STAMP TOOL HOLDING APPARATUS, STAMP TOOL POSITIONING APPARATUS, MULTI-COMPONENT TRANSFER APPARATUS, AND METHOD FOR MANUFACTURING ELEMENT ARRAY

A stamp tool holding device capable of holding a stamp tool while keeping a stamp surface of the stamp tool clean, a stamp tool positioning device that easily positions a stamp tool with respect to a transport head, a multi-element transfer device for efficiently transferring a transport object element such as an element using a stamp tool, and a method of manufacturing an element array using the same, wherein the stamp tool holding device has an installation stage on which a stamp tool is detachably installed. The installation stage has an installation surface on which a housing recess for accommodating a stamp layer of the stamp tool is formed, and a suction hole capable of detachably adsorbing a part of the stamp tool located around the stamp layer is formed on the installation surface.

TECHNICAL FIELD

The present invention relates to a stamp tool holding device, a stamp tool positioning device, a multi-element transfer device, and a method of manufacturing an element array.

BACKGROUND ART

In transport of an extremely small part, use of a stamp-shaped transport tool (stamp tool) having a large number of projections on a surface thereof has been studied. Patent Document 1 below discloses an example of the stamp-shaped transport tool. Conventionally, a stamp tool for allowing detachment of an object to be transported by a coefficient of thermal expansion has been disclosed.

An LED element referred to as a mini-LED or a micro-LED is an example of an extremely small part assumed to be an object to be transported of a stamp tool. The mini-LED or the micro-LED has a width of 1 to 8 μm, a length of 5 to 10 μm, and height of 0.5 to 3 μm, which are extremely smaller than those of a conventional general LED element.

As in a conventional art, an LED display is manufactured by picking up elements from a wafer on which a plurality of such LED elements is disposed and transporting the elements to a substrate corresponding to a display. However, there is a desire for a device and method for efficiently transferring a transport object element such as an element using the stamp tool.

SUMMARY

The present invention has been made in view of such actual circumstances, and an object thereof is to provide a stamp tool holding device capable of holding a stamp tool while keeping a stamp surface of the stamp tool clean, a stamp tool positioning device that easily positions a stamp tool with respect to a transport head, a multi-element transfer device for efficiently transferring a transport object element such as an element using a stamp tool, and a method of manufacturing an element array using the same.

To achieve the above-mentioned object, a stamp tool holding device according to the present invention is a stamp tool holding device including an installation stage for a stamp tool including a stamp layer having a portion allowed to detachably adhere to a transport object element to be detachably installed on the installation stage,

in which the installation stage has an installation surface on which a housing recess for accommodating the stamp layer is formed, and a suction hole capable of detachably adsorbing a part of the stamp tool located around the stamp layer is formed on the installation surface.

In the stamp tool holding device according to the present invention, by introducing a negative pressure into the suction hole in a state where the stamp layer is accommodated inside the housing recess, a part of the stamp tool is detachably adsorbed to the installation surface. As a result, the inside of the housing recess is sealed, dirt, dust, etc. are less likely to adhere to the stamp surface of the stamp layer accommodated inside the housing recess, and the stamp tool may be installed while keeping the stamp surface clean.

Preferably, the installation stage is detachably fixed to a base. The stamp tool needs to be replaced according to a request from a customer, the substrate (the substrate may be a sheet/which is similarly applied hereinafter) on which the element serving as the transport object element is built, etc. By preparing a plurality of installation stages according to a change of the stamp tool, the base does not need to be replaced, and by exchanging only the installation stage, a size change of the stamp tool may be addressed. In addition, a degree of flatness of each installation stage with respect to the base is preferably ensured, and there is no need to adjust the degree of flatness when the stamp tool is replaced.

Preferably, a gas flow hole for communicating with a space inside the housing recess to replace gas inside the housing recess is formed in the installation stage. By replacing gas in the recess, dirt, dust, etc. adhering to the surface of the stamp layer accommodated inside the housing recess can be discharged together with the gas, and a degree of cleanliness of the stamp layer can be improved.

A guide means is provided on an upper part of the installation stage at least along a first axis so that the stamp layer of the stamp tool drops into the housing recess. By providing the guide means on the installation stage, rough positioning of the stamp tool at least along the first axis (a second axis may be included) is facilitated. In addition, when the stamp tool is picked up by the transport head, positioning of the stamp tool with respect to the transport head is facilitated.

Preferably, the guide means includes guide members detachably provide on both sides of the installation stage along the first axis, and an inclined surface allowed to be engaged with a tapered surface of the stamp tool is formed on each of the guide members. With such a configuration, rough positioning of the stamp tool at least along the first axis (the second axis may be included) is further facilitated. In addition, when the stamp tool is picked up by the transport head, positioning of the stamp tool with respect to the transport head is further facilitated.

Preferably, at least two guide members are provided on each of the both sides of the installation stage along the first axis, and a claw portion of a chuck mechanism (also referred to as a clamping mechanism/which is similarly applied hereinafter) is insertable along a gap between the two guide members. With such a configuration, accurate positioning of the stamp tool may be performed at least along the first axis (the second axis may be included). In addition, when the stamp tool is picked up by the transport head, positioning (particularly positioning along the first axis) of the stamp tool with respect to the transport head becomes more accurate.

Preferably, the stamp tool holding device further includes a pair of positioning members disposed on both sides of the installation stage along a second axis direction and allowed to move to come into contact with and be separated from edge portions of the stamp tool installed on the upper part of the installation stage. Such a configuration enables high-accurate positioning of the stamp tool along the second axis in addition to the first axis. In addition, when the stamp tool is picked up by the transport head, positioning of the stamp tool with respect to the transport head is further facilitated.

A method of manufacturing an element array according to a first aspect of the present invention includes

picking up a stamp tool held by the stamp tool holding device according to any one of the above descriptions using a transport head, and

taking out transport object elements simultaneously from a substrate and transporting using the stamp tool attached on the transport head.

In the method of manufacturing the element array according to the first aspect of the present invention, the element array having the plurality of elements may be easily manufactured in a short time and at a low cost.

A method of manufacturing an element array according to a second aspect of the present invention includes

preparing stamp tool holding devices according to any one of the above descriptions, the number of which is equal to or greater than the number of substrates, on which each of substrates a plurality of types of elements serving as the transport object element,

installing a stamp tool prepared for each of the plurality of types of elements on each of the stamp tool holding devices,

picking up the stamp tool held by each of the stamp tool holding devices corresponding to each of the substrates from the stamp tool holding device using a transport head, and taking out the elements simultaneously and transporting them using the stamp tool attached on the transport head from a substrate corresponding to the stamp tool picked up, and

returning the stamp tool after the elements are taken out to a corresponding one of the stamp tool holding devices after elements are simultaneously taken out and transported.

In the method of manufacturing the element array according to the second aspect of the present embodiment, the element array in which the plurality of types of elements is arranged may be easily manufactured in a short time and at a low cost. Moreover, since the stamp tool used in accordance with each substrate corresponding to each of the plurality of types of elements is installed and stored in the dedicated stamp tool holding device, it is easy to maintain a degree of cleanliness of the stamp surface of each stamp tool at a high level while effectively preventing misalignment of the elements.

Preferably, the stamp tool includes

a stamp layer having a portion allowed to detachably adhere to a transport object element to be detachably installed on the installation stage,

a support plate, the stamp layer being fixed to the support plate, and

an adapter plate having a mounting surface, the support plate being replaceably attached thereto, and a transport head being allowed to be detachably attached thereon.

In this stamp tool, only the support plate to which the stamp layer is fixed can be replaced from the adapter plate without replacing the entire stamp tool. Therefore, it becomes easier to prepare stamp tool having different types of stamp layers at a low cost. In addition, even when the size of the stamp layer or the size of the support plate is changed, it becomes easy to unify the size of the adapter plate, and it becomes easy to share the transport head or an installation stage. In addition, since the stamp layer is fixed to the support plate, it is easy to ensure a degree of flatness of the stamp surface of the stamp layer.

Preferably, the support plate is replaceably attached to the adapter plate by an adhesive layer. By using the adhesive layer, the support plate can be easily replaceably attached to the adapter plate, and the degree of flatness of the support plate, that is, the degree of flatness of the stamp surface of the stamp layer can be easily ensured.

Preferably, the transport object element is a plurality of elements formed on a surface of a substrate, a plurality of projections corresponding to the elements is formed on the stamp layer, and the elements detachably adhere to the respective projections. With such a configuration, it becomes easy to take out a plurality of elements as a plurality of transport object elements from the substrate at the same time and transfer or mount the elements.

Preferably, the support plate has a glass plate or a ceramic plate having a flat surface. With such a configuration, it is easy to ensure the degree of flatness of the support plate, that is, the degree of flatness of the stamp surface of the stamp layer. In addition, in particular, when the support plate is made of a glass plate, it becomes easier to form an adsorbable surface around the stamp layer.

Preferably, a tapered surface having an outer diameter decreasing toward the support plate is formed on a side surface of the adapter plate. A claw portion of a clamping mechanism can be detachably engaged with the tapered surface formed on the side surface of the adapter plate. In addition, a mounting force of the stamp tool to the transport head by the clamping mechanism can be increased. Further, positioning of the stamp tool is facilitated along an inclined surface of a guide member installed in an upper part of the installation stage for the stamp tool.

Preferably, a maximum width of the adapter plate is set to be larger than a width of the support plate. With such a configuration, engagement between the inclined surface of the guide member and the tapered surface of the stamp tool is facilitated.

Preferably, an insertable surface facing the tapered surface of the adapter plate is present on a surface of the support plate on a side of the adapter plate. The presence of the insertable surface on the support plate of the stamp tool facilitates detachable engagement of the claw portion of the clamping mechanism with the tapered surface on the side surface of the adapter plate.

