Tape adhering apparatus and tape adhering method

A tape adhering apparatus and a tape adhering method for adhering an ACF tape formed from an anisotropic conductive film to a target adhering area on a substrate are disclosed. It is an objective of the invention to provide a tape adhering apparatus and a tape adhering method that enable shortening of a time consumed by operation for adhering one cut piece of an ACF tape. According to the present invention, the separator is peeled from the cut piece of the ACF tape by letting the tape conveyor means convey the tape member in synchronism with the transfer action of the transfer base and thereafter a cut portion of the ACF tape to be next adhered is placed at the cutting position of the tape cutting means by letting the tape conveyor means continually convey the tape member in the forward conveyance direction.

TECHNICAL FIELD

The present invention relates to a tape adhering apparatus and a tape adhering method for adhering an ACF tape formed from an anisotropic conductive film to a target adhering area on a substrate.

BACKGROUND ART

In the process of manufacture of a module, like a liquid crystal panel, there is employed a tape adhering apparatus that adheres a tape formed from an anisotropic conductive film called an ACF (Anisotropic Conductive Film) (hereinafter referred to as an “ACF tape”) to a plurality of electrodes arranged in a row on an upper surface of the substrate. The ACF tape is supplied in the form of a tape member that has a protective tape called a separator set integrally on one side of the tape.

A tape adhering apparatus has a substrate holding unit for holding a substrate; a transfer base that is transferable along a horizontal direction; a press tool provided so as to be vertically movable with respect to the transfer base; tape conveyor means that is disposed on the transfer base and that conveys a tape member forwards and backwards along a direction parallel to the direction of movement of the transfer base within a region immediately below the press tool; tape cutting means for cutting an ACF tape from the tape member conveyed by the tape conveyor means, to thus form a cut piece of the ACF tape on a separator; and transfer rollers that are disposed independently of the transfer base so as to be movable in the horizontal direction and that are moved toward the cut piece of the ACF tape adhered to the target adhering area on the substrate, thereby guiding the transfer base in such a direction as to peel the separator off from the cut piece of the ACF tape (see; for instance, Patent Document 1).

When the cut piece of the ACF tape is adhered to the substrate by such a tape adhering apparatus, processing pertaining to a train of operations, such as those mentioned below, is iterated. The operations include (1) a process for positioning the transfer base in such a way that one end of the press tool comes to a position immediately above one end of the target adhering area including electrodes on the substrate; (2) a process for conveying the tape member in such a way that a front end of the ACF tape is situated in an area below the press tool and that the cut portion of the ACF tape comes to a position immediately above the one end of the target adhering area; (3) a process for cutting the ACF tape by the tape cutting means advanced to the cut portion of the ACF tape located immediately below the press tool, thereby forming a cut piece of the ACF tape on the separator; (4) a process for lowering the press tool and pressing the cut piece of the ACF tape against the target adhering area on the substrate, thereby adhering the cut piece of the ACF tape to the target adhering area; (5) a process for moving the transfer rollers toward the cut piece of the ACE tape adhered to the target adhering area on the substrate, to thus peel the separator off from the cut piece of the ACF tape, and returning the transfer rollers to their original positions; and (6) a process for moving the transfer base in such a way that the press tool comes to a position above the target adhering area on the substrate where the cut piece of the ACF tape is to be adhered.

RELATED ART DOCUMENT

Patent Document

SUMMARY OF THE INVENTION

Problem that the Invention is to Solve

However, as mentioned above, the related-art tape adhering apparatus presses the ACF tape against the target adhering area on the substrate by the press tool, to thus adhere the tape to the area, and subsequently peels the separator from the cut piece of the ACF tape adhered to the substrate before transferring the transfer base in such a way that the press tool comes to a position above the target adhering area on the substrate where the cut piece of the ACF tape is to be adhered. To this end, the related-art tape adhering apparatus must reciprocally actuate the transfer rollers with respect to the transfer base (equivalent to process (5)), which makes a mechanism complicate. Moreover, the related-art tape adhering apparatus has another problem of an increase in time consumed in carrying out operation for adhering the ACF tape per cut piece. The tape cutting means for cutting the ACF tape has hitherto been caused to advance to a position immediately below the press tool when cutting the ACF tape. However, when the cut piece of the ACF tape is adhered to the target adhering area on the substrate by the press tool, the tape cutting means is to be withdrawn so as not to interfere in the press tool. For this reason, the related art tape cutting means also involve consumption of time to let the tape cutting means advance or recede.

An objective of the present invention is to provide a tape adhering apparatus and a tape adhering method that enable shortening of a time consumed in adhering operation per cut piece of an ACF tape.

