CN111948849A

CN111948849A - Method and system for manufacturing laminated body of optical display device

Info

Publication number: CN111948849A
Application number: CN202010799872.4A
Authority: CN
Inventors: 田村宜之; 秋山孝二; 大岛崇之; 矢野祐树
Original assignee: Nitto Denko Corp
Current assignee: Nitto Denko Corp
Priority date: 2016-11-01
Filing date: 2017-10-25
Publication date: 2020-11-17
Anticipated expiration: 2037-10-25
Also published as: CN111948849B; KR20190070933A; JP6634360B2; TWI704398B; JP2018072688A; KR102154006B1; TW201825984A; CN109891307A; WO2018084043A1; CN109891307B

Abstract

The invention provides a method and a system for manufacturing a laminated body of an optical display device, wherein the manufacturing method comprises the following steps: laminating an optical film having a first polarizing film peeled from a first release film together with an adhesive layer on one surface of a liquid crystal panel; laminating an optical film having a second polarizing film peeled from a second release film together with an adhesive layer on the other surface of the liquid crystal panel so that the absorption axis is in a crossed nicols relationship; a step of abutting a position adjusting unit against the liquid crystal panel to adjust the position of the liquid crystal panel; inspecting the liquid crystal panel; in the step of laminating the optical film having the second polarizing film, the optical film is laminated so as not to protrude from one of the longer sides of the liquid crystal panel, the liquid crystal panel is conveyed toward the step of performing position adjustment so that one side is parallel to the conveying direction of the liquid crystal panel, and the position adjustment means is brought into contact with one side from the side of the conveying direction of the liquid crystal panel to perform position adjustment of the liquid crystal panel.

Description

Method and system for manufacturing laminated body of optical display device

The present application is a divisional application of an invention patent application having an application date of 2017, 10 and 25, entitled "laminate for optical display device, method and system for manufacturing the same", and application No. 201780068152.7.

Technical Field

The present invention relates to a laminate for an optical display device, a method and a system for manufacturing the same. More specifically, the present invention relates to a laminate of an optical display device in which optical films having polarizing films are laminated on both surfaces of a rectangular liquid crystal panel so that absorption axes thereof are in a crossed nicols relationship, wherein the optical film having a polarizing film on one surface of the liquid crystal panel has a width or length corresponding to the width or length of the liquid crystal panel, and the optical film having a polarizing film on the other surface of the liquid crystal panel has a width or length larger than at least one of the width or length of the liquid crystal panel, and a method and a system for manufacturing the laminate.

Background

At the manufacturing site of optical display devices, a Roll To Panel (RTP) method is currently used (for example, patent document 1). In the RTP method, an optical display device is generally manufactured as follows. First, an optical film laminate having a predetermined width is fed from a roll. The optical film laminate includes a carrier film, an adhesive layer formed on one surface of the carrier film, and an optical film supported on the carrier film via the adhesive layer. The optical film may be a single layer film or a multilayer film. In general, a sheet-like optical film is formed between adjacent cut lines by continuously introducing the cut lines in the width direction into the fed optical film laminate.

An optical film continuously supported on a carrier film and formed in a sheet shape is peeled from the carrier film together with an adhesive layer by a peeling means arranged in the vicinity of a bonding position, and is conveyed to the bonding position. At the peeling unit, the carrier film side of the optical film laminate bypasses the top of the substantially wedge-shaped peeling unit having a top opposite to the attaching position. The optical film is peeled from the carrier film together with the adhesive layer by folding and conveying the carrier film bypassing the peeling unit in a direction substantially opposite to a direction in which the optical film is conveyed toward the bonding position. The optical film that reaches the bonding position is bonded to the corresponding bonding surface of the panel that is separately conveyed to the bonding position by a bonding unit having a pair of bonding rollers.

On the other hand, in recent years, optical display devices have been further reduced in size, thickness, and weight, and accordingly, not only the frame portion surrounding the liquid crystal display region is required to be narrowed (i.e., the frame is narrowed), but also no frame is required. As a method for satisfying these requirements, for example, as described in patent document 2, a technique has been proposed in which an optical film larger than a liquid crystal panel is bonded to one surface of the liquid crystal panel, the remaining portion of the optical film extending from an end portion of the optical film bonded to one surface of the liquid crystal panel is cut along the end portion of the liquid crystal panel, then an optical film larger than the liquid crystal panel is bonded to the other surface of the liquid crystal panel having one surface bonded with the optical film, and the remaining portion of the optical film extending from an end portion of the optical film bonded to the other surface of the liquid crystal panel is cut along the end portion of the liquid crystal panel, thereby manufacturing a laminate of an optical display device.

