JP2005144889A - Laminator - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a laminator capable of achieving a high yield and cost reduction without causing the positional shift of a film sheet in a lamination method adapted to a glass substrate, a metal substrate, a plastic substrate or the like for use in a liquid crystal display, a plasma display panel, an electric product or the like. <P>SOLUTION: In a method for laminating the a continuous film sheet 201 on a substrate 206 while allowing the same to travel, the side end surface of the film sheet 201 and the side end surface of the substrate 206 are detected by the CCD camera 213 of a position detecting means at least when the film sheet 201 begins to travel to control a taking-up roller 211 becoming a traveling control means. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a laminating apparatus that presses a resin film onto a printed board, a glass substrate, a metal substrate, or the like, or attaches a film applied onto the resin film.

  Conventionally, when laminating using a laminating apparatus, the following laminating apparatus has been proposed. That is, the laminated film sheet supplied from the roll-shaped unwinding roller is unwound so as to pass between the pair of upper and lower pressure-bonding rollers together with the substrate fed from the substrate supply port, and is pressure-bonded to the upper surface of the substrate. When a board | substrate exists intermittently, the laminated | multilayer film sheet | seat crimp-bonded is cut | disconnected using a separation cutter, and is isolate | separated for every board | substrate. Moreover, after a series of work is complete | finished, a laminated | multilayer film sheet is cut | disconnected and wound up by the winding roller (for example, nonpatent literature 1).

  FIG. 7 is a front view of a conventional laminating apparatus as seen in Non-Patent Document 1. In FIG. 7, the laminated film sheet 12 has a three-layer structure in which a film sheet 13 such as a dielectric material is applied on a long base film 15, and a cover film 14 is attached on the film sheet 13. After the unwinding roller 16 that has wound the laminated film sheet 12 is mounted on the laminating apparatus, the cover film 14 is peeled off, and the tip of the cover film 14 is wound around the cover film roller 17. The base film 15 and the film sheet 13 are passed through the intermediate roller 30 and between the upper press roller 20 and the lower press roller 21, and the film sheet 13 is laminated on the surface of the substrate 18. After the lamination is completed, the base film 15 is cut by the separation cutter 22 and then peeled off from the film sheet 13 to complete the lamination. Moreover, when the board | substrate 18 is intermittently thrown into a laminating apparatus and is conveyed intermittently, the removal area | region 24 which the film sheet 13 processes into a predetermined shape by the film sheet cutter 19 previously is provided.

  FIG. 8 shows a step of winding the cut base film 15 by the winding roller 23 after a series of operations is completed. In this conventional example, the winding auxiliary roller 25 is stored in the lower part of the substrate during the work process, but when the series of work is completed and the laminated film sheet 12 is taken up, it is moved upward as shown in FIG. The end of the laminated film sheet 12 is attached to the take-up roller 23 and taken up. In FIG. 5 and FIG. 6, the same reference numerals are used for the same parts.

FIG. 9 shows another example of a conventional laminating apparatus. The film sheet 42 supplied from the film roller 41 is guided to the upper press roller 44 through the transport roller 43. On the other hand, the long substrate 48 supplied by the substrate roller 49 is guided to the lower press roller 45 through the transport roller 46, and the long substrate 48 and the film sheet 42 are pressed by the upper press roller 44 and the lower press roller 45. The long substrate 48 laminated with the film sheet 42 is appropriately cut by a substrate cutter 47 and carried out. When the long substrate 48 wound around the substrate roller 49 is used up or when a series of operations is completed, the winding auxiliary roller 51 is moved up and down to move the end of the film sheet 42 to the winding roller 50. Adhere and wind up.
Published by E-journal Co., Ltd., “2001 FPD Technology Taizen”, October 25, 2000, P596

  However, in the conventional method in which the film sheet is continuously run while being unwound from the unwinding roller, the film is displaced during running. In particular, the film is liable to be displaced at the time of replacing the unwinding roller or restarting after stopping the continuous running.

  The present invention has been made in view of these problems, and provides a laminating apparatus that prevents a positional shift of a film at the time of film compression and has a high quality and a high yield.

  In order to solve the problems as described above, a laminating apparatus of the present invention is a laminating apparatus for pasting a sheet material formed on a continuous film on a substrate, and at least a film running means for continuously running the film; A film based on information from a winding means for winding up the starting end portion in the running direction of the film, a sticking means for sticking the sheet material to the substrate, a position detecting means for detecting the position of the side end surface of the film, and the information from the position detecting means Traveling control means for controlling the position of the side end face in the traveling direction, and the traveling control means has drive means for displacing the winding means.

  According to such a laminating apparatus, it is possible to control the running position by simply winding the film traveling direction start end portion on the winding means and displacing the winding means, and also replacing the substrate and changing the lot of the sheet material. In addition to being able to flexibly cope with this, it is possible to ensure the accuracy of the position of application to the substrate and to apply the substrate to the substrate with uniform tension.