Means for Solving the Problem

In one mode of the present invention, a tape adhering apparatus comprises a substrate holding unit that holds a substrate; a transfer base that is movable in a horizontal direction; a press tool disposed so as to be able to ascend or descend with respect to the transfer base; tape conveyor means that is disposed on the transfer base and that transfers a tape member, which is formed by putting a separator on one side of an ACF tape made up of an anisotropic conductive film, in a forward or backward direction along a direction parallel to a transfer direction of the transfer base in a region immediately below the press tool; tape cutting means that is disposed downstream of the region of, immediately below the press tool, the tape member conveyed by the tape conveyor means with respect to the forward transfer direction of the tape member and that cuts the ACF tape from the tape member conveyed by the tape conveyor means, thereby forming a cut piece of the ACF tape on the separator; tool elevation means that lowers the press tool while positioned at a location immediately above a target adhering area on the substrate, where a cut piece of the ACF tape formed on the separator is held by the substrate holding unit, as a result of the tape member being conveyed in a reverse direction by the tape conveyor means, thereby pressing the cut piece of the ACF tape to the target adhering area on the substrate and adhering the cut piece of the ACF tape to the target adhering area; and transfer base actuation means that transfers the transfer base with respect to the substrate holding unit in a direction opposite to the forward transfer direction of the tape member in the region immediately below the press tool in such a way that the press tool comes to an elevated position above the target adhering area on the substrate where the cut piece of the ACF tape is then adhered after the cut piece of the ACF tape is pressed against and adhered to the target adhering area on the substrate by the press tool. The tape conveyor means forwardly conveys the tape member in synchronism with actuation of the transfer base performed by the transfer base actuation means, thereby peeling the separator off from the cut piece of the ACF tape adhered to the target adhering area on the substrate, and further keeps conveying the tape member forwards, to thus place a cut portion of the ACF tape to be adhered next to the cutting position of the tape cutting means.

In another mode of the present invention, a tape adhering method is for a tape adhering apparatus including a substrate holding unit that holds a substrate; a transfer base that is movable in a horizontal direction; a press tool disposed so as to be able to ascend or descend with respect to the transfer base; tape conveyor means that is disposed on the transfer base and that transfers a tape member, which is formed by putting a separator on one side of an ACF tape made up of an anisotropic conductive film, in a forward or backward direction along a direction parallel to a transfer direction of the transfer base in a region immediately below the press tool; and tape cutting means that is disposed downstream of the region of, immediately below the press tool, of the tape member conveyed by the tape conveyor means with respect to the forward transfer direction of the tape member and that cuts the ACF tape from the tape member conveyed by the tape conveyor means, thereby forming a cut piece of the ACF tape on the separator. The method comprises a process of cutting, by use of tape cutting means, an ACF tape from a tape member conveyed by tape conveyor means, thereby forming a cut piece of the ACF tape on a separator; a process of conveying the tape member in the reverse direction by the tape conveyor means, thereby placing the cut piece of the ACF tape formed on the separator at a position immediately above a target adhering area on the substrate held by the substrate holding unit; a process of lowering the press tool while the cut piece of the ACF tape formed on the separator is kept positioned immediately above the target adhering area on the substrate, thereby pressing the cut piece of the ACF tape against the target adhering area on the substrate and adhering the cut piece of the ACF tape to the target adhering area; a process of next transferring the transfer base, with respect to the substrate holding unit, in a direction opposite to the forward transfer direction of the tape member in the region immediately below the press tool in such a way that the press tool comes to a position above the target adhering area on the substrate to which the cut piece of the ACF tape is to be adhered after the cut piece of the ACF tape is pressed against and adhered to the target adhering area on the substrate by the press tool, and letting the tape conveyor means convey the tape member in synchronism with transfer action of the transfer base, to thus peel the separator from the cut piece of the ACF tape adhered to the target adhering area on the substrate; and a process of peeling the separator from the cut piece of the ACF tape and letting the tape conveyor means continually convey the tape member in the forward conveyance direction, thereby placing a cut portion of the ACF tape to be next adhered at the cutting position of the tape cutting means.

Advantages of the Invention

In the present invention, the press tool presses and adheres the cut piece of the ACF tape against and to the target adhering area on the substrate. Subsequently, the tape member is forwardly conveyed in synchronism with actuation of the transfer base in such a way that the press tool comes to an elevated position above the target adhering area on the substrate to which the cut piece of the ACF tape is to be adhered, thereby peeling the separator from the cut piece of the ACF tape. Next, there are simultaneously performed processing pertaining to the process (process (5)) of peeling the separator from the cut piece of the ACF tape adhered to the target adhering area on the substrate and processing pertaining to the process (process (6)) of placing the press tool at an elevated position above the target adhering area on the substrate to which the cut piece of the ACF tape is to be adhered. Hence, a necessity for additionally providing transfer rollers for peeling the separator and reciprocally actuating the transfer rollers, such as that required in the related art, becomes obviated. Further, a time consumed by operation for adhering one cut piece of the ACF tape can be shortened.

