Stage apparatus

A stage apparatus that achieves a high accuracy in assembling and enables easy work at a real installation site. In a stage apparatus of the present invention, sub rails are arranged on respective sub base plates, which are connected respectively with the first and second main rails on a main base plate to extend the first and second main rails. Accordingly, when the sub base plates are fixed to the main base plate 11 with positional alignment performed therebetween, the accuracy in positional alignment of the sub base plates which has already been fixed to the main base plate is not affected.

BACKGROUND OF THE INVENTION

The present invention generally relates to a technical field of stage apparatuses, and particularly relates to a disassemblable stage apparatus.

Reference numeral105inFIG. 9represents a stage apparatus of a prior art.

The stage apparatus105includes a base plate111, and the base plate111is mounted on a floor with leg sections112ato112ddisposed at the four corners on the back surface side.

Rails117and118are arranged on the surface of the base plate111, and a gantry113is mounted thereon. A print head is disposed on the surface of the gantry113facing the base plate111. The print head is connected with a tank114, which supplies the print head with ejection liquid; and when a substrate107is mounted on the base plate111and ejection liquid is ejected from the print head, the ejection liquid lands on the substrate107.

The gantry113is arranged movable on the rails117and118; and when the gantry113ejects ejection liquid above the substrate107, as shown inFIG. 10, it is possible to land the ejection liquid on a desired position of the surface of the substrate107.

This ejection liquid is, for example, a raw material of an organic thin film for a liquid crystal oriented film, spacer dispersion liquid of a liquid crystal display device, raw material of a light emitting layer of an organic EL device, or the like; and the stage apparatus105is used to eject ejection liquid onto a large substrate.

However, substrates as an object of ejection are becoming larger and larger, and correspondingly, stage apparatuses are becoming larger; which makes it difficult to transport a stage apparatus fabricated at a factory to an installation site because of the problems in terms of cost and due to law restrictions. In such circumstances, countermeasure is taken even in conventional arts, and it has been tried to transport a base plate by dividing it.

SUMMARY OF THE INVENTION

However, there are problems in assembling a base plate once it has been divided at an installation site. Such problems include requiring a lot of work for position adjustment; and in connecting rails, if the accuracy of assembling rails is low, the running of the print head becomes unstable.

In order to solve the above-described problems, an embodiment of the present invention is directed to a stage apparatus, comprising: a main base plate in a quadrilateral shape; two sub base plates which are fixed to one side of the main base plate and separable each other; and a movable member arranged to be movable between a position above the main base plate and a position the two sub base plates fixed to the main base plate, wherein the two sub base plates are separable from the main base plate.

An embodiment of the present invention may be directed to a stage apparatus, further comprising: a first and second main rails which are linearly extended on the main base plate and disposed in parallel to each other; and sub rails that are respectively disposed on the two sub base plates and respectively connected to end portions of the first and second main rails, wherein the movable member runs on the first and second main rails and the sub rails on the two sub base plates and are movable between the position above the main base plate and the position above and between the two sub base plates.

As the positions of the first and second sub base plates can be independently aligned with a main base plate, the work for position alignment at a real installation site is easy; and the position alignment accuracy is improved.

DETAILED DESCRIPTION OF THE INVENTION

Reference numerals5inFIGS. 5(a) and5(b) represent a stage apparatus of the invention.FIG. 5(a) is a plan view, andFIG. 5(b) is a side view.

This stage apparatus5includes one main mounting table10and two or four (in this embodiment, four) sub mounting tables20ato20d.

At the upper portions of the main mounting table10and sub mounting tables20ato20d, the main base plate11and sub base plates21, which are in a quadrilateral shape and have the flat surfaces, are arranged.

First and second main rails17aand17b, which are in parallel to each other, are arranged on the surface of the main base plate11; and one sub rail18is disposed on the surface of each sub base plate21.

The first and second main rails17aand17bare arranged in parallel to two out of the four sides of the main base plate11and perpendicular to the other two sides; and at least one end of the first and second main rails17aand17bextends up to the same one side out of the four sides of the main base plate11, the one side being perpendicular to the first and second main rails17aand17b.

In this embodiment, both ends of the first and second main rails17aand17bextend up to the two sides that are perpendicular to the first and second main rails17aand17b.

The sub rails18are arranged in parallel to two out of the four sides of the sub base plates21, and perpendicular to the other two sides. At least one of the both ends of each sub rail18extends up to one side perpendicular to the sub rails18.

The surfaces of the main base plate11and sub base plates21are arranged so as to be horizontal at the same height.