In patent document 2, the step of cutting out the remaining portion is performed in a series of manufacturing apparatuses. Specifically, since the remaining portions of the optical films sequentially bonded to the two surfaces of the liquid crystal panel are laminated in the manufacturing apparatus in a state of protruding from all four sides of the two surfaces of the liquid crystal panel each time, the remaining portions of all four sides of the laminated body are cut off from the two surfaces of the liquid crystal panel along the end portions of the two surfaces of the liquid crystal panel, and the optical films have a size corresponding to the bonding surface, as an optical display device obtained as a product manufactured by the manufacturing apparatus.

Further, for example, patent document 3 or patent document 4 proposes a production system in which an optical film is attached to one surface of a liquid crystal panel so as to protrude therefrom, and an optical film is attached to the other surface of the liquid crystal panel so as not to protrude therefrom. In these systems, as in the case of patent document 2, the step of cutting off the remaining portion attached to one surface of the liquid crystal panel in a protruding manner is performed in a series of production systems.

Specifically, as an optical display device obtained as a product from a production system in which the remaining portions of the optical film bonded to one surface of the liquid crystal panel are laminated in a state of protruding from all four sides of the liquid crystal panel, the remaining portions of the optical film bonded to one surface of the liquid crystal panel are cut along the end portion of the liquid crystal panel, and the optical film bonded to the other surface of the liquid crystal panel is bonded so as not to protrude, the optical films on both surfaces of the liquid crystal panel have a size corresponding to the bonded surface, and are a laminated body similar to the case of patent document 2.

In the liquid crystal display device, polarizing films are bonded to both surfaces of a liquid crystal panel along a reference line (alignment mark) so that absorption axes thereof are in a crossed nicol relationship, because the liquid crystal display device has a light shutter function. As shown in the reference drawing of fig. 8, the polarizing film includes a display region having a region size on or exceeding the black matrix inside the liquid crystal panel.

As can be seen from the schematic diagram of fig. 1, the liquid crystal display device has a structure including, on at least both sides of a liquid crystal, CF-side members of a liquid crystal panel including glass substrates to which color filters are attached, and TFT-side members of a liquid crystal panel including glass substrates to which alignment films and transparent electrodes are attached. In general, one of the long sides of the liquid crystal panel on the TFT side protrudes further than the corresponding side of the liquid crystal panel on the CF side, and serves as a terminal having a transparent electrode built therein. The polarizing films are bonded to the CF-side glass substrate and the TFT-side glass substrate via optical compensation films so that the absorption axes thereof are in a crossed nicol relationship. Therefore, the liquid crystal panel is generally a transparent region except for the region to which the polarizing film is bonded.

Documents of the prior art

Patent document

Patent document 1 (Japanese patent application laid-open No. 4377964)

Patent document 2 (Japanese patent laid-open No. 2014-228563)

Patent document 3 (Japanese patent laid-open publication No. 2013-137538)

Patent document 4 (Japanese patent application laid-open No. 2014-224911)

Disclosure of Invention

Technical problem to be solved by the invention

In the RTP manufacturing apparatus and the RTP manufacturing method, the optical display device is formed without a frame by bonding the liquid crystal panel and the optical film in a state where the optical film is protruded from the end of the liquid crystal panel, and then cutting a protruded portion (that is, the remaining portion) of the optical film along the end of the liquid crystal panel.

However, as proposed in patent documents 2 to 4, if the remaining portions of the peripheral edge are cut off after being bonded so as to protrude from the end portions of the liquid crystal panels in a series of production lines, it takes time to precisely cut off all the remaining portions, and therefore, productivity is significantly reduced.

Further, for example, a customer who grasps the manufacturing process of the liquid crystal panel as in a panel manufacturer is required to have a degree of freedom in how to cut out the peripheral edge surplus portion (for example, cut out along an end portion of the liquid crystal panel, or cut out with a cut-out margin of several millimeters), and the customer is required to perform the cutting-out process of the peripheral edge surplus portion by himself.

Accordingly, it is desired to provide a laminate for an optical display device in which the remaining portion of the optical film is left without cutting off the remaining portion of the peripheral edge of the liquid crystal panel formed by sticking the optical film to the liquid crystal panel in a larger size.

However, in the RTP method, in order to leave a laminate in which the remaining portion of the optical film is left without cutting off the remaining portion of the peripheral edge of the liquid crystal panel on a series of production lines, it is difficult to confirm the alignment mark as the reference point of the display region of the liquid crystal panel because the absorption axis of the polarizing film is in the cross nicol relationship after the liquid crystal panel and the optical film are bonded in a state in which the liquid crystal panel and the optical film are protruded from the four sides of both surfaces of the liquid crystal panel (if the optical film is an optical film having a polarizing film). Therefore, the positions of the liquid crystal panel and the polarizing film are difficult to align.