The tape cutting means is disposed downstream of the region of, immediately below the press tool, of the tape member conveyed by the tape conveyor means with respect to the forward transfer direction of the tape member. Hence, occurrence of interference with the press tool, which would otherwise arise when the cut piece of the ACF tape is pressed against the substrate, is prevented. Therefore, a necessity for a configuration that allows advancement and receding of the tape cutting means becomes obviated. The mechanism of the tape adhering apparatus therefore becomes simple. Further, the time consumed by letting the tape cutting means advance and recede every time the ACF tape is cut is omitted. Hence, the time consumed by operation for adhering one cut piece of the ACF tape can be shortened even in view of this aspect. Since positioning of a cut position of the ACF tape can be performed by carrying out, without involvement of a change and interruption, forward conveyance of the tape member for peeling the separator, a work time will not increase when compared with the case where the cut position of the ACF tape of the tape member is positioned at a cutting position immediately below the press tool and where the tape cutting means is caused to advance to cut the ACF tape, such as those performed in the related art.

EMBODIMENT FOR IMPLEMENTING THE INVENTION

An embodiment of the present invention is hereunder described by reference to the drawings. A tape adhering apparatus1shown inFIGS. 1 and 2makes up a liquid crystal panel manufacturing line in conjunction with electrode cleaning equipment disposed at an upstream position and a tentative bonder and a principal pressure bonder, and the like, disposed at downstream positions. After receiving a substrate2as a liquid crystal panel substrate from the electrode cleaning equipment placed at the upstream position, the tape adhering apparatus1adheres a cut piece4S of a tape (an ACF tape4) formed from an anisotropic conductive film called an ACF (Anisotropic Conductive Film) to each of a plurality of electrodes3provided along an edge of an upper surface of the substrate2. Subsequently, the tape adhering apparatus1delivers the substrate2to the tentative pressure bonder disposed at the downstream position. In the present embodiment, the ACF tape4is supplied as a tape member Tp on one side of which a separator Sp serving as a protective tape is pasted (see an enlarged view inFIG. 1).

InFIGS. 1 and 2, the tape adhering apparatus1includes a base10; a table-shaped substrate holding unit12that holds the substrate2in a horizontal position in such a way that the electrodes3are upwardly oriented and that is transferred by a substrate holding unit transfer mechanism11placed on the base10; a portal frame13that is disposed on the base10and that has a transverse frame13aextending in a horizontal direction; a plate-like transfer base14that is placed at an elevated position above the substrate holding unit12while attached to the transverse frame13aof the portal frame13so as to be movable along the transverse frame13a(i.e., in the horizontal direction); and a backup stage15disposed on the base10so as to extend in a direction of transfer of the transfer base14.

For the convenience of explanation, a horizontal direction along which the transverse frame13aextends (i.e., the transfer base14is transferred) is taken as a right-left direction of the tape adhering apparatus1and referred to as an X-axis direction. Another horizontal direction orthogonal to the X-axis direction is taken as a front-back direction of the tape adhering apparatus1and referred to as a Y-axis direction. The vertical direction is taken as a Z-axis direction. Further, of right and left directions (i.e., directions oriented along the X-axis direction), a left direction is assigned to a left side of a drawing sheet ofFIG. 1, and a right direction is assigned to a right side of the drawing sheet ofFIG. 1. Of front and back directions (i.e., directions oriented along the Y-axis direction), a forward direction is assigned to a left side of a drawing sheet ofFIG. 2, and a backward direction is assigned to a right side of the drawing sheet ofFIG. 2.

InFIGS. 1 and 2, the substrate holding unit transfer mechanism11is made up of an X-axis table11athat is movable in the right-left direction (the X-axis direction) with respect to the base10, a Y-axis table11bthat is movable in the front-back direction (the Y-axis direction) with respect to the X-axis table11a, and a θ table11cthat is attached to the Y-axis table11band that is rotatable around the Z axis. The substrate holding unit12is attached to an upper surface of the θ table11c. The substrate holding unit12can be transferred within a horizontal plane by transfer of the X-axis table11ain the right-left direction (the X-axis direction), transfer of the Y-axis table11bin the front-back direction (the Y-axis direction), and rotation of the θ table11caround the up-down direction (the Z axis).

InFIGS. 1 and 2, a tool elevation cylinder21, a press tool22that is vertically movable with respect to the transfer base14by the tool elevation cylinder21, a tape conveyor unit23, a tape cutting unit24, peeling rollers25, and an imaging camera26are provided on a front surface of the transfer base14.

InFIGS. 1 and 2, the tool elevation cylinder21is disposed at a front center of the transfer base14while the piston rod21ais oriented downwards. The press tool22is attached to a lower end of the piston rod21a. The piston rod21aof the tool elevation cylinder21is caused to project downwardly, whereupon the press tool22ascends and descends between an elevated position shown inFIG. 1and a lowered position right below the elevated position. A heater22a(FIG. 1) that heats the press tool22is provided in the press tool22.