Preferably, an adsorbable surface is formed around the stamp layer on a surface of the support plate on a side of the stamp layer. When the adsorbable surface is present on the support plate of the stamp tool, the support plate can be adsorbed to an installation surface of the installation stage for the stamp tool, which facilitates sealing and holding of the stamp layer inside the housing recess. The stamp layer in the housing recess is kept clean.

A shim plate for adjusting a degree of parallelism (a degree of flatness) of the support plate may be interposed between the stamp layer and the adapter plate. With such a configuration, the degree of flatness of the support plate is improved, and the degree of flatness of the stamp surface is improved.

A method of manufacturing an element array according to a third aspect the present invention includes simultaneously taking out and transporting a plurality of transport object elements from a substrate using any one of the above-described the stamp tools. In the method of manufacturing an element array according to the present invention, the element array having the plurality of elements can be easily manufactured in a short time and at a low cost.

In addition, to achieve the above-mentioned object, a stamp tool positioning device according to the present invention includes

an installation stage, a stamp tool having a stamp layer having a portion being detachably installed on the installation stage, a transport object element being allowed to detachably adhere to the portion,

a transport head capable of picking up the stamp tool installed on the installation stage,

a first axis positioning mechanism configured to position and adjust a relative position of the stamp tool with respect to the transport head along a first axis, and

a second axis positioning mechanism configured to position and adjust a relative position of the stamp tool with respect to the installation stage along a second axis intersecting the first axis.

When it is presumed that all positioning of the stamp tool along the first axis and the second axis is performed with respect to the transport head, a positioning mechanism with respect to the transport head becomes complicated. As a result, driving control of the transport head becomes complicated, and the transport position accuracy of the transport head may deteriorate. In addition, when it is presumed that all positioning of the stamp tool along the first axis and the second axis is performed with respect to the installation stage, the positioning mechanism on the installation stage may become complicated, a required for the installation stage may become large, and movement control of the installation stage becomes difficult. Further, positioning between the installation stage and the transport head becomes complicated.

In the stamp tool positioning device of the present invention, positioning of the stamp tool along the second axis may be performed using the second axis positioning mechanism with respect to the installation stage, and positioning of the stamp tool along the first axis may be performed using the first axis positioning mechanism with respect to the transport head. Therefore, the positioning mechanism with respect to the transport head becomes simple and lightweight. As a result, driving control of the transport head is facilitated, and the transport position accuracy of the transport head is improved.

In addition, in the stamp tool positioning device of the present invention, positioning of the stamp tool along the second axis is performed with respect to the installation stage. However, accurate positioning of the stamp tool along the first axis is unnecessary. Therefore, the positioning mechanism on the installation stage is simplified, and the space required for the installation stage can be minimized. Therefore, movement control of the installation stage is facilitated. Further, positioning between the installation stage and the transport head may be performed with high accuracy only along the second axis, for example, and positioning along the first axis may be rough since positioning of the stamp tool along the first axis is performed by the first positioning mechanism with respect to the transport head.

Preferably, the first axis positioning mechanism additionally serves as a attaching means for detachably attaching the stamp tool on the transport head. Since the attaching means additionally serves as the positioning mechanism, there is no need to equip the transport head with a separate positioning mechanism as a part other than the attaching means.

In addition, even though the attaching means is not particularly limited, for example, a chuck mechanism (hereinafter also referred to as a “clamping mechanism”), etc. is illustrated. Chuck mechanisms are provided on mutually opposite sides of the transport head along the first axis, and are provided to be movable to come into contact with and be separated from the stamp tool.

Preferably, the second axis positioning mechanism includes at least a pair of second positioning members disposed on both sides of the installation stage along a direction of the second axis and allowed to move to come into contact with and be separated from the stamp tool installed on the installation stage.

With such a configuration, highly accurate positioning of the stamp tool along the second axis may be performed with respect to the installation stage. In addition, when the stamp tool is picked up by the transport head, positioning of the stamp tool with respect to the transport head is further facilitated.

Preferably, the installation stage has an installation surface on which a housing recess for accommodating the stamp layer is formed, and a suction hole capable of detachably adsorbing a part of the stamp tool located around the stamp layer is formed on the installation surface.

With such a configuration, by introducing a negative pressure into the suction hole in a state where the stamp layer is accommodated inside the housing recess, a part of the stamp tool is detachably adsorbed to the installation surface. As a result, the inside of the housing recess is sealed, dirt, dust, etc. are less likely to adhere to the stamp surface of the stamp layer accommodated inside the housing recess, and the stamp tool may be installed while keeping the stamp surface clean.

Preferably, the installation stage is detachably fixed to a base. The stamp tool needs to be replaced according to a request from a customer, the substrate (the substrate may be a sheet/which is similarly applied hereinafter) on which the element serving as the transport object element is built, etc. By preparing a plurality of installation stages according to a change of the stamp tool, the base does not need to be replaced, and by exchanging only the installation stage, a size change of the stamp tool may be addressed. In addition, a degree of flatness of each installation stage with respect to the base is preferably ensured, and there is no need to adjust the degree of flatness when the stamp tool is replaced.

Preferably, a gas flow hole for communicating with a space inside the housing recess to replace gas inside the housing recess is formed in the installation stage. By replacing gas in the recess, dirt, dust, etc. adhering to the surface of the stamp layer accommodated inside the housing recess can be discharged together with the gas, and a degree of cleanliness of the stamp layer can be improved.

Preferably, a guide means for guiding the stamp tool at least along a first axis is attached on the installation stage. By providing the guide means on the installation stage, rough positioning of the stamp tool at least along the first axis is facilitated. In addition, when the stamp tool is picked up by the transport head, highly accurate positioning of the stamp tool along the first axis with respect to the transport head is facilitated.

Preferably, the guide means includes a plurality of guide members detachably attached on both sides of the installation stage along the first axis. Preferably, an inclined surface allowed to be engaged with a tapered surface of the stamp tool is formed on each of the guide members. With such a configuration, rough positioning of the stamp tool at least along the first axis is further facilitated.

Preferably, at least two guide members are attached on each of the both sides of the installation stage along the first axis, and the first axis positioning mechanism is allowed to be in contact with the stamp tool by being inserted along a gap between the two guide members. With such a configuration, highly accurate positioning of the stamp tool with respect to the transport head becomes easy while having a simple configuration.

A method of manufacturing an element array of the present invention includes

transporting a stamp tool positioned by the stamp tool positioning device according to any one of the above descriptions using a transport head, and

taking out transport object elements simultaneously from a substrate and transporting them using the stamp tool attached on the transport head.

In the method of manufacturing the element array of the present invention, an element array having a plurality of elements positioned and arranged with high accuracy can be easily manufactured in a short time and at a low cost.

Preferably, the stamp tool includes

a stamp layer having a portion allowing a transport object element to detachably adhere thereto,

a support plate, the stamp layer being fixed to the support plate, and

an adapter plate having a mounting surface, the support plate being replaceably attached thereto, and a transport head being allowed to be detachably attached thereon.

In this stamp tool, only the support plate to which the stamp layer is fixed can be replaced from the adapter plate without replacing the entire stamp tool. Therefore, it becomes easier to prepare stamp tool having different types of stamp layers at a low cost. In addition, even when the size of the stamp layer or the size of the support plate is changed, it becomes easy to unify the size of the adapter plate, and it becomes easy to share the transport head or an installation stage. In addition, since the stamp layer is fixed to the support plate, it is easy to ensure a degree of flatness of the stamp surface of the stamp layer.

Preferably, the support plate is replaceably attached to the adapter plate by an adhesive layer. By using the adhesive layer, the support plate can be easily replaceably attached to the adapter plate, and the degree of flatness of the support plate, that is, the degree of flatness of the stamp surface of the stamp layer can be easily ensured.

Preferably, the transport object element is a plurality of elements formed on a surface of a substrate, a plurality of projections corresponding to the elements is formed on the stamp layer, and the elements detachably adhere to the respective projections. With such a configuration, it becomes easy to take out a plurality of elements as a plurality of transport object elements from the substrate at the same time and transfer or mount the elements.

Preferably, the support plate has a glass plate or a ceramic plate having a flat surface. With such a configuration, it is easy to ensure the degree of flatness of the support plate, that is, the degree of flatness of the stamp surface of the stamp layer. In addition, in particular, when the support plate is made of a glass plate, it becomes easier to form an adsorbable surface around the stamp layer.

Preferably, a tapered surface having an outer diameter decreasing toward the support plate is formed on a side surface of the adapter plate. A claw portion of a clamping mechanism can be detachably engaged with the tapered surface formed on the side surface of the adapter plate. In addition, a mounting force of the stamp tool to the transport head by the clamping mechanism can be increased. Further, positioning of the stamp tool is facilitated along an inclined surface of a guide member installed in an upper part of the installation stage for the stamp tool.

Preferably, a maximum width of the adapter plate is set to be larger than a width of the support plate. With such a configuration, engagement between the inclined surface of the guide member and the tapered surface of the stamp tool is facilitated.

Preferably, an insertable surface facing the tapered surface of the adapter plate is present on a surface of the support plate on a side of the adapter plate. The presence of the insertable surface on the support plate of the stamp tool facilitates detachable engagement of the claw portion of the clamping mechanism with the tapered surface on the side surface of the adapter plate.

Preferably, an adsorbable surface is formed around the stamp layer on a surface of the support plate on a side of the stamp layer. When the adsorbable surface is present on the support plate of the stamp tool, the support plate can be adsorbed to an installation surface of the installation stage for the stamp tool, which facilitates sealing and holding of the stamp layer inside the housing recess. The stamp layer in the housing recess is kept clean.

A shim plate for adjusting a degree of parallelism (a degree of flatness) of the support plate may be interposed between the stamp layer and the adapter plate. With such a configuration, the degree of flatness of the support plate is improved, and the degree of flatness of the stamp surface is improved.