In addition, since the laminate with the remaining portion of the optical film left thereon is flexible and unstable in the peripheral edge of the optical film, it is not possible to use a position adjusting means which is brought into contact with the side surface in the conveying direction, and a complicated position adjusting mechanism must be separately prepared.

In the RTP manufacturing apparatuses and methods described in patent documents 2 to 4, all the remaining portions of the optical film that are sticking to and sticking to the liquid crystal panel are cut off in the manufacturing process or in the production system, and it is obvious that the optical display device obtained as a product thus manufactured is a laminate having no protruding portion of the optical film.

In addition, the embodiments disclosed in

patent documents

3 and 4 each disclose only that after the polarizing films are attached to the TFT side while extending from four sides, the polarizing films that do not extend are attached to the CF side, and do not disclose that the polarizing films that do not extend are first attached to the TFT side and then the polarizing films that extend are attached to the CF side.

A further technical problem is that even if a laminate of a liquid crystal display device in which polarizing films are attached so as to extend from four sides only on the TFT side and polarizing films that do not extend are attached on the CF side is provided in a manufacturing apparatus or a production system in accordance with a new request of a customer, when the remaining portions of the extending portions are cut off, the risk of damaging the portions where the TFT-side terminals are built in cannot be eliminated. In addition, the laminate having the remaining four sides is deformed by coming into contact with the liquid crystal panel position adjusting means immediately before the inspection portion, and the risk of cracks or the like due to the deformation cannot be eliminated. The present invention also seeks to solve these technical problems.

Means for solving the problems

The above-described problems can be solved by a technique in which, in a laminate of an optical display device in which optical films having polarizing films are laminated so that absorption axes thereof are in a cross-nicol relationship on both sides of a rectangular liquid crystal panel, the optical film on the TFT side, which is one side of the liquid crystal panel, has a width or length corresponding to the width or length of the liquid crystal panel, and the optical film on the CF side, which is the other side of the liquid crystal panel, has a width or length larger than at least one of the width or length of the liquid crystal panel. In the case of such a laminate, the step of cutting off the remaining portion of the optical film extending from the liquid crystal panel and laminated can be performed by an apparatus different from a series of manufacturing apparatuses, and therefore, the productivity can be greatly improved.

In addition, since the laminate of the present invention has the cross nicol relationship only at the portion where the optical film on the TFT side surface and the optical film on the CF side surface overlap each other, the alignment mark of the liquid crystal panel and the edge of the liquid crystal panel can be easily read through the optical film on the CF side surface at the outer periphery of the optical film on the TFT side surface. In addition, since the optical film having a width or length larger than at least one of the width or length of the liquid crystal panel is laminated on the CF side surface which becomes the viewing side when the display device is assembled, the viewing side can be made frameless by cutting off the remaining portion of the optical film which is stuck to extend from the liquid crystal panel.

In one aspect, the present invention provides a laminate for an optical display device, specifically, as shown in a schematic view in fig. 1, a laminate 6 in which an optical film 10 having a first polarizing film and an optical film 20 having a second polarizing film are laminated on both surfaces of a rectangular liquid crystal panel 5 so that absorption axes thereof are in a crossed nicol relationship. In the laminate 6 of the optical display device, the first optical film 10 having a width or length corresponding to the width or length of the liquid crystal panel 5 is bonded to the TFT side 52 surface which is one surface of the liquid crystal panel 5, and the second optical film having a width or length larger than at least one of the width or length of the liquid crystal panel 5 is bonded to the CF side 51 surface which is the other surface of the liquid crystal panel 5. The laminate 6 is further laminated such that the second optical film 20 bonded to the CF side 51 does not protrude from one side 52y of the long sides of the TFT side 52. In the case of such a laminate, the position adjusting means 530 can be brought into contact with the one side 52y, and therefore, the position of the laminate 6 can be easily adjusted.

As is apparent from fig. 1, the liquid crystal panel 5 is composed of the CF side 51 member and the TFT side 52 member, and in the laminate 6, the protrusion 520 of the TFT side 52 member from the CF side 51 member is formed on the liquid crystal panel 5 on the long side 52y of the TFT side 52 member of the liquid crystal panel 5 where the second optical film 20 does not protrude, the terminal 50 is formed on the CF side surface 521 of the protrusion 520, and the second optical film 20 bonded to the CF side surface 51 is bonded so as not to cover the terminal 50 of the protrusion 520. In the case of the laminate 6, by bonding the second optical film 20 so as not to cover the terminal 50, it is not necessary to cut and remove the remaining portion of the second optical film 20 covering the terminal 50, compared with a laminate in which the second optical film 20 is bonded so as to cover the terminal 50, and the terminal 50 is not damaged.