Out of the four sides of the main base plate11, the two sides, at which the end portions of the first and second main rails17aand17bare located, will be referred to as main connection sides F, and the sides, at which one of the ends of the sub rails18is located, will be referred to as sub connection sides B. The respective sub mounting tables20ato20dare arranged such that the sub connection sides B of the sub base plates21are in tight contact with the main connection sides F of the main base plate11, so that the end portions of the sub rails18on the sub base plates21at the upper portions of the mounting tables20ato20dare in tight contact with the end portions of the first and second main rails17aand17b; in a case of two sub mounting tables, the main rails17aand17bare arranged so as to extend on the same side by the respective sub rails18; and in a case of four sub mounting tables, both ends of each of the first and second main rails17aand17bare in tight contact with the respective ends of sub rails18, and the first and second main rails17aand17bextend along the direction of both ends by the respective sub rails18.

In the figure, reference symbols19aand19brespectively represent the first and second extended rails extended from the first and second main rails17aand17bby the sub rails18.

A gantry13being a movable member is disposed on the main base plate11. A print head (not shown) is provided at the bottom surface portion of the gantry13. The gantry13is connected with a tank14containing ejection liquid.

When ejection liquid is supplied from the tank14, and then ejection mechanism inside the print head is operated, the ejection liquid is ejected from a plurality of ejection holes provided on the print head toward the main base plate11.

A substrate7is arranged on a portion of the surface of the base plate11, the portion being located between the main rails17aand17b.

The gantry13is mounted on the first and second extended rails19aand19bso as to be able to run on the extended rails19aand19b.

As ejection from the print head is controlled by a controller (not shown), as shown inFIGS. 6(a) and6(b), when ejection liquid is ejected from the print head with the gantry13located above the substrate7, the ejection liquid lands on the surface of the substrate7. By moving the gantry13, ejection liquid can be made to land on a desired position of the surface of the substrate7.

Although the stage apparatus5is to be disposed at a stand installation site where ejection work onto the substrate7is performed, as the main base plate11is large, the stage apparatus5cannot be transported from a temporary installation site (i.e., where the stage apparatus5has been assembled) to the real installation site in a state, as shown inFIGS. 5 and 6, with the sub mounting tables20ato20dconnected to the main mounting table10so as to make the main base plate11and sub base plates21in contact with each other.

As in the configuration of the stage apparatus5to be used as an embodiment of the present invention, each of the sub mounting tables20ato20dis arranged so as to be independently detachable with respect to the main mounting table10, with the sub mounting tables20ato20dattached, the sub connection sides B of the sub base plates21on each of the sub mounting tables20ato20dare in tight contact with the main connection sides F of the main base plate11, while in a state where the sub mounting tables20ato20dare detached from the main base plate11, the sub base plates21are separated from the main base plate11so as to be able to be independently transported.

With the above-described configuration, it is possible to perform the process of assembling at the temporary installation site; then disjoin after positional alignment; and transport from the temporary installation site to the real installation site; and the state of completion of positional alignment carried out at the temporary installation site is restored at the real installation site.

For use in describing the procedures,FIG. 1(a) is a plan view of the main mounting table10in a state of being disposed not at the real installation site but at the temporary installation site; andFIG. 1(b) is a side view of the main mounting table10.

Leg portions12ato12dare disposed near the four corners of the backside surface of the main base plate11.

InFIG. 1(a) (and as discussed below with respect toFIGS. 3 and 4), the main base plate11and main rails17aand17bare shown by a chain of double-dashed lines, and part of the leg sections12ato12dare shown by solid lines. The leg sections12ato12dare fixed on the back surface of the main base plate11.

Next,FIG. 2(a) is a plan view of the sub mounting tables20ato20d; andFIG. 2(b) is a side view thereof.

The sub mounting tables20ato20drespectively have a carriage22; and the sub base plates21are mounted on the respective carriages22.

Each carriage22is provided with a plurality of transporting wheels23. In this embodiment, the carriage22is provided with a pedestal27, and the transporting wheels23are arranged at four portions of the bottom surface of the pedestal27.

The main base plate11and sub base plates21are in a rectangular or square shape. Since the sub base plates21are set smaller than or equal to a half of the main base plate11in terms of size, two sub base plates21can be connected to each of the both sides of the main base plate11.

Since the transporting wheels23are arranged so that the transporting wheels23are able to move in a forward and backward direction, the portions of the main base plates11on which the sub base plates21are connected to the main base plate11being considered the heads of the sub mounting tables20ato20d, when the transporting wheels23touch the floor and a force is applied in the forward or backward direction, the transporting wheels23rotate and the sub mounting tables20ato20drun on the floor in the direction along which the force is applied.