In addition, to achieve the above-mentioned object, a multi-element transfer device according to the present invention includes

a stamp table, at least one stamp tool including a stamp layer having a portion allowed to detachably adhere to transport object elements be detachably installed on the stamp table,

a transport head capable of picking up the at least one stamp tool installed on the stamp table,

a first table on which a first substrate having the transport object elements on a surface of the first substrate is detachably fixed, and

a second table on which a second substrate having a surface is detachably fixed, the transport object elements disposed on the first substrate being transported by the stamp tool and moved to the surface of the second substrate, in which

the stamp table and the first table are disposed along a first axis,

the first table and the second table are disposed along a second axis intersecting the first axis,

the transport head is movable relative to at least the stamp table along a third axis intersecting both the first axis and the second axis,

the stamp tool has a mounting surface to which the transport head is detachably attached on an opposite side from the stamp layer,

the stamp tool is attached to the stamp table so that the mounting surface faces upward along the third axis,

the first table and the second table are movable relative to the transport head along at least the second axis, and

the stamp table is movable relative to the transport head along at least the first axis.

In the multi-element transfer device according to the present invention, the stamp tool is attached to the stamp table so that the mounting surface faces upward along the third axis, the first table and the second table are movable relative to the transport head at least along the second axis, and the stamp table is movable relative to the transport head at least along the first axis.

Therefore, the transport head can relatively move on the stamp table, the first table, and the second table. In addition, the stamp tool held by the transport head may be used to simultaneously transfer the plurality of transport object elements from the surface of the first substrate of the first table to the surface of the second substrate of the second table. In addition, the stamp tool after transferring the transport object elements from the first substrate to the second substrate is returned to the original stamp table using the transport head. As described above, in the multi-element transfer device of the present invention, the stamp tool may be used to efficiently transfer the transport object elements such as the elements.

In addition, when the transport object elements such as a plurality of types of elements are transferred from a plurality of first substrates corresponding thereto, respectively, to a single second substrate, the transport object elements may be transferred using a different stamp tool for each type. Therefore, it is easy to transfer different types of transport object elements to the single second substrate in a set arrangement. For example, it is easy to efficiently manufacture an element array having few pixel defects.

Preferably, the first substrate includes placement substrates, each of which has the transport object elements having mutually different types on each substrates,

the second substrate is a single mounting substrate or a single transfer substrate, and

the stamp table includes installation stages detachably holding stamp tools corresponding to the element placement substrates, respectively.

In addition, preferably, the multi-element transfer device further includes a control means configured to driving-control a positional relationship among the transport head, the first table, the second table, and the stamp table

so that the transport head picks up the stamp tool corresponding to each of the plurality of element placement substrates from a corresponding one of the installation stages,

takes out one type of the transport object elements from the corresponding element placement substrate using the stamp tool picked up, and transfers the transported elements taken out to the second substrate.

With such a configuration, when the transport object elements such as a plurality of types of elements are transferred from a plurality of element placement substrates corresponding thereto, respectively, to a single second substrate, the transport object elements may be transferred using a different stamp tool for each type. Therefore, it is easy to transfer different types of transport object elements to the single second substrate in a set arrangement. For example, it is easy to efficiently manufacture an element array having few pixel defects.

Preferably, the multi-element transfer device further includes an imaging means capable of performing simultaneous imaging in two directions, the imaging means being allowed to enter a space between a surface of the first substrate and the stamp layer of the stamp tool when the transport head holding the stamp tool is located on the first substrate,

in which the imaging means simultaneously captures images of a stamp surface of the stamp layer and the surface of the first substrate.

Preferably, the multi-element transfer device further includes a fine adjustment mechanism configured to change a relative position between the transport head and the first substrate based on a detection signal captured by the imaging means. By adjusting the relative position between the transport head and the first substrate using the fine adjustment mechanism, accurate positioning between the stamp layer of the stamp tool and the transport object element disposed on the surface of the first substrate is performed, and a plurality of small-sized transport object elements may be held with high accuracy on the stamp surface of the stamp layer.

The fine adjustment mechanism may change a relative rotation angle of the transport head around the third axis based on the detection signal captured by the imaging means. With such a configuration, positioning between the stamp surface of the stamp layer and the transport object element disposed on the surface of the first substrate becomes more accurate.

Preferably, the multi-element transfer device includes

a first axis positioning mechanism configured to position and adjust a relative position of the stamp tool with respect to the transport head along the first axis, and

a second axis positioning mechanism configured to position and adjust a relative position of the stamp tool with respect to the stamp table along the second axis intersecting the first axis.

With such a configuration, positioning of the stamp tool along the second axis may be performed using the second axis positioning mechanism with respect to the stamp table, and positioning of the stamp tool along the first axis may be performed using the first axis positioning mechanism with respect to the transport head. Therefore, the positioning mechanism with respect to the transport head becomes simple and lightweight. As a result, driving control of the transport head is facilitated, and the transport position accuracy of the transport head is improved.

In addition, positioning of the stamp tool along the second axis is performed with respect to the stamp table. However, accurate positioning of the stamp tool along the first axis is unnecessary. Therefore, the positioning mechanism on the stamp table is simplified, and the space required for the stamp table can be minimized. Therefore, movement control of the stamp table is facilitated. Further, positioning between the stamp table and the transport head may be performed with high accuracy only along the second axis, for example, and positioning along the first axis may be rough since positioning of the stamp tool along the first axis is performed by the first positioning mechanism with respect to the transport head.

Preferably, the first axis positioning mechanism additionally serves as a attaching means for detachably mounting the stamp tool on the transport head. Since the attaching means additionally serves as the positioning mechanism, there is no need to equip the transport head with a separate positioning mechanism as a part other than the attaching means.

In addition, even though the attaching means is not particularly limited, for example, a chuck mechanism (clamping mechanism), etc. is illustrated. Chuck mechanisms are provided on mutually opposite sides of the transport head along the first axis, and are provided to be movable to come into contact with and be separated from the stamp tool.

Preferably, the second axis positioning mechanism includes at least a pair of second positioning members disposed on both sides of the installation stage fixed to the stamp table along a direction of the second axis and allowed to move to come into contact with and be separated from the stamp tool installed on the installation stage.

With such a configuration, highly accurate positioning of the stamp tool along the second axis may be performed with respect to the installation stage. In addition, when the stamp tool is picked up by the transport head, positioning of the stamp tool with respect to the transport head is further facilitated.

Preferably, the installation stage has an installation surface on which a housing recess for accommodating the stamp layer is formed, and a suction hole capable of detachably adsorbing a part of the stamp tool located around the stamp layer is formed on the installation surface.

With such a configuration, by introducing a negative pressure into the suction hole in a state where the stamp layer is accommodated inside the housing recess, a part of the stamp tool is detachably adsorbed to the installation surface. As a result, the inside of the housing recess is sealed, dirt, dust, etc. are less likely to adhere to the stamp surface of the stamp layer accommodated inside the housing recess, and the stamp tool may be installed while keeping the stamp surface clean.

Preferably, the installation stage is detachably fixed to a base fixed to the stamp table. The stamp tool needs to be replaced according to a request from a customer, the substrate on which the element serving as the transport object element is built, etc. By preparing a plurality of installation stages according to a change of the stamp tool, the base does not need to be replaced, and by exchanging only the installation stage, a size change of the stamp tool may be addressed. In addition, a degree of flatness of each installation stage with respect to the base is preferably ensured, and there is no need to adjust the degree of flatness when the stamp tool is replaced.

Preferably, a gas flow hole for communicating with a space inside the housing recess to replace gas inside the housing recess is formed in the installation stage. By replacing gas in the recess, dirt, dust, etc. adhering to the surface of the stamp layer accommodated inside the housing recess can be discharged together with the gas, and a degree of cleanliness of the stamp layer can be improved.

Preferably, a guide means for guiding the stamp tool at least along a first axis is attached on the installation stage. By providing the guide means on the installation stage, rough positioning of the stamp tool at least along the first axis is facilitated. In addition, when the stamp tool is picked up by the transport head, highly accurate positioning of the stamp tool along the first axis with respect to the transport head is facilitated.

Preferably, the guide means includes a plurality of guide members detachably attached on both sides of the installation stage along the first axis. Preferably, an inclined surface allowed to be engaged with a tapered surface of the stamp tool is formed on each of the guide members. With such a configuration, rough positioning of the stamp tool at least along the first axis is further facilitated.

Preferably, at least two guide members are attached on each of the both sides of the installation stage along the first axis, and the first axis positioning mechanism is allowed to be in contact with the stamp tool by being inserted along a gap between the two guide members. With such a configuration, highly accurate positioning of the stamp tool with respect to the transport head becomes easy while having a simple configuration.

A method of manufacturing an element array of the present invention is characterized by taking out transport object elements simultaneously from a substrate using the multi-element transfer device according to any one of the above descriptions, and manufacturing the element array.

In the method of manufacturing the element array of the present invention, the element array having the plurality of elements positioned and arranged with high accuracy may be easily manufactured in a short time and at a low cost.

Preferably, the stamp tool includes

a stamp layer having a portion allowing a transport object element to detachably adhere thereto,

a support plate, the stamp layer being fixed to the support plate, and

an adapter plate having a mounting surface, the support plate being replaceably attached thereto, and a transport head being allowed to be detachably attached thereon.

In this stamp tool, only the support plate to which the stamp layer is fixed can be replaced from the adapter plate without replacing the entire stamp tool. Therefore, it becomes easier to prepare stamp tool having different types of stamp layers at a low cost. In addition, even when the size of the stamp layer or the size of the support plate is changed, it becomes easy to unify the size of the adapter plate, and it becomes easy to share the transport head or an installation stage. In addition, since the stamp layer is fixed to the support plate, it is easy to ensure a degree of flatness of the stamp surface of the stamp layer.

Preferably, the support plate is replaceably attached to the adapter plate by an adhesive layer. By using the adhesive layer, the support plate can be easily replaceably attached to the adapter plate, and the degree of flatness of the support plate, that is, the degree of flatness of the stamp surface of the stamp layer can be easily ensured.