In another aspect, the present invention provides a method of manufacturing a laminate for an optical display device. As one embodiment, the present invention includes an RTP method shown in the schematic diagram of fig. 4 and the block diagram of fig. 5, and a monolithic method shown in the schematic diagram of fig. 6 and the block diagram of fig. 7, as will be described in detail later. Fig. 2 and 3 schematically show an RTP scheme as a whole.

The present invention is based on the following features, both in the RTP method and the single-wafer method.

Specifically, as shown in the schematic diagrams of fig. 2 and 3, a laminate 6 of an optical display device is manufactured using a first optical film laminate 1 and a second optical film laminate 2, the first optical film laminate 1 having a width or a length corresponding to the width or the length of a rectangular liquid crystal panel 5 and being composed of an optical film 10 having a first polarizing film supported on a first release film via an adhesive layer, the second optical film laminate having a width or a length larger than at least one of the width or the length of the liquid crystal panel 5 and being composed of an optical film 20 having a second polarizing film supported on a second release film, which is a second release film, via an adhesive layer.

The method includes a step (downstream step) of laminating an optical film 20 having a second polarizing film peeled from a second release film together with an adhesive layer on a surface of a CF side 51 of a liquid crystal panel 5 on which the optical film 10 having the first polarizing film is laminated so that an absorption axis is in a cross Nicol relationship, as a downstream step of the upstream step, from a step (upstream step) of laminating the optical film 10 having the first polarizing film together with the adhesive layer on a surface of a TFT side 52 of the liquid crystal panel 5, wherein the upstream step is omitted in FIGS. 4 and 5 or 6 and 7 described later, and the downstream step is described in detail in FIGS. 4 and 5 or 6 and 7.

The method may further comprise: a step of laminating the optical film 20 having the second polarizing film on the face of the CF side 51 of the liquid crystal panel, wherein the second optical film 20 is laminated so as not to protrude from one side 52y of the longer sides of the liquid crystal panel 5, and the liquid crystal panel is conveyed toward the step of adjusting the position of the laminate 6 of the liquid crystal panel 5 so that the one side 52y is parallel to the conveying direction of the liquid crystal panel 5, and the position adjusting means 530 is brought into contact with the one side 52y from the side of the conveying direction of the laminate 6 to adjust the position of the liquid crystal panel 5; and inspecting the laminated body 6 of the liquid crystal panel 5 for defects and the like after the step.

In the method, preferably, in the step of laminating the optical film 20 having the second polarizing film on the CF side 51 surface of the liquid crystal panel, the liquid crystal panel 5 is composed of the CF side 51 member and the TFT side 52 member, the projection 520 in which the TFT side 52 member projects from the CF side member is formed on the liquid crystal panel 5 on the one side 52y, the terminal 50 is formed on the CF side surface of the projection 520, and the second optical film 20 is laminated so as not to cover the terminal 50.

In another aspect, the present invention provides a system for manufacturing a laminate for an optical display device. As one embodiment, the present invention includes an RTP system shown in the schematic diagram of fig. 4 and the block diagram of fig. 5, and a monolithic system shown in the schematic diagram of fig. 6 and the block diagram of fig. 7, as will be described in detail later. Fig. 2 and 3 show RTP system systems schematically shown as a whole.

The present invention is based on the following features, whether RTP-based or monolithic.

Specifically, as shown in the schematic diagrams of fig. 2 and 3, the present system is a system including a transport unit 300, a first bonding section 100, and a second bonding section 200, wherein the transport unit 300 transports a rectangular liquid crystal panel 5, the first bonding section 100 laminates an optical film 10 having a first polarizing film on a TFT side 52, which is one surface of the transported liquid crystal panel 5, the optical film 10 having a width or a length corresponding to the width or the length of the liquid crystal panel 5, and the second bonding section 200 laminates an optical film 20 having a second polarizing film on a CF side 51 of the liquid crystal panel 5, which is a surface of the TFT side 52 on which the optical film 10 having the first polarizing film is laminated, such that an absorption axis is in a cross nicol relationship, and the optical film 20 has a width or a length larger than at least one of the width or the length of the liquid crystal panel 5.

