The glass substrate5is transferred to the palette61such that the surface of the glass substrate5, on which the alignment film is formed, is turned upward.

The process P23is a process for rubbing alignment films of the surfaces of the glass substrates5arranged on the palette61in the process P21, which is called a rubbing treatment. The glass substrates5are arranged in the palette61in parallel on the same plane such that alignment film is turned upward, and thus rubbing can be performed at the same time on all the glass substrates5on the palette61. Through the rubbing process, the alignment film has a function of aligning liquid crystal, which is brought into contact therewith, along a rubbing direction. Through the processes P21and P23, the counter substrate82is finished.

The process P31is a process for bonding the counter substrate82to the composite element substrate by the sealant so as to form a bonded substrate. Bonding is performed by bringing the composite element substrate into contact with the counter substrate82and pressing them, and drying the sealant in a state in which the composite element substrate and the counter substrate82are aligned (positioned).

The process P32is a process for injecting liquid crystal into a space surrounded by the composite element substrate, the counter substrate82, and the sealant. This process is performed by dropping liquid crystal in the injection slot under vacuum and introducing liquid crystal into the space by capillarity.

The process P33is a process for sealing the injection slot in a state in which a gap between the composite element substrate and the counter substrate82is adjusted to a suitable state. Sealing is performed by coating ultraviolet curable resin to the injection slot and curing the resin.

The process P34is a process for breaking the bonded substrate subjected to the liquid crystal injection and sealing to a size corresponding to an individual liquid crystal display device so as to manufacture the liquid crystal panel80as a single product (seeFIG. 11A). Breaking is performed by forming scribe grooves in the surface of the composite element substrate and cutting the composite element substrate along the scribed grooves. The liquid crystal panel80has the element substrate81and the counter substrate82having sizes corresponding to the single product obtained by cutting the composite element substrate.

The process P35is a process for mounting an FPC (Flexible Printed Circuit)84for electrical connection to the outside (seeFIG. 11A), a dustproof glass83so as to prevent foreign substances from being attached to the surface of the liquid crystal panel80(seeFIG. 11A), and a cover85for protection of the liquid crystal panel80or heat dissipation (seeFIG. 11B) on the liquid crystal panel80obtained in the process P34. Through these processes, the liquid crystal display device100is manufactured.

According to the method of manufacturing a liquid crystal display device described above, the glass substrate5can be transferred from the substrate storage case51to the palette61without human hands, and thus the liquid crystal display device100can be manufactured with high yield. Further, the liquid crystal display device100can be manufactured by fewer workers.

Although the embodiment of the invention has been described, various modifications can be added to the embodiment within the scope without departing from the spirit of the invention. The following modifications can be exemplified.

First Modification

Although the glass substrate5is transferred from the substrate storage case51to the palette61in the embodiment, if the substrate transfer apparatus1of this embodiment is used, the glass substrate5can be transferred from the palette61to the substrate storage case51, that is, in a direction opposite to the above-described direction. Hereinafter, a method of transferring the glass substrate5from the palette61to the substrate storage case51will be described with reference toFIGS. 12A to 12C.

In this modification, first, as shown inFIG. 12A, the substrate holding mechanism30moves to the hold position, and holds the glass substrate5stored in the substrate storage surface62of the palette61. More specifically, the absorption collect31included in the substrate holding mechanism30absorbs and holds the glass substrate5. Next, the substrate holding mechanism30, which holds the glass substrate5, moves the hold position, and simultaneously the rotary pocket20moves to the fourth position. At that time, the pocket21moves to the second position. Subsequently, as shown inFIG. 12B, the absorption collect31of the substrate holding mechanism30discharges the glass substrate5, and places the glass substrate5in the pocket21. Next, the pocket21, in which the glass substrate5is placed, moves to the first position, and simultaneously the rotary pocket20moves to the third position. In this state, as shown inFIG. 12C, the hand11of the substrate transfer mechanism10grips the glass substrate5. Gripping is performed by using a gap between the partition walls211cof the pocket21and causing the grip fingers to grip the end surface of the glass substrate5. The hand11, which grips the glass substrate5, inserts the glass substrate5in the substrate storage case51along the support groove52of the substrate storage case51, and then opens the glass substrate5, such that the glass substrate5is stored in the substrate storage case51. According to such processes, the glass substrate5can be transferred from the palette61to the substrate storage case51by using the substrate transfer apparatus1.

In this modification, the transfer direction of the glass substrate5is opposite to the above-described embodiment, but the operations of the respective parts of the substrate transfer apparatus1are the same as those in the embodiment, such that the detailed descriptions thereof will be omitted.

Second Modification

The substrate transfer apparatus1according to the above-described embodiment transfers the glass substrate5, but a target to be transferred is not limited thereto. Any object having a substrate shape can be transferred. For example, a quartz substrate, a silicon substrate, and the like can be transferred. Further, as long as the substrate transfer apparatus1can transfer by the above-described transfer method, the size of a substrate to be transferred is not particularly limited.

Third Embodiment

In the above-described embodiment, the hand11has the grip fingers, and is configured to grip the glass substrate5. However, any hand can be used as long as it can ‘hold’ the glass substrate5. For example, like the absorption collect, a unit for absorbing and holding the glass substrate5can be used.

Fourth Embodiment

In the above-described embodiment, the pocket21is configured to move between the first position inclined from the horizontal state and the second position in the horizontal state. Alternatively, the second position may be fixed. In this case, it is preferable that the substrate storage case51store the glass substrate5in a horizontal state, the substrate transfer mechanism10holds the glass substrate5in the horizontal state, and parallel moves the glass substrate5to be placed in the pocket21. As an example of such a substrate transfer mechanism10, a substrate transfer mechanism having an absorbing mechanism for absorbing and holding the glass substrate5in the horizontal state from the top can be exemplified.

Fifth Embodiment

The above-described embodiment manufactures a transmissive liquid crystal display device100by using a pair of glass substrates, but the method of transferring a substrate according to the invention can be applied to the manufacture of various electro-optical devices, such as an LCOS (Liquid Crystal on Silicon) using a silicon substrate with a reflecting film, or the like.

The entire disclosure of Japanese Patent Application No. 2005-094766, filed Mar. 3, 2005, is expressly incorporated by reference herein.