Preferably, the transport object element is a plurality of elements formed on a surface of a substrate, a plurality of projections corresponding to the elements is formed on the stamp layer, and the elements detachably adhere to the respective projections. With such a configuration, it becomes easy to take out a plurality of elements as a plurality of transport object elements from the substrate at the same time and transfer or mount the elements.

Preferably, the support plate has a glass plate or a ceramic plate having a flat surface. With such a configuration, it is easy to ensure the degree of flatness of the support plate, that is, the degree of flatness of the stamp surface of the stamp layer. In addition, in particular, when the support plate is made of a glass plate, it becomes easier to form an adsorbable surface around the stamp layer.

Preferably, a tapered surface having an outer diameter decreasing toward the support plate is formed on a side surface of the adapter plate. A claw portion of a clamping mechanism (chuck mechanism) can be detachably engaged with the tapered surface formed on the side surface of the adapter plate. In addition, a mounting force of the stamp tool to the transport head by the clamping mechanism can be increased. Further, positioning of the stamp tool is facilitated along an inclined surface of a guide member installed in an upper part of the installation stage for the stamp tool.

Preferably, a maximum width of the adapter plate is set to be larger than a width of the support plate. With such a configuration, engagement between the inclined surface of the guide member and the tapered surface of the stamp tool is facilitated.

Preferably, an insertable surface facing the tapered surface of the adapter plate is present on a surface of the support plate on a side of the adapter plate. The presence of the insertable surface on the support plate of the stamp tool facilitates detachable engagement of the claw portion of the clamping mechanism with the tapered surface on the side surface of the adapter plate.

Preferably, an adsorbable surface is formed around the stamp layer on a surface of the support plate on a side of the stamp layer. When the adsorbable surface is present on the support plate of the stamp tool, the support plate can be adsorbed to an installation surface of the installation stage for the stamp tool, which facilitates sealing and holding of the stamp layer inside the housing recess. The stamp layer in the housing recess is kept clean.

A shim plate for adjusting a degree of parallelism (a degree of flatness) of the support plate may be interposed between the stamp layer and the adapter plate. With such a configuration, the degree of flatness of the support plate is improved, and the degree of flatness of the stamp surface is improved.

DETAILED DESCRIPTION

Hereinafter, the present invention will be described based on embodiments illustrated in the drawings.

First Embodiment

As illustrated inFIGS.9to11, a multi-element transfer device200includes a transport device20, a stamp table100, an element table102serving as a first table, and a mounting table104serving as a second table. As illustrated inFIG.2A, the transport device20has a transport head22that detachably transports the stamp tool10.

First, the stamp tool10will be mainly described. As illustrated inFIG.1A, the stamp tool10includes a stamp layer12, a support plate14, and an adapter plate16.

On the stamp layer12, projections11protruding downward along a Z-axis are formed in a matrix at predetermined intervals in an X-axis direction and a Y-axis direction. For example, an X-axis direction width x1of the projections11and an X-axis direction interval x2of adjacent projections11are determined according to an X-axis direction width x3, an X-axis direction interval x4, etc. of elements (an example of a transport object element)32rfor red light emission mounted on a surface of a mounting substrate (hereinafter the substrate may be a sheet) illustrated inFIG.5F.

Note that although not illustrated inFIG.1A, the above description is similarly applied to a Y-axis direction width of the projections11and a Y-axis direction interval of adjacent projections11. The projections11are disposed in a matrix on a lower surface of the stamp layer12, and the number of projections disposed is not particularly limited, and is one to several hundred thousand.

In the present embodiment, in the drawings, an X-axis (first axis), a Y-axis (second axis), and the Z-axis (third axis) are substantially perpendicular to one another, the X-axis and Y-axis are parallel to a planar direction of the stamp layer12, and the Z-axis is parallel to a direction in which the projections11protrude.

As illustrated inFIG.1A, a protrusion height z1of the projections11of the stamp layer12is determined in relation to a Z-axis direction height z2of the elements32rillustrated inFIG.5B, and is preferably, for example, 1 to 8 times the Z-axis direction height z2. A Z-axis direction thickness z3of the stamp layer12is not particularly limited, and is preferably about 0.25 times or more the protrusion height z1of the projections11. Note that the X-axis direction width x3(the Y-axis direction width is about the same) of the elements32ris, for example, 1 to 150 μm, and the height z2is, for example, 1 to 150 μm.

The stamp layer12and the projections11may be made of different materials as long as the stamp layer12and the projections11are strongly bonded, or may be made of the same material. By using the same material, a possibility that the projections11will be peeled from the stamp layer12is reduced. At least the projections11are made of an adhesive material, and are configured to allow the elements32rdisposed with a predetermined fixing force F1on an element forming substrate30illustrated inFIG.5Bto adhere thereto with predetermined adhesion force F2. The material and shape of the projections11are determined so that, when a lower end of a projection11is pressed against an upper surface of an element32rwith a predetermined force, the adhesion force F2of the projection11with respect to the element32rbecomes greater than the fixing force F1of the element32rwith respect to the substrate30.

The material of the projections11is not particularly limited, and examples thereof include polydimethylsiloxane (PDMS), organosilicon compounds, and viscoelastic elastomer such as polyether rubber. The stamp layer12may be made of the same material as that of the projections11, and a surface of the stamp layer12other than the projections11is preferably non-adhesive. It is preferable not to pick up the elements32rby adhesion except for the projections11.

As illustrated inFIG.1A, the stamp layer12is fixed to support plate14. The support plate14is made of a material having higher rigidity and a superior degree of flatness than the stamp layer12, and is preferably made of a glass plate, a metal plate, a ceramic plate, etc. A thickness of the support plate14is not particularly limited, and is preferably 0.5 mm or more.

The stamp layer12may be formed directly on a surface of the support plate14, or may be fixed by an adhesive layer. In any case, the stamp layer12is fixed to the surface of the support plate14with a sticking force sufficiently higher than the adhesion force F2illustrated inFIG.5B. In a post-process, the element32ris peeled off from the projection11and disposed on, for example, a mounting substrate70illustrated in FIG.5C1. Thus, at that time, it is important that the stamp layer12does not peel off from the support plate14.

As illustrated inFIG.1A, the support plate14is detachably fixed to an adhesive surface16bof the adapter plate16by an adhesive layer15on a surface opposite to the stamp layer12. Adhesion between the support plate14and the adapter plate16by the adhesive layer15is adhesion sufficiently higher than the adhesion force F2illustrated inFIG.5B. However, the support plate14can be removed from the adhesive surface16bof the adapter plate16when replacing the stamp layer12after repeated use. The adhesive layer15may include a double-sided adhesive tape, etc.

An X-axis direction width and a Y-axis direction width of the support plate14are preferably larger than those of the stamp layer12, and larger than an X-axis direction width and a Y-axis direction width of the adhesive surface16bof the adapter plate16. On a surface of the support plate14on the stamp layer side, a flat adsorbable surface14b, on which the stamp layer12is not formed, is formed around the stamp layer12. In the present embodiment, the stamp layer12has a rectangular shape when viewed in the Z-axis direction. However, the support plate14may have a rectangular or circular shape. The adsorbable surface14bcan be detachably attached to an installation surface84of an installation stage82illustrated inFIG.7.

An upper surface of the adapter plate16opposite to the adhesive surface16bis a flat mounting surface16a. At least both side surfaces of the adapter plate16in the X-axis direction are tapered surfaces16cso that the area of the mounting surface16ais larger than the area of the adhesive surface16b. That is, the tapered surface16c, outer diameters of which decrease toward the stamp layer12, are formed on at least the side surfaces of the adapter plate16in the X-axis direction.

In the present embodiment, the tapered surfaces16care also formed on the both side surfaces of the adapter plate16in the Y-axis direction, and the tapered surfaces16care formed along the entire circumference of the side surfaces of the adapter plate16. In the present embodiment, the adapter plate16has a rectangular shape when viewed in the Z-axis direction, and at least a maximum X-axis direction width of the adapter plate16is preferably larger than the X-axis direction width of the support plate14. Note that as illustrated inFIG.7, a maximum Y-axis direction width of the adapter plate16may be substantially equal to the Y-axis direction width of the support plate14, or may be larger or smaller than the Y-axis direction width of the support plate14.

On a surface of the support plate14opposite to the adsorbable surface14billustrated inFIG.1A, a flat insertable surface14cfacing the tapered surfaces16cis formed around the adhesive surface16bof the adapter plate16. On the insertable surface14clocated on both sides in the X-axis direction, a claw portion26aof a chuck mechanism (also referred to as a clamping mechanism/first axis positioning mechanism)26illustrated inFIG.2Bis engaged with each of the tapered surfaces16cof the adapter plate16. In addition, an inclined surface89of a guide member88of an installation stage82illustrated inFIGS.6A and8is engaged with each of the tapered surfaces16cof the adapter plate16located on both sides in the X-axis direction.

A thickness of the adapter plate16illustrated inFIG.1Ain the Z-axis direction is sufficiently larger than the thickness of the support plate14, and is preferably 1.2 times or more, and preferably about 2 to 6 times the thickness of the support plate14. Note that an edge portion16dincluding a chamfered portion or an R-portion is formed on an outer peripheral edge portion of the mounting surface16aon the upper surface of the adapter plate16.

Tip surfaces92of a pair of positioning members (second axis positioning mechanism)90illustrated inFIGS.6A to6Ccome into contact with edge portions16dof the adapter plate16located on both sides in the Y-axis direction to position a Y-axis direction position of the stamp tool10placed on the installation stage82. Rough positioning of an X-axis direction position of the stamp tool10is performed by the inclined surface89of the guide member88of illustrated inFIGS.6A and8, and accurate positioning is performed by a claw portion26aof a clamping mechanism26of the transport device20illustrated inFIGS.2B and8.