The system further comprises: a conveying unit 100 in which the second optical film 20 laminated on the CF side 51 surface of the liquid crystal panel 5 at the second laminating unit 200 is laminated so as not to protrude from one side 52y of the long sides of the liquid crystal panel 5, the conveying unit 100 conveying the one side 52y in parallel to the conveying direction of the liquid crystal panel 5; a position adjustment unit 500 for adjusting the position of the liquid crystal panel 5 by bringing the position adjustment means 530 into contact with one side 52y from the side of the liquid crystal panel 5 in the conveyance direction; and an inspection unit 600 for inspecting the liquid crystal panel 5 subjected to the position adjustment for defects in the laminate 6.

In the present system, it is also preferable that the liquid crystal panel 5 is composed of CF-side 51 components and TFT-side 52 components, a protrusion 520 in which the TFT-side 52 components protrude from the CF-side components is formed on the liquid crystal panel 5 on one side 52y, the terminal 50 is formed on a CF-side surface 521 of the protrusion 520, and the second optical film 20 is laminated on the second bonding section 200 so as not to cover the terminal 50.

Drawings

Fig. 1 is a schematic view of a laminate of an optical display device.

Fig. 2 is a schematic diagram showing the entire apparatus for manufacturing a laminate of an RTP optical display device.

Fig. 3 is a schematic view of a second bonding section of the apparatus for manufacturing a laminate constituting an RTP optical display device.

Fig. 4 is a schematic view showing an operation procedure of the second bonding section of fig. 3.

Fig. 5 is a block diagram of the action steps of fig. 4.

Fig. 6 is a schematic view showing an operation procedure of the single-piece second bonding portion.

FIG. 7 is a block diagram of monolithic action steps.

Fig. 8 is a reference diagram showing a structure of a bonding position of a polarizing film of a liquid crystal panel.

Detailed Description

The laminate of the optical display device, the method for producing the same, and the system for producing the same according to the present invention will be described below with reference to the drawings. Fig. 1 is a schematic view of a laminate of an optical display device of the present invention. Fig. 2 and 3 are schematic views showing the entire apparatus for manufacturing a laminate of an RTP optical display device and a second bonding unit constituting the manufacturing apparatus. As for the overall manufacturing apparatus of the laminate constituting the monolithic optical display device and the schematic view of the second bonding section constituting the manufacturing apparatus, as an apparatus for laminating a monolithic optical film formed in a sheet shape on a liquid crystal panel, it is easy to think from fig. 2 and 3, and the corresponding drawings are omitted so as not to complicate the description.

Therefore, fig. 4 and 5, and fig. 6 and 7 each show a step of bonding an optical film 10 having a first polarizing film (hereinafter referred to as a first optical film 10) to a TFT side 52 surface which is one surface of a liquid crystal panel 5, a step of bonding an optical film 20 having a second polarizing film (hereinafter referred to as a second optical film 20) to a CF side 51 surface which is the other surface of the liquid crystal panel 5, or a second bonding section 200 of the liquid crystal panel 5 treated by the first bonding section 100, in which the optical film 10 has a width or length corresponding to the width or length of the liquid crystal panel 5. That is, in any of these figures, the step of bonding the first optical film 10 having the width or length corresponding to the width or length of the liquid crystal panel 5 to the TFT side 52 surface of the liquid crystal panel 5 or the first bonding portion 100 is omitted.

The overall configuration of the apparatus a for manufacturing a laminate of an RTP optical display device will be briefly described with reference to fig. 2. First, the rectangular liquid crystal panel 5 is conveyed from the upstream process to the first bonding section 100 by the conveying unit 300. The first optical film 10 having a width or length corresponding to the width or length of the liquid crystal panel 5 and peeled from the fed first optical film laminate 1 is conveyed to the bonding position 101 of the first bonding section 100 via the wedge-shaped peeling unit 60 having the apex 61, and the first optical film 10 is bonded to the surface of the TFT side 52 of the liquid crystal panel 5 conveyed to the first bonding position 101 by the first bonding unit 102.

The outline of the operation in the second bonding section 200 of the apparatus a for producing a laminate constituting an RTP optical display device and the steps downstream of the second bonding section 200 will be briefly described with reference to fig. 3. The liquid crystal panel 5 in which the first optical film 10 is laminated on the TFT side surface of the liquid crystal panel in the first bonding section 100 is rotated by 90 ℃ in the rotation and inversion section 150 (fig. 2) during conveyance to the second bonding section 200, and is conveyed to the second bonding section 200 in an inverted state by the conveyance unit 300.

The second optical film 20 having a width or length larger than at least one of the width or length of the liquid crystal panel 5, which is peeled from the fed second optical film laminate 2 by the peeling unit 60 having a wedge shape provided in the first laminating portion 100 and having the same top 61, is conveyed to the laminating position 201 of the second laminating portion 200, and the second optical film 20 is laminated on the face of the CF side 51 of the liquid crystal panel 5 conveyed to the laminating position 201 by the RTP laminating unit 202.