One or a plurality of sub positioning members241,242formed of a roller and rotation shaft are arranged on a pedestal27.

In this embodiment, two sub positioning members241and242are provided, being disposed separately from each other and locating on either side of the moving direction, at the heads of the forward direction of the sub mounting tables20ato20don the pedestal27.

The leg portions12ato12dare in contact with the floor, and have a support portion15supporting the main base plate11and a main positioning member16in the form of a plate provided on the perimeter side surfaces of the support section15. The respective main positioning members16are disposed above the floor at a constant distance from the floor, and gaps are formed between the main positioning members16and the floor.

As the sub positioning members241and242are arranged such that they are movable and fixable with respect to the pedestals27, with the distance between the sub positioning members241and242set in advance to be large, when the sub mounting table20d(as the sub mounting table20dshown inFIG. 3) is moved forward with the head portion thereof being directed toward the leg portion12dso as to be the main rail17a, or17b, and the sub rail18being in a straight line, the pedestal27is inserted between the main positioning member16and the floor, as with the sub mounting table20ashown in the figure.

The main positioning members16are disposed on the side surfaces (of the leg portions12ato12d) which are in parallel to the main rails17aand17b.

Each main positioning member16is disposed at the same height as the sub positioning members241and242, while the distance between the sub positioning members241and242is set larger than the width of the main positioning member16, so that the pedestal27is inserted under the main positioning member16without a contact between the sub positioning members241,242and the main positioning member16; and the sub base plate21and main base plate11contact each other, as with the sub mounting table20bshown in the figure.

In this state, there is a large margin of error that differs from an ideal positional relationship between the main base plate11and sub base plate21.

On the sub mounting tables20ato20d, adjustment mechanisms30, which are capable of changing the respective heights, inclinations, and the horizontal positions and directions of the sub base plates21, is provided.

Each of these adjustment mechanisms30includes a coarse adjustment mechanism31capable of generally changing the height, inclination, and horizontal position and direction of the sub base plate21; and a fine adjustment mechanism32capable of changing in a more finely manner than is done with the coarse adjustment mechanism31.

Since the coarse adjustment mechanism31is arranged so as to be able to change the height, inclination, and horizontal position to a larger extent than the fine adjustment mechanism32, first, in each of the sub mounting tables20ato20d, the coarse positional adjustment mechanism31performs schematic position alignment of the sub base plate21with the main base plate11.

Assuming that the floor of the temporary installation site is horizontal and that the main base plate11is set in advance by a main adjustment mechanism (not shown) provided on the main mounting table10such that the surface of the main base plate11is horizontal, the sub base plates21are made horizontal at almost the same height as the surface of the main base plate11and the relative positions and directions thereof with respect to the main base plate11are coarsely adjusted by the coarse adjustment mechanisms31. Thus, schematic positional alignment is performed.

In this state, although some margin of error different from the state of ideal position alignment is still included, when an initial error E1represents the error amount (absolute value) before the coarse adjustment, and the coarse adjustment error E2represents the error amount (absolute value) after the coarse adjustment, the coarse adjustment error E2is smaller than the initial error E1by the amount which has been coarsely adjusted.

In a state subsequent to the coarse adjustment, the sub base plates21are in contact with the main base plate11, so that the sub mounting tables20ato20dcannot move forward but can move along a left-right direction and backward.

Next, with the coarse adjustment mechanism31(i.e., the course adjustment screw) being fixed, and with the coarsely adjusted relative position between the sub base plate21and main base plate11being maintained so as not to change, when the sub positioning members241and242are moved and fixed to the pedestal27in a state of being in contact with the main positioning member16, the main positioning member16is sandwiched by the sub positioning members241and242.

Since the support portions15are located more toward the inside than toward the perimeter of the main base plate11, and each main positioning member16is formed so as to be wider at the portion where it is distant from the perimeter of the base plate11and narrower at the portion where it is near the perimeter of the main base plate11, in a state such that the positioning members241and242sandwich the main positioning members16, the sub mounting tables20ato20dare able to move outward (backward) from the main base plate11and unable to move forward or in the left-right direction with respect to the leg portions12ato12d.

Next, with the use of the fine adjustment mechanisms32, the respective heights, inclinations, and horizontal positions and directions of the sub base plates21, and the positions of the sub base plates21with respect to the main base plate11, are finely adjusted for each of the sub mounting tables20ato20d.