InFIGS. 1 and 2, the tape conveyor unit23is made up of a feed reel31that feeds a tape member Tp, a tape recovery unit32that recovers the tape member Tp supplied from the feed reel31by vacuum suction, and a plurality of guide rollers that guide the tape member Tp from the feed reel31to the tape recovery unit32(a first guide roller33a, a second guide roller33b, a third guide roller33c, and a pair of fourth guide rollers33d). The feed reel31is driven by a feed reel drive motor31adisposed on a back of the transfer base14. Likewise, the tape recovery unit32is driven by a tape recovery unit actuation mechanism32adisposed on the back of the transfer base14.

InFIG. 1, the first guide roller33ais movable within a roller transfer groove14aformed in an upper left portion of the transfer base14so as to extend in a vertical direction, and remains forced upwardly by an un-illustrated force member. The second guide roller33bis disposed in a lower left portion of the transfer base14and below the first guide roller33a. The third guide roller33cis positioned on the right side of the second guide roller33band in a lower right portion of the transfer base14. The pair of fourth guide rollers33dare placed above the third guide roller33cand side by side at a right center area of the transfer base14along the right-left direction. When the press tool22is at the elevated position, the second guide roller33band the third guide roller33care situated at a position below a lower surface of the press tool22(seeFIG. 1). When the press tool22is situated at the lowered position, the second guide roller33band the third guide roller33care disposed at a position above the lower surface of the press tool22.

InFIG. 1, the tape member Tp supplied from the feed reel31is guided by, in this sequence, the first guide roller33a, the second guide roller33b, the third guide roller33c, and the pair of fourth guide rollers33d(both surfaces of the tape member Tp are nipped, from both sides, between the pair of fourth guide rollers33d) and delivered to the tape recovery unit32.

Appropriate tension is imparted to the tape member Tp as a result of the first guide roller33abeing forced upwardly within the roller transfer groove14a. Between the first guide roller33aand the second guide roller33bis held the tape member Tp in an attitude such that the tape is stretched in the vertical direction within the left area of the transfer base14. In contrast, between the second guide roller33band the third guide roller33cis held the tape member Tp in an attitude such that the tape is stretched in a right-left direction (the X-axis direction) within a lower area of the transfer base14(when the press tool22is situated at the elevated position). Moreover, the tape member Tp is held within the right area of the transfer base14, while stretched in the vertical direction, between the third guide roller33cand the pair of fourth guide rollers33dand between the pair of fourth guide rollers33dand the tape recovery unit32.

The tape transfer unit23feeds the tape member Tp from the feed reel31while attracting the tape member Tp by suction by the tape recovery unit32, so that the tape member Tp can be conveyed in a forward direction (a direction along which the tape travels from left to right in a region Rg immediately below the press tool22and which is designated by arrow A shown inFIG. 1). The feed reel31takes up the tape member Tp while the tape recovery unit32is attracting the tape member Tp by suction, whereby the tape member Tp can be conveyed in an opposite direction (a direction from right to left in the region Rg located immediately below the press tool22).

In the embodiment, the tape conveyor unit23is provided on the transfer base14. The tape conveyor unit23acts as tape conveyor means that conveys the tape member Tp forward and backward in a direction parallel to the transfer direction (the X-axis direction) of the transfer base14in the region Rg located immediately below the press tool22.

The tape cutting unit24is situated at a position on the tape member Tp between the third guide roller33cand the pair of fourth guide rollers33dthat is downstream of the region Rg of, immediately below the press tool22, the tape member Tp conveyed by the tape conveyor unit23. The tape cutting unit24is made up of a cutter24athat is disposed so as to be movable in the right-left direction (i.e., a direction orthogonal to a surface of the tape member Tp) in the right region of the tape member Tp extending in the vertical direction between the third guide roller33cand the pair of fourth guide rollers33d; a cutter drive cylinder24bthat drives the cutter24ain such a way that the cutter24ais transferred between a housing position on the right side and a projecting position on the left side (designated by arrow B shown inFIG. 1); and a backboard24cthat is disposed opposite the cutter24ain the horizontal direction (i.e., a position opposite to the cutter24awith the tape member Tp sandwiched therebetween) in the left area of the tape member Tp extending in the vertical direction between the third guide roller33cand the pair of fourth guide rollers33d.

In the tape cutting unit24, clearance equal to the thickness of the separator Sp is secured between the cuter24asituated at the projecting position and the backboard24c. Therefore, when the cutter24sis transferred from the housing position to the projecting position by the cutter drive cylinder24bwhile the tape member Tp remains extended in the vertical direction between the third guide roller33cand the pair of fourth guide rollers33d, the cutter24ais pressed against, at right angles to, the ACF tape4on the right surface of the tape member Tp. Only the ACF tape4is thereby cut from the tape member Tp. The backboard plate24cacts, at this time, as a stiffening plate that supports the separator Sp on the left surface of the tape member Tp, to thus generate reactive force against a pressing load of the cutter24aon the tape member Tp.