In the first bonded portion 100, the first optical film 10 laminated on the TFT side 52 surface of the liquid crystal panel 5 does not protrude from the peripheral edge of the liquid crystal panel 5. On the other hand, in the second bonding portion 200, the second optical film 20 laminated on the CF side 51 surface of the liquid crystal panel 5 so that the absorption axis is in the cross nicol relationship is laminated so as to protrude from the peripheral edge of the liquid crystal panel 5. The flexible optical film 20 must be carefully conveyed to the downstream process as well as the liquid crystal panel (i.e., the laminate 6) formed by stretching and laminating.

In the downstream process of the laminated body 6 produced from the second bonding section 200, the laminated body 6 positioned by the position adjusting section 500 is inspected for defects or the like through at least the inside of the laminated body by an imaging device, and the laminated body 6 of the optical display device is produced by an inspection section 600 for inspecting the bonding position of the first optical film 10 and/or the second optical film 20 to the liquid crystal panel 5 by reading the alignment mark 53.

Next, how to laminate the second optical film 20 on the CF side 51 surface of the liquid crystal panel 5 extending from the peripheral edge of the liquid crystal panel 5 in the RTP method will be described with reference to the schematic diagram of fig. 4 and the block diagram of fig. 5.

Fig. 4 shows a state in which the first optical film 10 has been laminated on the surface of the TFT side 52 in the upstream process and does not protrude to the terminal 50 of the protruding portion 520. Therefore, in step 1 shown in fig. 4 and 5, the carrier film 3 (hereinafter, referred to as the second carrier film 3) of the second release film of the second optical film laminate 2 is wound, and the second optical film 20 is peeled from the second carrier film 3 by the peeling unit 60, and the second optical film 20 is protruded by a predetermined distance. The predetermined distance is a bonding start position where the second optical film 20 is bonded to the CF side 51 surface of the liquid crystal panel 5. In step 2, the front end (or rear end) 20' of the second optical film 20 is determined by the sensor 90 in a protruded state.

In step 3 shown in fig. 4 and 5, after the liquid crystal panel 5 on which the first optical film 10 is laminated is fixed by suction by the liquid crystal panel fixing unit 310 and the position of the liquid crystal panel 5 is specified by the liquid crystal panel position detection sensor 91, the position of the liquid crystal panel fixing unit 310 is adjusted so as to be aligned with the position of the second optical film 20 specified in step 1. In step 4, the liquid crystal panel 5 on which the first optical film 10 is laminated is released from the liquid crystal panel fixing unit 310.

In step 5 shown in fig. 4 and 5, the front end 5' of the liquid crystal panel 5 is moved to the bonding position 201 by the transport unit 300 of the liquid crystal panel 5. In step 6, a portion slightly inside the front end 5 'of the liquid crystal panel 5 and the front end 20' of the second optical film 20 is sandwiched between the bonding roller 203 and the bonding receiving roller 204 constituting the RTP bonding unit 202.

In step 7 shown in fig. 4 and 5, the RTP bonding unit 202 is operated while the second carrier film 3 is wound, and the second optical film 20 is bonded to the liquid crystal panel 5 on which the first optical film 10 has been laminated in the first bonding unit 100. As shown in fig. 4, the second optical film 20 starts the bonding operation by a distance α from the short side of the liquid crystal panel 5 and a distance β from the long side of the pair of long sides of the terminals 50 of the liquid crystal panel 5. In step 8, after the second optical film 20 is laminated on the liquid crystal panel 5 on which the first optical film 10 is laminated, the bonding roller 203 and the bonding receiving roller 204 are opened.

As shown in fig. 1, the liquid crystal panel 5 includes CF-side 51 components and TFT-side 52 components, and on one side 52y, a protrusion 520 is formed on the liquid crystal panel 5, in which the TFT-side 52 components protrude from the CF-side components, and a terminal 50 is formed on a CF-side surface 521 of the protrusion 520. Therefore, in the step of laminating the second optical film 20 on the CF side 51 surface of the liquid crystal panel 5, the laminated body 6 manufactured through the steps shown in fig. 4 and 5 is laminated with the second optical film 20 in a state in which the second optical film 20 is protruded from three sides other than the one side 52y of the long side of the liquid crystal panel 5 so as not to cover the terminal 50.