With respect to the error amount (absolute value) of the relative positional relationship between the sub base plates21and the main base plate11in a state of fine adjustment, the error amount differs from the ideal positional relationship by a fine adjustment error E3, the fine adjustment error E3being nearly zero, wherein E1>E2>E3≈0.

After the fine adjustment, the state of fine adjustment is maintained by fixing the fine adjusting screws of the fine adjustment mechanisms32.

The stands25are disposed between the pedestals27and sub base plates21. The sub base plates21are fixed to the stands25. As the stands25are provided with coupling members33, when the stands25are fixed to the leg portions12ato12dby the coupling members33, the relative position between the main base plate11and the sub base plates21is fixed via the stands25and leg portions12ato12din a state such that the coarse adjustment and the fine adjustment have been performed.

By the above-described procedure, the stage apparatus5is assembled in a state such that the positions of the sub base plates21and the position of the main base plate11are aligned with each other, and the sub rails18are connected straight to both ends of the main rails17aand17b; and thus, the first and second extended linear rails19aand19bare obtained.

After performing the above-described temporary assembling at the temporary installation site (i.e., when the coupling members33are removed), the couplings between the main mounting table10and sub mounting tables20ato20dare released, and the sub mounting tables20ato20dare moved back so that the main table10and the sub mounting tables20ato20dare separated from each other, the main mounting table10and the sub mounting tables20ato20dapproaching a state that allows individual transportation.

At this time, the fixation of the sub positioning members241and242is not released, and the distance between the sub positioning members241and242is not changed. Further, fixation of (coarse adjustment screw and fine adjustment screw of) the coarse adjustment mechanisms31and fine adjustment mechanisms32is maintained so that a state of having the coarse adjustment and the fine adjustment completed does not change.

The main mounting table10and sub mounting tables20ato20dare individually loaded on a vehicle or the like, and transported to the real installation site by land, sea, or the like, and then, the main mounting table10is disposed at a predetermined position of the real installation site.

Next, the sub mounting tables20ato20dare disposed so as to be oriented to the leg portions12ato12d; and as shown inFIG. 7, the sub mounting tables20ato20dare respectively made to move forward toward the leg portions12ato12din order that the sub mounting tables20ato20din the assembled condition made at the temporary installation site can be restored.

As the width of the main positioning members16is larger toward the deeper side in the moving direction of the sub mounting tables20ato20d, when the pedestals27of the respective sub mounting tables20ato20dget under the main positioning members16, the main positioning members16are inserted between the sub positioning members241and242; and when the sub positioning members241and242come in contact with the main positioning members16, the sub mounting tables20ato20dstop moving forward.

This state is the same as shown inFIG. 4; that is, when the floor of the temporary installation site and that of the real installation site are horizontal, and the sub positioning members241and242and the main positioning members16are in contact with each other at the same positions as the contact positions that were taken at the temporary installation site, the positional relationship between the sub mounting tables20ato20dand the main mounting table10at the temporary installation site is restored.

More specifically, as the sub base plates21and the main base plate11are in the same condition in both coarsely and finely adjusted conditions, real assembly at the real installation site is completed when the stands25of the sub mounting tables20ato20dand the leg portions12ato12dof the main mounting table10are coupled and fixed with each other by the coupling members33, and the pedestals27are fixed with respect to the leg portions12ato12d.

However, because the coupling between the sub mounting tables20ato20dand the main mounting table10was released and then the sub mounting tables20ato20dand the main mounting table10were separated so as to be transported, a small error E4in positional alignment may have occurred due to vibration, change in temperature, or the like during transportation.

Also, when the surface of the main base plate11is reset to be horizontal, due to the real installation site not being horizontal, an error in positional alignment occurs.

Such an error E4in positional alignment is comparable in size to a fine adjustment error E3, and the state of having the coarse adjustment completed is maintained.

Accordingly, after the surface of the main base plate11is made horizontal, when the fixation of the fine adjustment mechanisms32is released to have the heights and inclinations in the vertical direction and the horizontal positions and directions of the sub mounting tables20ato20dfinely adjusted with the fine adjustment mechanisms32, and when the stands25of the sub mounting tables20ato20dand the leg portions12ato12dof the main mounting table10are coupled and fixed with each other by the coupling members33, then the positions of the sub base plate21with respect to the main base plate11are changed, which may make the alignment error E4become small; and thus, the positional alignment error between the main base plate11and the sub base plates21can be made comparable in size to the fine adjustment error E3which was there before the transportation.