Next, the transport device will be mainly described. An adsorbing surface24of the transport head22of the transport device20illustrated inFIG.2Acan be adsorbed to the mounting surface16aon the upper surface of the adapter plate16illustrated inFIG.1A. A vacuum suction hole serving as a primary attaching means is formed on the adsorbing surface24of the transport head22, and by generating a negative pressure in the vacuum suction hole, the mounting surface16aof the adapter plate16of the stamp tool10is vacuum-adsorbed to the adsorbing surface24. A vacuum adsorption force of the adsorbing surface24to the mounting surface16aof the adapter plate16of the stamp tool10is assumed to be a primary mounting force F3a.

In addition, in the present embodiment, the chuck mechanism26is attached on the transport head22via an opening/closing mechanism28. The claw portion26ais formed inside the chuck mechanism26. The chuck mechanism26including the claw portion26ais moved, for example, in the X-axis direction by the opening/closing mechanism28, so that the claw portion26aopens the entire lower surface of the adsorbing surface24as illustrated inFIG.2A, or the claw portion26ais located below each of both sides of the adsorbing surface24in the X-axis direction as illustrated inFIG.2B.

A tapered engaging surface26bis formed on each claw portion26a. The tapered surface of the engaging surface26bis adapted to a shape of the tapered surface16cof the adapter plate16of the stamp tool10, and can be engaged with the tapered surface16c. As illustrated inFIGS.2A and2B, before the mounting surface16aof the adapter plate16is adsorbed to the adsorbing surface24of the transport head22, the claw portion26aof the chuck mechanism26is opened by the opening/closing mechanism28. After the mounting surface16aof the adapter plate16is adsorbed to the adsorbing surface24of the transport head22, the chuck mechanism26moves in a direction in which the claw portion26ais closed by the opening/closing mechanism28, and the engaging surface26bis engaged with the tapered surface16c.

As a result, the stamp tool10is attached on the transport head22with a total mounting force F3of a primary mounting force F3agenerated by a vacuum suction hole serving as a primary attaching means formed in the transport head22and a secondary mounting force F3bgenerated by the chuck mechanism26as serving as a secondary attaching means. As the transport head22becomes smaller, the primary mounting force F3aalone generated by the vacuum suction hole of the transport head22tends to hardly become larger than the fixing force F1illustrated inFIG.5B. In the present embodiment, when the secondary mounting force F3bgenerated by the chuck mechanism26serving as the secondary attaching means is added to the primary mounting force F3a, the total mounting force F3(=F3a+F3b) reliably becomes larger than the fixing force F1.

In addition, by attaching the stamp tool10on the transport head22by the chuck mechanism26, the stamp tool10(specifically, the projection of the stamp layer12) is positioned with respect to the transport head22along the X-axis.

(Method of Manufacturing Display Element Array and Device Used for Manufacturing the Same)

Next, a description will be given of a method of manufacturing a display element array using the transport device20having the stamp tool10according to the present embodiment, an installation stage which is a part of a stamp tool positioning device, and other devices.

First, the transport device20illustrated inFIG.2Apicks up the stamp tool10disposed on the installation stage82illustrated inFIGS.6A to8. In the present embodiment, at least three stamp tools are preferably prepared, for example for the three primary colors of light R, G and B, and each stamp tool is preferably installed on each installation stage82. Alternatively, the installation stage82is replaced with respect to a base81for each of the stamp tools10for R, G and B.

The base81of the installation stage82is positioned and fixed on the stamp table100illustrated inFIGS.9to11. For example, the stamp table100is positioned and fixed on an integrated table110. In examples illustrated inFIGS.9to11, only a single stamp table is illustrated to be installed on the integrated table110.

However, on the integrated table110, for example, three stamp tables100to which respective bases81for three installation stages82are fixed, respectively, for the respective stamp tools10for R, G, and B may be arranged side by side at predetermined intervals in the Y-axis direction.

In addition, besides the three stamp tables100, three large stamp tables, to which respective bases for three installation stages are fixed, respectively, may be further arranged side by side with predetermined intervals in the Y-axis direction for the respective stamp tools for R, G, and B having different sizes. These three large stamp tables having different sizes are arranged outside the three stamp tables100having smaller size in the X-axis direction.

In the present embodiment, as illustrated inFIGS.9to11, on the integrated table110, in addition to the stamp table100, the element table102and the mounting table104are positioned and fixed. The element table102is a table on which the element forming substrate30illustrated inFIG.5Ais positioned and detachably fixed.

Note thatFIGS.9to11illustrate that only the single element table102is installed. However, on the integrated table110, for example, three element tables102, on which three element forming substrates30are positioned and detachably fixed for the respective elements32r,32g, and32bfor R, G, and B, respectively, may be arranged side by side at predetermined intervals in the Y-axis direction. Alternatively, in the present embodiment, three element forming substrate element placement substrates30may be positioned and detachably fixed on a single element table102. Note that the element table102and the stamp table100are disposed apart from each other in the X-axis direction on the integrated table110.

The mounting table104is a table on which the mounting substrate70illustrated in FIG.5C1is positioned and detachably fixed. The mounting substrate70is disposed apart from the element table102in the Y-axis direction on the integrated table110. In the present embodiment, a single mounting substrate70is positioned and fixed on the integrated table110. Alternatively, a plurality of mounting substrates70may be positioned and fixed on the integrated table110.

Upper surfaces of the respective tables100,102and104positioned and fixed on the integrated table110are preferably in substantially the same X-Y plane. However, the upper surfaces do not have to be in the same plane. When the upper surfaces of the respective tables100,102and104are in substantially the same X-Y plane, movement amount along the Z-axis of the transport head22relatively moved above the respective tables100,102and104can be made substantially the same, and it becomes easy to control movement of the transport head22along the Z-axis. The transport head22of the transport device20can be moved in the X-axis and Y-axis directions and disposed above the respective tables100,102and104, which are positioned and fixed on the integrated table110, in the Z-axis direction. The integrated table110is configured to be movable relative to the transport head22along the X-Y plane including the X-axis and the Y-axis.

To improve positioning accuracy, it is preferable that the transport head22moves relative to each of the tables100,102and104only in the Z-axis direction, and each of the tables100,102and104moves relative to transport head22along the X-Y plane. Alternatively, the transport head may move only in the X-axis or Y-axis and Z-axis directions, and the respective tables100,102and104may move relative to the transport head22along the Y-axis or the X-axis. Alternatively, the transport head may move in the X-axis, the Y-axis and the Z-axis, and each of the tables100,102and104may be fixed without moving.

In addition, even though the integrated table110illustrated inFIGS.9to11is illustrated as a single member, the integrated table110does not have to be configured as a single member and may be configured as a plurality of members. In addition, the element table102and the mounting table104may be positioned and fixed on the same base and may move in the same direction (for example, the Y-axis direction) in common. Further, apart from the tables102and104, the integrated table110may be separated so that the stamp table100(including stamp tables having different sizes) moves, for example, in the Y-axis direction. In that case, the transport head22is preferably movable not only in the Z-axis direction but also in the X-axis direction.

In the following description, one installation stage82illustrated inFIGS.6A to8will be described. However, the description is similarly applied to the other installation stages. As illustrated inFIGS.6A and7, the block-shaped installation stage82is installed on the base81in a detachable and replaceable manner using bolts, etc. As illustrated inFIG.7, a housing recess86and the installation surface84surrounding the housing recess86are formed in an upper part of the installation stage82in the Z-axis direction. The housing recess86is formed, for example, by counterbore-molding a center of an upper surface of the square pole-shaped stage82. As illustrated inFIG.7, the housing recess86is adapted to completely accommodate the stamp layer12of the stamp tool10.

In addition, suction holes85are formed at a plurality of locations in a circumferential direction on the installation surface84formed around the housing recess86to detachably adsorb and hold the adsorbable surface14bof the support plate14on the installation surface84. In addition, a plurality of gas flow holes83formed in the stage82communicates with the housing recess86. By adsorbing the adsorbable surface14bof the support plate14on the installation surface84, the housing recess86can be sealed except for the gas flow holes83. By allowing cleaning gas to flow into a housing space86through the gas flow holes83, dust and impurities adhering to the stamp layer12can be discharged to the outside.

Two guide members88are detachably attached by bolts, etc. at each side of the stage82on both side surfaces substantially perpendicular to the X-axis. The inclined surface89is formed on an upper side of an inner surface of the guide member88. The tapered surface16cof the adapter plate16illustrated inFIG.1Acan be in contact with each inclined surface89, and the tapered surface16cof the adapter plate16facing in the X-axis direction slides along each inclined surface89. Therefore, the adapter plate16of the stamp tool10is dropped onto the stage82while sliding on the inclined surface89, and the stamp layer12is housed inside the housing recess86as illustrated inFIG.7. In addition, rough positioning of the stamp tool10with respect to the stage82in the X-axis direction is performed.

As illustrated inFIG.6A, four guide members88are attached to the stage82so as to be located inside both edge portions16dof the adapter plate16of the stamp tool10in the Y-axis direction. The positioning members (second axis positioning mechanism)90in the Y-axis direction are disposed on both sides of the stage82in the Y-axis direction so as to be movable in the Y-axis direction. The tip surfaces92are formed on the positioning members90, respectively, these tip surfaces92face each other along the Y-axis, and each of the tip surfaces92can come into contact with the edge portion16dof the adapter plate16in the Y-axis direction as illustrated inFIG.7. The stamp tool10is positioned with respect to the stage82in the Y-axis direction by the tip surface92coming into contact with the edge portion16dof the adapter plate16in the Y-axis direction.

Next, a description will be given of a method of picking up the stamp tool10from the installation stage82illustrated inFIGS.6A and7using the transport device20illustrated inFIG.2A.