Next, how to stack the second optical film 20 on the CF side 51 surface of the liquid crystal panel 5 by extending from the peripheral edge of the liquid crystal panel 5 in the single-sheet system will be described with reference to the schematic diagram of fig. 6 and the block diagram of fig. 7.

In step 1 shown in fig. 6 and 7, the second optical film 20, which is formed into a sheet shape and is stored in the optical film storage section 700 and in which the second release film 3 'is laminated via the adhesive layer, is taken out one sheet, and the second release film 3' side is placed on the first aligning table 701 so as to face downward. In step 2, after the first aligning table 701 fixes the second optical film 20 by suction with the first suction fixing portion 702, the position of the leading end 20' of the second optical film 20 is determined by the optical film position sensor 92.

In step 3 shown in fig. 6 and 7, the position of the single sheet laminating unit 703 is adjusted to be aligned with the determined position of the leading end 20' of the second optical film 20, and the second suction fixing portion 704 of the single sheet laminating unit 703 is brought into contact with the second optical film 20 side. In step 4, after the second suction fixing portion 704 of the single-piece bonding unit 703 is operated, the first suction fixing portion 702 of the first aligning stage 701 is released, and the single-piece bonding unit 703 is moved. In step 5, the second release film 3' is peeled from the second optical film 20 by a separate predetermined unit (not shown) in a state of being fixed to the single sheet bonding unit 703.

In step 6 shown in fig. 6 and 7, the liquid crystal panel 5 having the first optical film 10 laminated thereon is suction-fixed to the second alignment stage 705 by the third suction-fixing portion 706, and the position of the liquid crystal panel 5 is determined by the single-piece liquid crystal panel sensor 707. In the liquid crystal panel 5, the first optical film 10 is laminated on the TFT-side surface of the liquid crystal panel 5 in the upstream process, and the third suction fixing portion 706 of the second alignment stage 705 is suction-fixed to the TFT-side surface 52 of the liquid crystal panel 5.

In step 7 shown in fig. 6 and 7, the single-piece bonding unit 703 is tilted in a state where the second optical film 20 is fixed by the second suction fixing portion 704 of the single-piece bonding unit 703, and then the front end 5 ' of the liquid crystal panel 5 is pressed by the bonding roller 703 ' of the single-piece bonding unit 703 slightly inward of the front end 20 ' of the second optical film 20 in a state where the single-piece bonding unit 703 is tilted. In step 8, the second positioning stage 705 is moved while the laminating roller 703' is pressed against each liquid crystal panel, the second suction fixing portion 704 of the single-sheet laminating unit 703 is gradually released, and the second optical film 20 is laminated on the CF side 51 surface of the liquid crystal panel 5.

In step 9 shown in fig. 6 and 7, the operation of laminating the second optical film 20 on the liquid crystal panel 5 is completed. In step 10, the second alignment stage 705 is released from the stack 6 produced in step 9. As is apparent from fig. 1, in the liquid crystal panel 5, the protrusion 520 is formed so that the TFT-side member 52 protrudes from the CF-side member, the terminal 50 is formed on the CF-side surface 521 of the protrusion 520, and in the resultant laminated body 6, the second optical film 20 laminated on the CF-side 51 surface of the liquid crystal panel 5 is laminated so that the second optical film 20 does not cover the terminal 50 and so that the second optical film 20 protrudes from three sides other than the one side 52y of the long side of the liquid crystal panel 5.

As described above, in both the RTP method and the monolithic method, the laminated body 6 of the optical display device produced has the first optical film 10 of a normal size laminated on the surface of the TFT side 52 of the liquid crystal panel 5 so as not to protrude from the periphery of the liquid crystal panel 5, and the second optical film 20 of a size protruding from the periphery of the three sides of the liquid crystal panel 5 laminated on the surface of the CF side 51 of the liquid crystal panel 5 so as not to cover the terminals 50 provided on the surface 521 of the CF side of the protruding portion 520 of the liquid crystal panel.

The present invention has been described with reference to the embodiments and the accompanying drawings, but the present invention is not limited thereto, and it is apparent that a person having ordinary knowledge in the art to which the present invention pertains can make various modifications and variations within a range equivalent to the technical idea of the present invention and the scope of the claims.