More particularly, in the stage apparatus5to be used in an embodiment of the present invention, for each of the sub base plates21of the respective sub mounting tables20ato20d, a positional alignment can be independently performed regardless of positional alignments of the sub base plates21of any other of the sub mounting tables20ato20d. In a case of arranging two sub rails on one sub base plate and connecting the two sub rails with the first and second main rails17aand17b, when, in a state such that a positional alignment between one sub rail and the first main rail17aor second main rail17bhad been completed, positional alignment between the other sub rail and the first main rail17aor second main rail17bwas performed, an error would occur in positional alignment between the sub rail which is finished with another positional alignment, and the first main rail17aor second main rail17b. However, in the stage apparatus5to be used in an embodiment of the present invention, as a positional alignment work of one sub base plate21does not affect the positional alignment condition of the other sub base plates21, an error does not occur on the sub base plate21having already been subjected to positional alignment.

FIGS. 5(a) and5(b) are a plan view and a side view respectively of the stage apparatus5that is assembled in the above-discussed procedure at the real installation site and are in a state such that the main rails17aand17bon the main mounting table10and the sub rails18on the sub mounting tables20ato20dare linearly connected with each other so as to form the first and second extended rails19aand19b, and the gantry13is mounted on the first and second extended rails19aand19b.

In the figures, as the gantry13is located on the sub mounting tables20cand20dwhich are disposed outside the main mounting table10, the cleaning of the print head and the like can be performed at this location. Further, since the gantry13is not on a substrate, it is possible to replace a substrate7on the main mounting table10.

As the accuracy of positional alignment between the main base plate11and the sub base plates21is high, even when the gantry13is moved on and in the middle of the sub mounting tables20ato20dand the main mounting table10as shown inFIGS. 6(a) and6(b), the movement does not cause vibration.

The stands25are separable from the carriages22, and when the stands25are fixed to the leg portions12ato12dby the coupling members33, even when the carriages22are removed from under the stands25as shown inFIG. 6(b), the sub base plates21are in a state of being fixed to the main base plate11.

As described above, in accordance with an embodiment of the present invention, prior to the assembling of the sub mounting tables20ato20dand the main mounting table10at a real installation site, in a temporary installation site (for example, in a factory where the stage apparatus5has been manufactured) having the positions of the sub base plates21and the main base plate11aligned with each other in advance, then the sub base plates21and the main base plate11separated from each other such that the aligned state can be restored, to be transported, which enables assembly thereof at the real installation site.

Incidentally, the coupling members33to be used for assembly may be arranged on the sub mounting tables20ato20d, or may be arranged on the main mounting table10. Also, the coupling members33may be arranged to be removable from both of the sub mounting tables20ato20dand the main mounting table10.

In the foregoing embodiment, the main positioning members16are formed of plate-shaped members, and the sub positioning members241and242are formed of rollers in contact with the side surfaces of the main positioning members16. However, the main positioning members16and the sub positioning members241and242are not limited thereto, and can be any types of members that re-create the relative positional relationship between the sub base plates21and the main base plate11. The main positioning members may also be formed of rolls, and the sub positioning members may be formed of plate-shaped members.

Further, in the forgoing embodiment, though the main positioning members16were fixed inside the leg portions12ato12d, so that the positional relationship between the main positioning members16and the main base plate11was fixed, while the sub positioning members241and242were arranged movable and fixable with respect to the pedestals27. However, the positional relationship between the sub positioning members241and242and the sub base plate21may be fixed, and the relative positions between the main positioning members16and the main base plate11may be arranged so as to be changeable and fixable. In this case, after fixing by the coupling members33to follow coarse adjustment, the main positioning members16may be moved to come in contact with the sub positioning members241and242so as to fix the positions of the main positioning members16relative to the main base plate11.

Incidentally, reference numeral6inFIG. 8represents a stage apparatus for which two sub base plates21are connected to one main connecting side F of one main base plate11, and no sub base plate is connected to the other side.

Further, though in the foregoing embodiment, the gantry13is disposed on the main and sub mounting tables10and20ato20dof the stage apparatus5or6in accordance with the present invention to be used as an inkjet device, the invention is not limited thereto. A laser irradiation device may be disposed on the stage apparatus5or6in accordance with the invention to be used as a heating device, inspection device, or an exposure device, too. Further, a substrate positional alignment device may be used as an aligner.

In short, the stage apparatus5or6in accordance with the invention is not limited to one for use in an inkjet device.

Further, a movable member is not limited to the gantry13, and may be one that moves on the main base plate11and sub base plates21(for example, a mounting table to mount an object of processing, such as a substrate).