First, the positioning members90are used to position the stamp tool10on the stage82in the Y-axis direction. Thereafter, as illustrated inFIG.9, a positional relationship of the X-Y axis between the stamp table100and the transport head22is changed, the stage82illustrated inFIG.8moves together with the base81, and the stage82is positioned below the transport head22of the transport device20as illustrated inFIG.2A. Note that the transport head22may be moved without moving the stage82, or both of the transport head22and the stage82may be moved. The transport head22may be rotated around the Z-axis as necessary.

After the stamp tool10on the stage82is positioned under the transport head22in the Z-axis, the head22is moved downward along the Z-axis so that a lower end of the transport head22is brought into contact with the mounting surface16aof the adapter plate16, and vacuum adsorption by the transport head22is started. Next, as illustrated fromFIG.2AtoFIG.2B, the clamping mechanism26is closed, and the engaging surfaces26bof the claw portions26aare engaged with the tapered surfaces16clocated on both sides of the adapter plate16in the X-axis direction, respectively, to perform positioning in the X-axis direction. In addition, positioning of the stamp tool10in the X-axis direction may be performed by preparing a stopper surface as necessary on the engaging surfaces26bof the claw portion26a, and brining the stopper surface into contact with the edge portion16dof the adapter plate16in the X-axis direction.

Thereafter, the pair of positioning members90illustrated inFIG.7are opened in the Y-axis direction to release contact between the edge portion16dof the adapter plate16and the tip surface92. Before and after the release, adsorption of the support plate14to the installation surface84of the stage by the suction holes85of the stage82is released. Thereafter, when the transport head22is moved upward along the Z-axis, as illustrated inFIG.2B, the stamp tool10is positioned at a lower end of the transport head22in the X-axis and Y-axis and is held in a state where levelness of the stamp tool10is maintained.

Next, in a state where the stamp tool10is attached on the transport head22as illustrated inFIG.2B, the transport device20is relatively moved in the X-axis and Y-axis directions, and is located on the element table102as illustrated inFIG.10. As illustrated inFIG.10, the multi-element transfer device200includes an imaging device122, which serves as an imaging means capable of performing simultaneous imaging in two directions, allowed to enter a space between a surface of the element forming substrate30(seeFIG.3A) installed on the element table102and the stamp layer12of the stamp tool10held by the transport head22. Note that the imaging device122may be retracted from under the transport head22. In addition, when the transport head22moves on the mounting table104, a similar imaging device122may be inserted therebetween.

As illustrated inFIG.3A, the imaging device122can simultaneously capture images of the projection11(seeFIG.2B) on the stamp surface of the stamp layer12and the surface of the element forming substrate30. As illustrated inFIG.10, the imaging device122is communicatively connected to a control device120as control means. The control device120receives a detection signal from the imaging device122and controls a fine adjustment mechanism (not illustrated) that changes a relative position between the transport head22and the device forming substrate30.

The fine adjustment mechanism may include a mechanism for finely adjusting a relative position of the transport head22with respect to the substrate30along the X-axis and the Y-axis, and a mechanism for finely adjusting a relative angle of the transport head22with respect to the substrate30around the Z-axis. In addition, the mechanism for finely adjusting a relative position of the transport head22with respect to the substrate30along the X-axis and the Y-axis may be included in a main drive device for changing a relative position of the transport head22with respect to the element table102(mounting table104or stamp table) along the X-axis and the Y-axis. The main drive device and fine control mechanism are controlled by control device120. In addition, the control device120also controls Z-axis direction movement of the transport device20including the transport head22illustrated inFIG.8, driving of the chuck mechanism26, driving of the positioning members90illustrated inFIG.6A.

On the element table102illustrated inFIG.10, the element forming substrate30is positioned and disposed as illustrated inFIG.3A. As illustrated inFIG.5A, on the surface of the element forming substrate30, for example, an element32rfor red light emission, an element32gfor green light emission, or an element32bfor blue light emission is incorporated. The substrate30may be, for example, a sapphire substrate, a glass substrate, a GaAs substrate, a SiC substrate, etc., depending on the type of device (blue light emitting device, red light emitting device, green light emitting device, etc.).

In the present embodiment, the elements32r,32g, and32bare, for example, micro LED elements. Note that in the following description, only the element32rwill be described. However, the other elements32gand32bare also processed in a similar manner using separate stamp tools10, respectively. The stamp tool10is preferably prepared for each type of the different elements32r,32g, and32b. However, the transport head22may be used in common.

The stamp tool10in a standby state is disposed, for example, on the stage82illustrated inFIGS.6A and7, and the stamp layer12is sealed inside the housing recess86and kept clean. The stamp tool10in the standby state not held by the transport head22may be disposed, for example, on the stamp table100illustrated inFIG.9, and may be disposed on separate stamping tables disposed next to each other along the Y-axis of the table100illustrated inFIG.9.

The imaging device122illustrated inFIG.3Asimultaneously captures images of the projections11(seeFIG.2B) on the stamp surface of the stamp layer12and the surface of the element forming substrate30, a detection signal thereof is received by the control device120illustrated inFIG.10, and a relative position between the transport head22and the element forming substrate30illustrated inFIG.3Ais changed using the fine control mechanism. As a result, arrangement of the projections11on the stamp surface of the stamp layer12and arrangement of the element32rformed on the surface of the substrate30are accurately positioned. As a result, a large number of small-sized elements32rmay be held on the stamp surface of the stamp layer12with high accuracy.

Thereafter, as illustrated fromFIG.3AtoFIG.3B, after the imaging device122is moved from a position below the transport head22and retracted, the transport device20is moved downward in the Z-axis direction to press the projection11of the stamp tool10against an upper surface of the element32rof the substrate30. As a result, the element32radheres to the projection11. Thereafter, as illustrated inFIG.3C, the stamp tool10is lifted upward in the Z-axis direction together with the transport device20. As a result, as illustrated inFIG.5B, the element32radheres to each projection11, and the element32ris picked up from the substrate30together with the projection11. The element32rleft on the substrate30is similarly picked up by the stamp layer12of the transport device20later.

Next, for example, the elements32rpicked up by the projections11of the stamp layer12are transported by the transport device20onto the mounting substrate (the substrate may be a sheet/which is similarly applied hereinafter)70illustrated in FIG.5C1and mounted. The mounting substrate70illustrated in FIG.5C1is positioned and disposed on the mounting table104illustrated inFIG.10. Therefore, as illustrated inFIGS.10and11, the main drive device is driven by the control device120, the element table102and the mounting table104are moved relative to the transport head22in the Y-axis direction, and the transport head22is positioned on the mounting table.

Thereafter, an array of the elements32radhering to the projections11of the stamp layer12illustrated inFIG.5Bis transferred onto the mounting substrate70illustrated in FIG.5C1. To this end, the elements32radhering to the projections11of the stamp layer12are pressed against the surface of the mounting substrate70, and then the stamp layer12is lifted together with the transport device20. As a result, a plurality of elements32ris transferred to the surface of the mounting substrate70at the same time. By repeating the above operation according to the size of the mounting substrate70, a plurality of elements32ris disposed in a matrix on the mounting substrate70. The stamp tool10after use is returned to the stage82of an original stamp tool holding device80installed on the stamp table100by the transport head22.

As illustrated in FIG.5C1, the other elements32gand32bare also transported to the substrate70in a similar manner as described above using the stamp tool10, which is different for each type of the elements32gand32b. Three elements32r,32g, and32bof R, G, and B constitute one pixel unit, and by disposing these pixel units in a matrix, a color display screen can be obtained.

It is preferable that anisotropic conductive paste (ACP) is applied to the surface of the mounting substrate70. Alternatively, it is preferable that an anisotropic conductive film (ACF) is disposed thereon. As illustrated in FIG.5C1, after disposing the elements32r,32g, and32bon the substrate70via the ACP or ACF, the respective elements32r,32g, and32bmay be pressed toward the substrate70and heated using a heating/pressurizing device (not illustrated). As a result, the terminals of each of the elements32r,32g, and32bcan be connected to the circuit pattern of the mounting substrate.

In the transport device20according to the present embodiment, the mounting force F3to the mounting surface16aof the adapter plate16by the transport head22illustrated inFIG.2Bis greater than the fixing force F1illustrated inFIG.5B, and the adhesion force F2of the projection11of the stamp layer12on the element32ris greater than the fixing force F1. Therefore, the stamp tool10can easily pick up the element32rdisposed on the surface of the substrate30from the substrate30and transport the element32rwithout being left on the substrate30side.

In addition, in the present embodiment, the mounting force F3to the mounting surface16aof the adapter plate16by the transport head22illustrated inFIG.2Bis a sum of the primary mounting force F3acorresponding to the adsorption force of the vacuum suction hole and the secondary mounting force F3bgenerated by the clamping mechanism26serving as the secondary attaching means. That is, in the present embodiment, only by providing the clamping mechanism26to a general transport head22having a vacuum suction hole, it becomes easy to set the mounting force F3to the mounting surface16aof the adapter plate16by the transport head22to be greater than the fixing force F1of the element32rto the substrate30illustrated inFIG.5B.

Further, in the present embodiment, on both side surfaces of the adapter plate16in the X-axis direction, the tapered surfaces16care formed to decrease in outer diameter toward the stamp layer12. In addition, the claw portion26aof the clamping mechanism26can be engaged with the tapered surface16c. With this configuration, the claw portion26aof the clamping mechanism26can be easily engaged with the tapered surface16con the side surface of the adapter plate16in a detachable manner. In addition, the mounting force F3of the stamp tool10to the transport head22by the clamping mechanism26can be increased. In addition, by detachably engaging the claw portion26aof the clamping mechanism26with the tapered surface16con the side surface of the adapter plate16, the stamp tool10can be positioned with respect to the transport head22in the X-axis direction at the same time.