InFIG. 1, the ACF tape4on the right surface of the tape member Tp extending in the vertical direction between the third guide roller33cand the pair of fourth guide rollers33dis cut by the tape cutting unit24while the head of the tape is pulled up, by a length Ls, with reference to a cutting position M that is a position (a height) at which the cutter24atravels right and left. The length Ls corresponds to a length of a target adhering area Sa (a plurality of electrodes3exist within each of the target adhering areas Sa inFIG. 1) on the substrate2, where an attempt is made to adhere the ACF tape4to the electrodes3, in the X-axis direction. The ACF tape4is cut by the cutting unit24, whereby the cut piece4S of the ACE tape4having the length Ls is formed on the separator Sp.

Specifically, in the present embodiment, the tape cutting unit24is disposed downstream of the region Rg of, immediately below the press tool22, the tape member Tp conveyed by the tape conveyor unit23with respect to the forward transfer direction of the tape member Tp. The tape cutting unit24acts as tape cutting means that cuts the ACF tape4from the tape member Tp conveyed by the tape conveyor unit23, to thus form the cut piece4S of the ACF tape4on the separator Sp.

InFIG. 1, the peeling rollers25are made up of a pair of roller members that vertically nip a downstream portion (a portion of the right side of the region Rg, immediately below the press tool22, of the tape member Tp conveyed by the tape conveyor unit23) with respect to the forward transfer direction of the tape member Tp than the region Rg located immediately below the press tool22of the tape member Tp conveyed by the tape conveyor unit23. The peeling rollers25are provided on the transfer base14. When the transfer base14is moved in the horizontal direction, the peeling rollers25are also transferred along with the transfer base14in the horizontal direction.

The imaging camera26is mounted on a lower right side of the transfer base14with an imaging field of view of the camera oriented downward. The imaging camera26travels along with horizontal transfer of the transfer base14and captures images of positioning marks (not shown) provided on both right and left ends of the substrate2held by the substrate holding unit12.

An operation performance control unit40aof the controller40(FIG. 3) installed in the tape adhering apparatus1controls operation of a transfer base actuation mechanism41(FIG. 3) made up of an un-illustrated actuator, or the like, whereby the transfer base14travels in the X-axis direction (the right-left direction) with respect to the transverse frame13aof the portal frame13.

The operation performance control unit40aof the controller40controls operation of a substrate holding unit actuation mechanism42made up of an un-illustrated actuator, or the like, (FIG. 3), whereby the substrate2held by the substrate holding unit12travels.

The operation performance control unit40aof the controller40controls operation of the feed reel drive motor31aand operation of the tape recovery unit actuation mechanism32a, whereby the tape conveyor unit23conveys the tape member Tp (FIG. 3).

The head position of the ACF tape4of the tape member Tp is calculated from information about the number of rotations of the one fourth guide roller33ddetected by a rotation number detection sensor43(FIG. 3), data pertaining to a radius of the one fourth guide roller33d, and the like. Moreover, the operation performance control unit40aof the controller40controls operation of the cutter drive cylinder24b, whereby the cutter24aof the tape cutting unit24travels right and left; namely, the cutter24acuts the ACF tape4(FIG. 3).

The operation performance control unit40aof the controller40controls operation of the tool elevation cylinder21, whereby the press tool22is vertically actuated (FIG. 3). The operation performance control unit40aof the controller40controls operation of a heater activation mechanism44(FIG. 3), whereby the heater22aprovided in the press tool22heats the press tool22.

The operation performance control unit40aof the controller40controls imaging operation of the imaging camera26(FIG. 3). Image data captured by the imaging camera26are stored in an image data storage unit40bof the controller40. An image recognition unit40c(FIG. 3) received a command from the operation performance control unit40aperforms image recognition on the basis of the image data stored in the image data storage unit40b.

By reference to a flowchart ofFIG. 4and descriptive operation diagrams ofFIGS. 5(a) to7(c), explanations are given to procedures through which the tape adhering apparatus1performs operation (tape adhering operation) for adhering the cut piece4S of the ACF tape4to the target adhering area Sa on the substrate2.

In order to let the tape adhering apparatus1adhere the cut piece4S of the ACF tape4to the target adhering area Sa on the substrate2, the operation performance control unit40aof the controller40first conveys the substrate2received from an electrode cleaning device, which is disposed at an upstream position, by an un-illustrated substrate carry-in mechanism, thereby letting the substrate holding unit12hold the substrate2(a substrate carry-in and holding process pertaining to step ST1shown inFIG. 4).

The operation performance control unit40aof the controller40lets the substrate holding unit12hold the substrate2and activates the substrate holding unit transfer mechanism11to thus transfer the substrate holding unit12, thereby bringing a lower surface of an edge of the substrate2equipped with the electrodes3into contact with an upper surface of the backup stage15(see the substrate2designated by a dashed line shown inFIG. 2). The substrate2is positioned in such a way that the plurality of electrodes3are arranged in a direction parallel to the transfer direction of the transfer base14(i.e., the X-axis direction) and also come to a position immediately below the press tool22(a substrate positioning process pertaining to step ST2shown inFIG. 4).

