Screen printing device and screen printing method

1. A screen printing device that abuts a substrate against a mask plate in which pattern holes are formed to print a paste, the screen printing device comprising:

a substrate positioning unit that holds a substrate carried from an upstream side, and moves the substrate relatively in a horizontal direction and a vertical direction to position the substrate at a given position;

a screen print unit that allows a squeegee to slide on the mask plate onto which the paste is supplied, to print the paste on the substrate through the pattern holes;

an imaging unit that has two imaging optical axes of which imaging directions are upward and downward, respectively, and conducts mark imaging operation of imaging a substrate recognition mark and a mask recognition mark formed on the substrate and the mask plate, respectively;

an imaging unit moving mechanism that moves the imaging unit in the horizontal direction with respect to the substrate and the mask plate;

a recognition processing unit that subjects an imaging result in the mark imaging operation to recognition processing, thereby conducting mark recognition processing for detecting positions of the substrate recognition mark and the mask recognition mark;

an optical axis calibration processing unit that detects relative positions of the imaging optical axes on a mask lower surface and a substrate upper surface which are imaging surfaces of the two imaging optical axes, respectively, by imaging two reference marks associated with the relative positions by the imaging unit, individually, and outputs the detected relative positions as inter-optical-axis relative position data;

a surface correction data creation processing unit that obtains a position error of the imaging optical axes occurring on the imaging surfaces in the horizontal direction caused by the move of the imaging unit by the imaging unit moving mechanism, as a positional deviation in the horizontal direction which is specific to each of reference points set in an ordered array for a substrate area on which the substrate is held and a mask area on which a mask plate is installed, respectively, and outputs the obtained position error as surface correction data representing a local positional deviation state in each of surfaces of the substrate area and the mask area; and

a substrate positioning control unit that controls the imaging unit, the imaging unit moving mechanism, and the recognition processing unit so as to execute the mark imaging operation and the mark recognition processing, and controls the substrate positioning unit on the basis of the inter-optical-axis relative position data, the surface correction data, and the result of the mark recognition processing to execute substrate positioning operation for positioning the substrate and the mask plate.

2. The screen printing device according to claim 1 ,

wherein the imaging unit is configured to arrange two imaging cameras having postures in which the imaging surfaces are oriented in opposite vertical directions, in parallel in a plan view.

3. The screen printing device according to claim 1 ,

wherein the optical axis calibration processing unit detects the relative positions of the imaging optical axes by a teaching operation of aligning the two imaging optical axes with the two reference marks by manual operation, individually, on a teaching screen where the reference marks are imaged, individually.

4. The screen printing device according to claim 1 ,

wherein a calibration substrate having a reference point formed in an ordered array is held on the substrate area, and a calibration mask having a reference point formed in an ordered array is installed on the mask area.

5. The screen printing device according to claim 1 ,

wherein the surface correction data creation processing unit detects the positional deviation for each of the reference points through a teaching operation of aligning the two imaging optical axes with the reference points through manual operation, individually, on a teaching screen on which the reference points are imaged.

6. A screen printing method in which a substrate is abutted against a mask plate having pattern holes formed therein to print a paste, the screen printing method comprising:

holding a substrate carried from an upstream side by a substrate positioning unit;

imaging a substrate recognition mark formed on the substrate, and a mask recognition mark formed on the mask plate installed in a screen printing unit by an imaging unit that has two imaging optical axes of which imaging directions are upward and downward, respectively, and is moved in a horizontal direction with respect to the substrate and the mask plate by an imaging unit moving mechanism;

recognizing an imaging result in the imaging of the marks by a recognition processing unit, thereby detecting positions of the substrate recognition mark and the mask recognition mark;

positioning the substrate to the mask plate by controlling the substrate positioning unit on the basis of the position detection results of the substrate recognition mark and the mask recognition mark; and

printing a paste on the substrate through the pattern holes by sliding a squeegee on the mask plate having the pattern holes to which the paste is supplied,

wherein, prior to the imaging of the marks, there are executed:

performing an optical axis calibration processing by detecting horizontal relative positions of the respective imaging optical axes on a mask lower surface and a substrate upper surface which are imaging surfaces of the two imaging optical axes, respectively, by imaging two reference marks associated with the relative positions, individually, and outputting the detected relative positions as inter-optical-axis relative position data; and

performing a surface correction data creation processing by obtaining a position error of the imaging optical axes occurring on the imaging surfaces in the horizontal direction caused by the move of the imaging unit by the imaging unit moving mechanism, as a positional deviation in the horizontal direction which is specific to each of reference points set in an ordered array for a substrate area on which the substrate is held and a mask area on which a mask plate is installed, respectively, and outputting the obtained position error as surface correction data representing a local positional deviation state in each of surfaces of the substrate area and the mask area, and

wherein in the imaging of the marks, the imaging unit moving mechanism is controlled on the basis of the inter-optical-axis relative position data and the surface correction data, whereby an error of the relative position between the imaging optical axes in the horizontal direction is corrected, and the position error of the two imaging optical axes in the horizontal direction are corrected.

7. The screen printing method according to claim 6 ,

wherein in the optical axis calibration processing, the relative positions of the imaging optical axes are detected by a teaching operation of aligning the two imaging optical axes with the two reference marks by manual operation, individually, on a teaching screen where the reference marks are imaged, individually.

8. The screen printing method according to claim 6 ,

wherein a calibration substrate having a reference point formed in an ordered array is held on the substrate area, and a calibration mask having a reference point formed in an ordered array is installed on the mask area.

9. The screen printing method according to claim 8 ,

wherein in the surface correction data creation processing, in any one or both of the calibration substrate and the calibration mask, the surface correction data is created taking into account calibration data obtained by measuring the positional deviation from a regular position of each of the reference points in advance.

10. The screen printing method according to claim 6 ,

wherein in the surface correction data creation processing, the positional deviation for each of the reference points is detected through a teaching operation of aligning the two imaging optical axes with the reference points through manual operation, individually, on a teaching screen on which the reference points are imaged.