In addition, when the tapered surfaces16care formed to decrease in outer diameter toward the stamp layer12on both side surfaces of the adapter plate16in the X-axis direction, rough positioning of the stamp tool10in the X-axis direction is facilitated along the inclined surface89of the guide member88installed in an upper part of the stage82illustrated inFIG.6A. In particular, as illustrated inFIG.1A, when the maximum width of the adapter plate16in the X-axis direction is larger than the width of the support plate14, the inclined surface89of the guide member88and the tapered surface16cof the stamp tool10are easily engaged with each other.

In addition, the presence of the insertable surface14con the support plate14of the stamp tool10facilitates detachable engagement of the claw portion26aof the clamping mechanism26with the tapered surface16con the side surface of the adapter plate16. A reason therefor is that, since a space is formed between the insertable surface14cand the tapered surface16cdue to the presence of the insertable surface14c, an engagement start position can be determined based on the space in positioning when starting engagement of the claw portion26aof the clamping mechanism26with the tapered surface16c. Further, when the adsorbable surface14bis present on the support plate14of the stamp tool10, as illustrated inFIG.7, the support plate14can be adsorbed to the installation surface84of the stage82, and the stamp layer12is easily sealed and held inside the housing recess86. The adsorbable surface14bcan be easily formed around the stamp layer12by configuring the support plate14using a glass plate, etc.

The stamp tool10further includes the support plate14to which the stamp layer12is fixed and to which an adapter plate16is replaceably attached. With this configuration, only the support plate14to which the stamp layer12is fixed can be replaced from the adapter plate16without replacing the entire stamp tool10. Therefore, it becomes easy to prepare the stamp tool10having different types of stamp layers12at a low cost. In addition, by using the adapter plate16in common, it is unnecessary to use different types of transport heads in accordance with the stamp tools, and the overall structure of the transport device can be simplified.

In the present embodiment, the plurality of projections11corresponding to the elements32r(32g,32b) is formed on the stamp layer12, and the elements32r(32g,32b) detachably adhere to the respective projections11. With this configuration, a plurality of elements32r(32g,32b) may be taken out from the substrate30at the same time. In the element array manufacturing method of the present embodiment, an element array having the plurality of elements32r(32g,32b) can be easily manufactured.

In addition, in the present embodiment, as illustrated inFIG.6A, the installation stage82is replaceably attached to the base81. Therefore, the stage82corresponding to the stamp tool10may be prepared, and only the stage82may be replaced when changing to a different type of stamp tool10. Since a degree of flatness of the stage82is ensured with respect to the base81, there is no need to adjust a degree of flatness of the stamp tool10when the stamp tool10is replaced.

Therefore, in the present embodiment, the transport head22can favorably pick up the stamp tool10from the installation stage82without causing an error in adsorption by the transport head22or an error in gripping by the clamping mechanism26.

As illustrated inFIG.7, in the stamp tool holding device80according to the present embodiment, by introducing a negative pressure into the suction hole85in a state where the stamp layer12is accommodated inside the housing recess86, the adapter plate16of the stamp tool10is detachably adsorbed to the installation surface84. As a result, the inside of the housing recess86is sealed, dirt, dust, etc. are less likely to adhere to the stamp surface (projections11) of the stamp layer12accommodated inside the housing recess86, and the stamp tool10may be installed while keeping the stamp surface clean.

In addition, in the present embodiment, the installation stage82is detachably fixed to the base81. The stamp tool10needs to be replaced according to a request from a customer, the substrate30on which the element serving as the transport object element is built, etc. By preparing a plurality of installation stages82according to a change of the stamp tool10, the base81does not need to be replaced, and by exchanging only the installation stage82, the size of the stamp tool10may be changed. In addition, a degree of flatness of each installation stage82with respect to the base81is ensured, and there is no need to adjust the degree of flatness when the stamp tool10is replaced.

Further, in the present embodiment, a gas flow hole83that communicates with a space inside the housing recess86to replace gas inside the housing recess86is formed in the installation stage82. By replacing gas in the recess86, dirt, dust, etc. adhering to the surface of the stamp layer12accommodated inside the housing recess86can be discharged together with the gas, and a degree of cleanliness of the stamp layer12can be improved.

As illustrated inFIG.6A, in the present embodiment, the guide member88is attached in the upper part of the installation stage82to guide the stamp layer12of the stamp tool10at least along the X-axis so that the stamp layer12falls inside the housing recess86. By providing the guide member88on the installation stage82, rough positioning of the stamp tool10at least along the X-axis is facilitated. In addition, when the stamp tool10is picked up by the transport head22, positioning of the stamp tool10with respect to the transport head22is facilitated.

In the present embodiment, the guide member88is detachably attached on each of both sides of the installation stage82along the X-axis, and the inclined surface89that can be engaged with the tapered surface16cof the stamp tool10is formed on each guide member88. With such a configuration, rough positioning of the stamp tool10at least along the X-axis is further facilitated. In addition, when the stamp tool10is picked up by the transport head22, positioning of the stamp tool10with respect to the transport head22is further facilitated.

In the present embodiment, at least two guide members88are attached on each of both sides of the installation stage82along the X-axis, and the claw portion26aof the chuck mechanism26illustrated inFIG.2Ais insertable along a gap between the two guide members88. Such a configuration enables highly accurate positioning of the stamp tool10at least along the X-axis. In addition, when the stamp tool10is picked up by the transport head22, positioning of the stamp tool10with respect to the transport head22(especially positioning along the X-axis) becomes even more accurate.

As illustrated inFIGS.6A to6C, a pair of positioning members90, which can move to come into contact with and be separated from the edge portions16dof the stamp tool10installed in the upper part of the installation stage82, is disposed on both sides of the installation stage82along the Y-axis direction. With such a configuration, it is possible to perform highly accurate positioning of the stamp tool10along the Y-axis in addition to the X-axis. In addition, when the stamp tool10is picked up by the transport head22, positioning of the stamp tool10with respect to the transport head22is further facilitated.

In addition, the stamp tool positioning device of the present embodiment includes the installation stage82illustrated inFIG.7, the transport head22illustrated inFIG.8, the clamping mechanism26serving as the first axis positioning mechanism, and the positioning member90serving as the second axis positioning mechanism. That is, in the present embodiment, positioning of the stamp tool10along the Y-axis is performed using the positioning members90with reference to the installation stage82as illustrated inFIG.7, and positioning of the stamp tool10along the X-axis may be performed using the clamping mechanism26with reference to the transport head22as illustrated inFIG.2B. Therefore, the positioning mechanism for the transport head22can be simplified, and the transport head can be made lighter. As a result, driving control of the transport head22is facilitated, and transport position accuracy of the transport head22is improved.

In addition, in the stamp tool positioning device of the present embodiment, while positioning of the stamp tool10along the Y-axis is performed with respect to the installation stage82, accurate positioning of the stamp tool10along the X-axis is unnecessary. Therefore, a positioning mechanism of the installation stage82is simplified, and a space required for the installation stage82can be minimized. Therefore, movement control of the installation stage82is facilitated. Further, for example, positioning between the installation stage82and the transport head22may be performed with high accuracy only along the Y-axis, and positioning along the X-axis may be rough. A reason therefor is that positioning of the stamp tool10along the X-axis is performed by the clamping mechanism26with reference to the transport head22.

In addition, in the present embodiment, the clamping mechanism26also serves as a attaching means for detachably attaching the stamp tool10on the transport head22. Since the clamping mechanism26serving as the attaching means also serves as a positioning mechanism, it becomes unnecessary to equip the transport head22with a separate positioning mechanism as a part other than the attaching means.

In the multi-element transfer device200according to the present embodiment illustrated inFIG.10, the stamp tool10is attached to the stage82of the stamp table100so that the mounting surface16afaces upward along the Z-axis as illustrated inFIG.8. In addition, as illustrated inFIG.10, the element table102and the mounting table104are relatively movable with respect to the transport head22at least along the Y-axis, and the stamp table100is relatively movable with respect to the transport head22at least along the X axis.

Therefore, the transport head22is relatively movable over the stamp table100, the element table102, and the mounting table104. In addition, using the stamp tool10held by the transport head22, the plurality of elements32r(32g,32b) may be simultaneously transferred from the surface of the element forming substrate30of the element table102to the surface of the mounting substrate70of the mounting table104. In addition, the stamp tool10after transferring the elements32rfrom the element forming substrate30to the mounting substrate70is returned to the original installation stage82of the stamp table100by using the transport head22. As described above, in the multi-element transfer device200of the present embodiment, the stamp tool10may be used to efficiently transfer the plurality of elements32r(32g,32b).

In addition, when a plurality of types of elements32r,32g, and32bis transferred from a plurality of element forming substrates30corresponding thereto, respectively, to the single mounting substrate70, the respective elements32r,32g, and32bmay be transferred using different types of stamp tools10. Therefore, it is easy to transfer the elements32r,32g, and32bof different types to the single mounting substrate70in a set arrangement, and for example, it is easy to efficiently manufacture an element array having few pixel defects.

A method of manufacturing an element array of the present embodiment includes a process of transporting the stamp tool10positioned by the stamp tool positioning device using the transport head22, and

a process of simultaneously taking out and transporting the elements32r(32g,32b) serving as the plurality of transport object elements from the substrate30using the stamp tool10attached on the transport head22.

In the method of manufacturing the element array of the present embodiment, the element array having the plurality of elements positioned and arranged with high precision may be easily manufactured in a short time and at a low cost.

A method of manufacturing an element array according to another embodiment includes

a process of preparing stamp tool holding devices80, the number of which is equal to or greater than the number of substrates30on which the plurality of types of elements serving as the transport object elements is disposed, respectively,

a process of installing the stamp tool10prepared for each of the plurality of types of elements on each of the stamp tool holding devices80,

a process of picking up the stamp tool10held by each stamp tool holding device80corresponding to each substrate30from the stamp tool holding device80using the transport head22, and simultaneously taking out and transporting the plurality of elements32r(or32g,32b) using the stamp tool10attached on the transport head22from the substrate30corresponding to the stamp tool10picked up, and

a process of returning the stamp tool10after the plurality of elements32r(or32g,32b) is taken out to the corresponding empty stamp tool holding device80after the plurality of elements32r(or32g,32b) is simultaneously taken out and transported.