When positioning the substrate2, the operation performance control unit40aof the controller40captures images of positioning marks provided on both ends of the substrate2by the imaging camera26by moving the transfer base14in the right-left direction (the X-axis direction). The operation performance control unit40aof the controller40causes the image recognition unit40cto recognize acquired image data, thereby checking whether or not a positional displacement exits between the image and the adhere position on the backup state15of the substrate2.

After positioning the substrate2, the operation performance control unit40aof the controller40controls operation of the transfer base actuation mechanism41, thereby actuating the transfer base14in the right-left direction (designated by arrow C1shown inFIG. 5(a)). The operation performance control unit40aof the controller40positions the transfer base14in such a way that the left end of the press tool22comes to a position immediately above the target adhering area Sa on the substrate2to which the press tool22is now about to adhere the cut piece4S of the ACF tape4from now (FIG. 5(a): a transfer base positioning process pertaining to step ST3shown andFIG. 4).

After positioning the transfer base14, the operation performance control unit40aof the controller40controls operation of the tape conveyor unit23, thereby conveying the tape member Tp in the forward direction (designated by arrow D1shown inFIG. 5(a)). The operation performance control unit40aof the controller40positions the ACF tape4in such a way that the head of the ACF tape4comes to a position that is higher than the cutting position M, where the tape cutting unit24cuts the ACF tape4, by a length Ls equivalent to the length of the target adhering area Sa achieved in the X-axis direction (FIG. 5(a): an ACF tape positioning process pertaining to step ST4shown inFIG. 4).

After positioning the ACE tape4, the operation performance control unit40aof the controller40controls actuation of the cutter drive cylinder24b, thereby transferring the cutter24ain the right-left direction (designated by arrow E shown inFIG. 5(b)) and cutting the ACF tape4. The operation performance control unit40aof the controller40forms the cut piece4S of the ACF tape4having a length Ls on the separator Sp (FIG. 5(b): an ACF tape cutting process pertaining to step ST5shown inFIG. 4).

After forming the cut piece4S of the ACF tape4on the separator Sp by cutting the ACF taper4, the operation performance control unit40aof the controller40controls operation of the tape conveyor unit23, thereby conveying the tape member Tp in an opposite direction (designated by arrow D2shown inFIG. 5(c)). The operation performance control unit40aof the controller40sets the cut piece4S of the ACF tape4formed on the separator Sp to a position that is positioned below the press tool22and immediately above the target adhering area Sa on the substrate2held by the substrate holding unit12(FIG. 5(c): an ACF tape cut piece positioning process pertaining to step ST6shown inFIG. 4).

After positioning the cut piece4S of the ACF tape4, the operation performance control unit40aof the controller40controls operation of the tool elevation cylinder21, to thus lower the press tool22to a lowered position (designated by arrow F1shown inFIG. 6(a)). The operation performance control unit40aof the controller40presses the cut piece4S of the ACF tape4to the edge of the substrate2along with the separator Sp by the press tool22previously heated by the heater22a, thereby adhering the cut piece4S of the ACF tape4to the target adhering area Sa on the substrate2(FIG. 6(a): an ACF tape cut piece adhering process pertaining to step ST7shown inFIG. 4).

As mentioned above, in the present embodiment, the tape conveyor unit23conveys the tape member Tp in the opposite direction with respect to the tool elevation cylinder21. The tool elevation cylinder21thereby acts as tool elevation means that lowers the press tool22while the cut piece4S of the ACF tape4formed on the separator Sp remains situated at the position immediately above the target adhering area Sa on the substrate2held by the substrate holding unit12, to thus adhere the cut piece4S of the ACF tape4to the target adhering area Sa on the substrate2.

After adhering the cut piece4S of the ACF tape4to the target adhering area Sa on the substrate2by use of the press tool22, the operation performance control unit40aof the controller40controls operation of the tool elevation cylinder21, thereby elevating the press tool22to the elevated position (designated by arrow F2shown inFIG. 6(b)).

Since the cut piece4S of the ACF tape4remains adhered to the target adhering area Sa on the substrate2while the press tool22is held at the elevated position, the tape member Tp located between the second guide roller33band the third guide roller33cremains pulled downward as designated byFIG. 6(b).