Description of the symbols

A: apparatus for manufacturing laminated body of optical display device

1: first optical film laminate

2: second optical film laminate

3: second carrier film

3': second release film

5: liquid crystal panel

5': front end of liquid crystal panel

50: terminal of liquid crystal panel

51: CF side of liquid crystal panel

52: TFT side of liquid crystal panel

53: alignment mark of liquid crystal panel

52 y: one side of the long side of the TFT side of the liquid crystal panel

520: TFT-side protrusion of liquid crystal panel

521: CF side surface of the protrusion

6: a laminate:

10: optical film having first polarizing film (first optical film)

20: optical film having second polarizing film (second optical film)

20': front end of the second optical film

60: stripping unit

61: top of stripping unit

90: front (or rear) end detection sensor of second optical film

91: liquid crystal panel position detection sensor

92: optical film position sensor

100: first bonding part

101: first attaching position

102: first attaching unit

150: rotating and turning part

200: second bonding part

201: bonding position

202: RTP attachment unit

203: laminating roller

204: bonding receiving roller

300: transport unit

310: liquid crystal panel fixing unit

500: position adjusting part

530: position adjusting unit

600: inspection section

630: perspective inspection camera

700: optical film housing part

701: a first aligning table

702: first adsorption fixing part

703: single-piece type attaching unit

703': laminating roller of single-sheet laminating unit

704: second adsorption fixing part

705: second alignment table

706: third adsorption fixing part

707: single-chip liquid crystal panel sensor

Claims

1. A method for manufacturing a laminate for an optical display device, wherein the laminate for an optical display device is manufactured using a first optical film laminate and a second optical film laminate,

the first optical film laminate has a width or length not extending from one surface of the rectangular liquid crystal panel and is composed of an optical film having a first polarizing film supported on a first release film via an adhesive layer,

the second optical film laminate has a width or length larger than at least one of a width or length of the other surface of the liquid crystal panel, and is composed of an optical film having a second polarizing film supported on a second release film via an adhesive layer,

the method is characterized in that it consists in,

the second release film is in a strip shape,

an optical film having the second polarizing film is continuously supported on the second release film,

the method comprises the following steps:

laminating an optical film having the first polarizing film peeled from the first release film together with an adhesive layer on one surface of the liquid crystal panel;

laminating an optical film having a second polarizing film, which is peeled from the second release film together with an adhesive layer, on the other surface of the liquid crystal panel on which the optical film having the first polarizing film is laminated, so that an absorption axis of the optical film has a crossed nicols relationship;

a step of, after the step of laminating the liquid crystal panels so as to have the orthogonal nicol relationship, bringing a position adjusting means into contact with the liquid crystal panels having the optical films laminated on both surfaces thereof to adjust the positions of the liquid crystal panels;

a step of inspecting the liquid crystal panel after the step;

in the step of laminating the optical film having the second polarizing film on the other surface of the liquid crystal panel, the optical film is laminated so as not to protrude from one side of the long sides of the liquid crystal panel, the liquid crystal panel is conveyed toward the step of performing position adjustment so that the one side is parallel to the conveying direction of the liquid crystal panel, and the position adjustment means is brought into contact with the one side from the side of the conveying direction of the liquid crystal panel to perform position adjustment of the liquid crystal panel.

2. The method of manufacturing a laminate for an optical display device according to claim 1,

one surface of the liquid crystal panel is a TFT side surface, and the other surface of the liquid crystal panel is a CF side surface.

3. The method of manufacturing a laminate for an optical display device according to claim 1 or 2,

the liquid crystal panel includes a member on one surface side and a member on the other surface side, and a protrusion portion protruding from the member on the one surface side is formed on the liquid crystal panel on the one surface side, a terminal is formed on the other surface side of the protrusion portion, and an optical film having the second polarizing film is laminated so as not to cover the terminal.

4. A system for manufacturing a laminated body of an optical display device, comprising:

a conveying unit which conveys the rectangular liquid crystal panel;

a first bonding section that laminates, to one surface of the liquid crystal panel being conveyed, an optical film having a width or length that does not protrude from the one surface of the liquid crystal panel and having a first polarizing film;

a second laminating unit for laminating an optical film having a second polarizing film and having a width or length larger than at least one of the width or length of the other surface of the liquid crystal panel, to the other surface of the liquid crystal panel on which the optical film having the first polarizing film is laminated, so that an absorption axis of the optical film has a cross nicol relationship;

the second release film is in a strip shape,

the system for manufacturing a laminate for an optical display device includes:

a conveying unit that stacks the optical film on the second bonding unit so as not to protrude from one side of the long sides of the liquid crystal panel, the conveying unit conveying the optical film so that the one side is parallel to a conveying direction of the liquid crystal panel;

a position adjustment unit that makes a position adjustment unit abut against the one side from a side of the liquid crystal panel in a transport direction to adjust a position of the liquid crystal panel;

and an inspection unit for inspecting the liquid crystal panel subjected to the position adjustment.

5. The system for manufacturing a laminated body of an optical display device according to claim 4,

6. The system for manufacturing a laminated body of an optical display device according to claim 4 or 5,