In the method of manufacturing the element array according to the present embodiment, the element array in which the plurality of types of elements32r,32g, and32bis arranged may be easily manufactured in a short time and at a low cost. Moreover, since the stamp tool10used in accordance with each substrate30corresponding to each of the plurality of types of elements32r,32g, and32bis installed and stored in the dedicated stamp tool holding device80, it is easy to maintain a degree of cleanliness of the stamp surface of each stamp tool10at a high level while effectively preventing misalignment of the elements32r,32g, and32b.

Second Embodiment

As illustrated inFIG.1B, in a stamp tool10aused in a transport device of the present embodiment, a shim plate18is interposed between the stamp layer12and the adapter plate16to adjust a degree of parallelism of the support plate14. An inclined surface14ais formed on a part of a side surface of the support plate, and the shim plate18is engaged with the inclined surface14aso that the degree of parallelism of the support plate14can be adjusted. The degree of parallelism of the support plate14can be adjusted using a mode in which the shim plate18is installed between the support plate14and the adapter plate16via the adhesive layer15.

Note that since the purpose of installing the shim plate18is to adjust a degree of parallelism, a position where the shim plate18is installed is not limited thereto. The shim plate18may be installed across the entire periphery of the adapter plate16, or may be installed intermittently. For example, as illustrated inFIGS.1C,1D, and1E, adhesive layers15may be provided at four corners of the adapter plate16, and shim plates18may be provided only at two locations on one side in the Y-axis direction between the adhesive surface16band the support plate14with the adhesive layer15interposed therebetween. With this configuration, when the adapter plate16(or the support plate14) has a rectangular shape, a small amount of degree of parallelism can be adjusted.

That is, as illustrated inFIG.1C, when the adapter plate16(or the support plate14) has a rectangular shape, the degree of parallelism can be adjusted by disposing the shim plate18on one of opposing sides. In addition, when the adapter plate16(or the support plate14) has a circular shape, the degree of parallelism can be adjusted by disposing the shim plate18in one of circular arc regions at point-symmetrical positions.

More specifically, for example, as illustrated inFIG.1E, when a thickness of the stamp layer12varies along the Y-axis direction, the shim plate18may be disposed in a gap between the support plate14and the adapter plate16on one side in the Y-axis direction. In this way, the mounting surface16aand a stamp surface of the stamp layer12become parallel to each other, and the degree of parallelism can be adjusted. Note that, inFIG.1E, in order to facilitate description, thicknesses and inclinations of the stamp layer12, the shim plate18, and the adhesive layer15are illustrated to be larger than actual thicknesses and inclinations.

Other configurations and effects of the transport device and the stamp tool of the present embodiment are the same as those of the first embodiment, and a detailed description thereof will be omitted.

Third Embodiment

As illustrated inFIG.4A, in the transport device of the present embodiment, an elastically deformable engaging projection26cis attached on the engaging surface26bof the claw portion26aof the chuck mechanism26, and the engaging projection26ccan be engaged with the tapered surface16cof the adapter plate16. The engaging projection26cis made of, for example, a spring material, and may protrude in an arc shape from the engaging surface26b. In addition, as illustrated inFIG.4B, the engaging surface26bdoes not have to be a flat surface, and may be a convex curved surface that can be engaged with the tapered surface16cof the adapter plate16. Other configurations and effects of the transport device and the stamp tool of the present embodiment are the same as those of the first or second embodiment, and a detailed description thereof will be omitted.

Fourth Embodiment

In the present embodiment, a description will be given of a method of mounting an element by a transfer method using the device according to any one of the first to third embodiments described above. In the following description, description of a part overlapping with the first to third embodiments described above will be omitted.

In the method of the present embodiment, as illustrated inFIG.5B, the element32rpicked up by the projection11of the stamp layer10is transferred onto a first transfer substrate (second substrate)50illustrated in FIG.5C2by the transport device20and disposed on an adhesion layer52.

An array of elements32radhering to the projections11of the stamp layer12illustrated inFIG.5Bis transferred onto the adhesion layer52of the substrate50made of an adhesion sheet, etc. illustrated in FIG.5C2. To this end, the elements32radhering to the projections11of the stamp layer12are pressed against a surface of the adhesion layer52, and then the stamp layer12is lifted together with the transport device20. As a result, a plurality of elements32ris simultaneously transferred to the surface of the adhesion layer52. Note that, therebefore, the transport device20illustrated inFIG.3Cis moved onto the substrate50illustrated in FIG.5C2by a transport mechanism of the transport device20.

Adhesion of the adhesion layer52of the adhesion sheet made of the substrate50is adjusted so that adhesion of the adhesion layer52becomes greater than adhesion of the projections11. The adhesion layer52is made of, for example, an adhesive resin such as natural rubber, synthetic rubber, acrylic resin, or silicone rubber, and a thickness z4thereof is preferably about 0.5 to 2.0 times a height z2of the element32r(seeFIG.5B). Note that, in order to smooth movement of the element32rfrom the projection11to the adhesion layer52, an operation (for example, applying heat) may be added to facilitate peeling of the element32rfrom the projection11.

Other elements32gand32bare also transferred to the adhesion layer52of the substrate50in the same manner as described above. Three elements32r,32g, and32bof R, G, and B form one pixel unit, and pixel units may be disposed in a matrix to form a color display screen.

Next, as illustrated inFIG.5D, the entire array of the three elements32r,32g, and32bdisposed on the surface of the first transfer substrate50is transferred to an adhesion layer62of a second transfer substrate60, so that respective terminals of the elements32r,32g, and32bare disposed to face the outside of the substrate60. For this transfer, a technique such as a laser lift method may be used, and a transfer method using a difference in adhesion, a transfer method involving heat peeling, etc. may be used. With the terminals of the elements32r,32g, and32bfacing the outside of the substrate60, a tin plating film may be formed on each terminal using an electroless plating method, etc.

Next, as illustrated inFIGS.5E and5F, the entire array of the three elements32r,32g, and32bis transferred from the adhesion layer62of the substrate60to the mounting substrate70. For the transfer, a technique such as the laser lift method may be used, and a transfer method using a difference in adhesion, a transfer method involving heat peeling, etc. may be used.

Note that, after the transfer, in order to connect the terminal of each of the elements32r,32g, and32bto a circuit pattern of the mounting substrate, for example, it is preferable that anisotropic conductive paste (ACP) is applied to the surface of the mounting substrate70, or an anisotropic conductive film (ACF) is disposed thereon. As illustrated inFIG.5F, after disposing the elements32r,32g, and32bon the substrate70via the ACP or ACF, the respective elements32r,32g, and32bmay be pressed toward the substrate70and heated using a heating/pressurizing device (not illustrated). As a result, the terminals of each of the elements32r,32g, and32bcan be connected to the circuit pattern of the mounting substrate.

Note that the present invention is not limited to the above-described embodiments, and various modifications can be made within the scope of the present invention.

For example, the stamp tool is not limited to the stamp tool10of the embodiment described above, and other stamp tools can be used. The transport head22may be provided with at least one of an electrostatic adsorption mechanism, a fitting mechanism, and a screwing mechanism as a secondary attaching means other than the clamping mechanism26. In addition, in the transport head22, an electrostatic adsorbing mechanism, a fitting mechanism, or a screwing mechanism may be used as the first axis positioning mechanism other than the clamping mechanism26. By providing these mechanisms in the transport head, the stamp tool10can be easily positioned with respect to the transport head22.

In addition, in the above-described embodiments, as the primary attaching means of the transport head22, vacuum adsorption using vacuum suction holes is used. However, in the present invention, it may be unnecessary to use vacuum adsorption, and the stamp tool10may be detachably attached on the transport head22only by the first axis positioning mechanism such as the clamping mechanism26. In addition, in the above-described embodiments, when positioning can be performed without using the clamping mechanism26, and the stamp tool10can be detachably held with sufficient holding force with respect to the transport head22, a vacuum adsorbing mechanism or an electrostatic adsorbing mechanism may be attached on the transport head. Alternatively, as the primary attaching means other than the clamping mechanism26, an electrostatic adsorbing mechanism, a fitting mechanism, a screwing mechanism, or other attachment/detachment devices may be attached on the transport head22.

Further, the stamp tool held by the stamp tool holding device according to the embodiments described above is not limited to the stamp tool10described above, and may be other stamp tools.

Further, in the above-described embodiments, as illustrated inFIG.8, a single stamp table100is prepared for each single installation stage82. However, the plurality of these stamp tables100is all driven in the same manner along the X-axis and/or the Y-axis, and thus may be regarded as the single stamp table100. It is obvious that three or more installation stages82may be disposed on the single stamp table100. In addition, similarly, as illustrated inFIG.3A, the single element table102is prepared for each single element forming substrate30. However, the plurality of these element tables102is all driven in the same manner along the X-axis and/or the Y-axis, and thus may be regarded as the single element table102. It is obvious that three or more element forming substrates30may be disposed on the single element table102.

In addition, the transport device20having the stamp tool positioning device according to the present embodiment is used to pick up the elements32r(32g,32b) from the element forming substrate30. However, the application is not limited thereto, and the transport device20may be used to pick up the elements32r(32g,32b) from a substrate (sheet) having an adhesion layer transferred from the substrate30by the laser lift method, etc.

In addition, the transport device20having the stamp tool positioning device according to the present embodiment may be used to pick up an element other than the elements32r,32g, and32bfor red, green, and blue light emission. A fluorescent element, etc. may be indicated as another display element. In addition, the other element is not limited to the display element, and may be an electronic element such as a light receiving element, a ceramic capacitor, or a chip inductor, or a semiconductor element.

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