After raising the press tool22to the elevated position, the operation performance control unit40aof the controller40determines if the target adhering area Sa to which the cut piece4S of the ACF tape4is to be adhered still remains on the substrate2where adhering of the cut piece4S of the ACF tape4is now being performed (a determination process pertaining to step ST8shown inFIG. 4). As a consequence, when the target adhering area Sa to which the cut piece4S of the ACF tape4is to be adhered still remains on the substrate2, the operation performance control unit40aof the controller40controls operation of the transfer base actuation mechanism41. The operation performance control unit40aof the controller40transfers the transfer base14leftwards (as designated by arrow C2shown inFIG. 6(c),FIG. 7(a), andFIG. 7(b)), thereby positioning the transfer base14in such a way that the left end of the press tool22comes to a position immediately above the left end of the target adhering area Sa on the substrate2to which the press tool is now (about to) adhere the cut piece4S of the ACF tape4(FIG. 7(b)). In the meantime, operation of the tape conveyor unit23is controlled, thereby conveying the tape member Tp in the forward direction (as designated by arrow D3shown inFIG. 6(c),FIG. 7(a), andFIG. 7(b)). The separator Sp adhered to the upper surface of the cut piece4S of the ACF tape4affixed onto the substrate2is conveyed by the tape conveyor unit23while being pulled upward by the peeling rollers25. Therefore, the separator Sp is separated from the cut piece4S of the ACF tape4adhered to the target adhering area Sa on the substrate2(in sequences shown inFIGS. 6(b),6(c), and7(a): a transfer base positioning process doubling as a separator peeling process pertaining to step ST9shown inFIG. 4).

In the embodiment, the transfer base actuation mechanism41acts as transfer base actuation means. The transfer base actuation means moves the transfer base14with respect to the substrate holding unit12in a direction opposite to the direction in which the tape member Tp is forwardly conveyed in the region Rg immediately below the press tool22in such way that the press tool22comes to a position above the target adhering area Sa on the substrate2to which the cut piece4S of the ACF tape4is next adhered after the cut piece4S of the ACF tape4is pressed against and adhered to the target adhering area Sa on the substrate2by the press tool22.

After positioning of the transfer base14that doubles as peeling of the separator Sp is performed, the operation performance control unit40aof the controller40lets the tape conveyor unit23keep conveying the tape member Tp in the forward direction even after peeling of the separator Sp is completed (designated by arrow D4shown inFIG. 7(c): a tape member conveyance continuation process pertaining to step ST10shown inFIG. 4). Turning back to step ST4, the ACF tape4is positioned in such a way that the head of the ACF tape4comes to an elevated position above the cutting position M where the tape cutting unit24cuts the ACF tape4, by a length Ls equivalent to the length of the target adhering area Sa in the X-axis direction (FIG. 7(c)).

In the meantime, when the target adhering area Sa where the cut piece4S of the ACF tape4is to be adhered is not present on the substrate2in step ST8, the operation performance control unit40aof the controller40causes the tape conveyor unit23to convey the tape member Tp in the forward direction while actuating the transfer base14leftwards. The operation performance control unit40aof the controller40thereby peels the separator Sp from the cut piece4S of the ACF tape4adhered to the target adhering area Sa on the substrate2(a separator peeling process pertaining to step ST11shown inFIG. 4). In step ST10, the operation performance control unit40aof the controller40transfers the transfer base14by an amount of travel that is enough to allow peeling of the separator Sp.

After peeling the separator Sp in step ST11, the operation performance control unit40aof the controller40conveys, to the tentative pressure bonder disposed at a downstream position, the substrate2held by the substrate holding unit12(i.e., the substrate2to which the cut piece4S of the ACF tape4has finished being adhered) by use of an un-illustrated substrate carry-out mechanism (a substrate carry-out step pertaining to step ST12shown inFIG. 4).

As mentioned above, a tape adhering method performed by the tape adhering apparatus1of the present embodiment includes processes (1) to (5). Process (1) (an ACF tape cutting process pertaining to step ST5) is for cutting the ACF tape4from the tape member Tp conveyed by the tape conveyor unit23, by the tape cutting unit24disposed downstream of the region Rg, immediately below the press tool22, of the tape member Tp conveyed by the tape conveyor unit23with respect to the forward conveyance direction of the tape member Tp, to thus form the cut piece4S of the ACF tape4on the separator Sp. Process (2) (an ACF tape cut piece positioning process pertaining to step ST6) is for conveying the tape member Tp in the reverse direction by the tape conveyor unit23, thereby placing the cut piece4S of the ACF tape4formed on the separator Sp at a position immediately above the target adhering area Sa on the substrate2held by the substrate holding unit12. Process (3) (an ACF tape cut piece adhering process pertaining to step ST7) is for lowering the press tool22while the cut piece4S of the ACF tape4formed on the separator Sp is kept positioned immediately above the target adhering area Sa on the substrate2, thereby pressing the cut piece4S of the ACF tape4against the target adhering area Sa on the substrate2and adhering the cut piece4S of the ACF tape4to the target adhering area Sa. Process (4) (a transfer base positioning process doubling as a separator peeling process pertaining to step ST9) is for subsequently transferring the transfer base14in a direction opposite to the forward conveyance direction of the tape member Tp, which is achieved in the region Rg immediately below the press tool22, with respect to the substrate holding unit12in such a way that the press tool22comes to a position above the target adhering area Sa on the substrate2to which the cut piece4S of the ACF tape4is to be adhered after the cut piece4S of the ACE tape4is adhered to the target adhering area Sa on the substrate2by the press tool22, and letting the tape conveyor unit23convey the tape member Tp in synchronism with transfer action of the transfer base14(therefore, in synchronism with transfer of the peeling rollers25toward the cut piece4S of the ACF tape4adhered onto the substrate2), to thus peel the separator Sp from the cut piece4S of the ACF tape4adhered to the target adhering area Sa on the substrate2. Process (5) (an ACF tape positioning process pertaining to step ST4) is for peeling the separator Sp from the cut piece4S of the ACF tape4and letting the tape conveyor unit23continually convey the tape member Tp in the forward conveyance direction, thereby placing a cut portion of the ACF tape4to be next adhered at the cutting position M of the tape cutting unit24.

As mentioned above, in the tape adhering apparatus1of the embodiment, the tape cutting unit24is disposed downstream of the region Rg of, immediately below the press tool22, the tape member Tp conveyed by the tape conveyor unit with respect to the forward transfer direction of the tape member. After the cut piece4S of the ACF tape4is pressed and adhered to the target adhering area Sa on the substrate2by the press tool22, the transfer base actuation mechanism41actuates the transfer base14. The tape member Tp is conveyed in the forward direction in synchronism with actuation of the transfer base14.

In the tape adhering apparatus1(the tape adhering method) of the present embodiment, the press tool22presses and adheres the cut piece4S of the ACF tape4against and to the target adhering area Sa on the substrate2. Subsequently, the tape member Tp is forwardly conveyed in synchronism with actuation of the transfer base14in such a way that the press tool22comes to an elevated position above the target adhering area Sa on the substrate2to which the cut piece4S of the ACF tape4is to be adhered, thereby peeling the separator Sp from the cut piece4S of the ACF tape4. There are simultaneously performed processing pertaining to the process of peeling the separator Sp from the cut piece4S of the ACF tape4adhered to the target adhering area Sa on the substrate2and processing pertaining to the process of subsequently placing the press tool22at an elevated position above the target adhering area Sa on the substrate2to which the cut piece4S of the ACF tape4is to be adhered. Hence, a necessity for additionally providing transfer rollers for peeling the separator Sp and reciprocally actuating the transfer rollers, such as that required in the related art, becomes obviated. Further, a time consumed by operation for adhering one cut piece of the ACF tape4can be shortened.

The tape cutting unit24is disposed downstream of the region Rg of the tape member Tp, immediately below the press tool22, conveyed by the tape conveyor unit23with respect to the forward transfer direction of the tape member Tp. Hence, occurrence of interference with the press tool22, which would otherwise arise when the cut piece4S of the ACF tape4is pressed against the substrate2, is prevented. Therefore, a necessity for a configuration that allows advancement and receding of the tape cutting unit24becomes obviated. The mechanism of the tape adhering apparatus therefore becomes simple. Further, the time consumed by letting the tape cutting unit24advance and recede every time the ACE tape4is cut is omitted. Hence, the time consumed by operation for adhering one cut piece4S of the ACF tape4can be shortened even in view of this aspect. Since positioning of a cut position of the ACF tape4can be performed by carrying out, without involvement of a change and interruption, forward conveyance of the tape member Tp for peeling the separator Sp, a work time will not increase when compared with the case where the cut position of the ACF tape4of the tape member Tp is positioned at a cutting position immediately below the press tool22and where the tape cutting means is caused to advance to cut the ACF tape4, such as those performed in the related art.

Although the embodiment of the present invention has been described thus far, the present invention is not limited to the previously-described embodiment. For instance, the tape cutting unit24of the embodiment is configured so as to cut the ACF tape4by pressing the cutter24a, which travels in a horizontal direction, at right angles against the surface of the ACF tape4. Instead, the tape cutting unit24may also be configured so as to have a rotary blade that rotates around an axis parallel to the direction of extension of the tape member Tp and to let the rotary blade rotating in a widthwise direction of the tape member Tp run on the ACF tape4, thereby cutting the ACF tape4.

The essential requirement is that the tape cutting unit24be disposed downstream of the region Rg, immediately below the press tool22, of the tape member Tp conveyed by the tape conveyor unit23, with respect to the forward conveyance direction of the tape member Tp with respect to located immediately below the press tool22. No specific limitation are imposed on the location of the tape cutting unit24.

Although the present invention has been described in detail by reference to the specific embodiment, it is manifest to those skilled in the art that the present invention be susceptible to various alterations or modifications without departing the spirit and scope of the present invention.

The present patent application is based on Japanese Patent Application (JP-2010-254688) filed on Nov. 15, 2010, the entire subject matter of which is incorporated herein by reference.

INDUSTRIAL APPLICABILITY

There are provided a tape adhering apparatus and a tape adhering method that enable shortening of a time consumed to perform operation for adhering one cut piece of an ACF tape.

DESCRIPTIONS OF THE REFERENCE NUMERALS AND SYMBOLS