  Further, the winding means may be a winding roller, and the driving means may move the winding roller in a direction perpendicular to the running direction of the film. According to such a laminating apparatus, the traveling direction position of the film can be controlled with a simple apparatus configuration.

  The winding means may be a winding roller, and the driving means may displace at least one of the end portions of the winding roller. According to such a laminating apparatus, the traveling direction position of the film can be controlled with a simple apparatus configuration.

  Furthermore, the position detecting means may mechanically or optically detect the amount of displacement from a predetermined position of the side end surface of the film for at least two points in the traveling direction of the film. According to such a laminating apparatus, position detection can be performed with high accuracy, and traveling direction position control can also be realized with high accuracy.

  Further, the laminating apparatus of the present invention is a laminating apparatus for pasting a sheet material onto a substrate while traveling a sheet material formed on a continuous film, and at least a film traveling roller for continuously traveling the film, and a film A removal cutter unit that removes a predetermined area of the sheet material formed thereon and processes the sheet material into a predetermined shape, a pressure roller for attaching the sheet material to the substrate, and a relative position detection sensor that measures the relative position of the sheet material and the substrate And an auxiliary cutter unit that controls the removal region of the removal cutter unit based on information from the relative position detection sensor.

  According to such a laminating apparatus, the relative position between the substrate and the sheet material affixed to the substrate is measured, and the region where the sheet material is removed is controlled. A stable and high quality laminating apparatus with a high yield can be realized.

  According to the laminating apparatus of the present invention, the running direction position of the side end surface of the film is controlled by simply winding the film running direction start end on the winding means and displacing the winding means. Positional accuracy can be ensured and it can be applied to the substrate with uniform tension.

  Embodiments of the present invention will be described below with reference to the drawings.

(First embodiment)
In this embodiment, the case where the laminating apparatus of the present invention is used for a typical plasma display panel (hereinafter referred to as PDP) as a flat panel display device will be described.

  FIG. 6 shows the configuration of the PDP. 6A is a perspective view of the front plate of the PDP, and FIG. 6B is a partially enlarged cross-sectional view of the AA cross section in FIG. 6A. This PDP includes a front plate and a back plate arranged to face each other. On the front glass substrate 1 serving as a substrate of the front plate, a transparent electrode 2, a bus electrode 3, a black stripe 4, Dielectric layer 5 and MgO dielectric protective layer 6 are formed in this order. A PDP is formed by attaching a drive circuit to a panel obtained by bonding the front plate and the back plate.

A method for manufacturing the front plate of this PDP will be briefly described. A front glass substrate 1 serving as a substrate for the front plate is formed of a glass material that can withstand a heat treatment process included in the formation process of the bus electrode 3, the black stripe 4, the dielectric layer 5, and the like. High strain point glass formed by a float process is used. After forming a film on the front glass substrate 1 by sputtering using a material such as ITO or SnO ₂ , a transparent electrode pattern is formed by exposure, development, and etching processes to form a transparent electrode 2. Next, the black stripe 4 is formed using a photosensitive material that is black using black pigment or RuO as a pigment.

A film sheet made of a photosensitive material containing Ag as a main component is applied thereon by a laminating method, followed by patterning by exposure and development, and baking to form the bus electrode 3. Next, a dielectric film sheet containing PbO—B ₂ O ₃ —SiO ₂ -based glass as a main component is attached by a laminating method and fired to form the dielectric layer 5. Next, MgO is formed by sputtering or vapor deposition to form the dielectric protective layer 6 to complete the front plate.

  As described above for the PDP front plate, the bus electrode 3 and the dielectric layer 5 can be formed by a laminating method, but if their relative positions vary in each laminating process, it will lead to a final failure. Therefore, the laminate must be made with high accuracy in the given positional relationship.

  FIG. 1 is a perspective view showing a laminating apparatus according to a first embodiment of the present invention, and FIG. 2 is a front view thereof. 1 and 2, a laminated film sheet 200 has a three-layer structure of a film sheet 201 that is a sheet material that is a component of a PDP, a cover film 202 that is a film, and a base film 203. It is wound and installed.

  First, the laminated film sheet 200 is unwound from the film roller 204 in the arrow B direction, and the cover film 202 is peeled off from the laminated film sheet 200 and taken up by the cover film roller 205. These form film running means.

  Next, in order to remove the film sheet 201 in a predetermined area corresponding to the gap between the series of substrates 206 and form the film sheet removal area 208, the film sheet 201 is cut by the film sheet removal cutter 207 which is a removal cutter unit. After the film is inserted, the film sheet 201 in this region is attached to the adhesive tape or the like and removed.

  In this way, the laminated film sheet 200 from which the film sheet removal region 208 has been removed at a predetermined interval and the substrate 206 inserted from the direction of the arrow A are sandwiched between the upper pressure roller 209 and the lower pressure roller 210 and are thermocompression bonded. A film sheet 201 is laminated on the surface of the substrate 206.

  Next, after the base film 203 is cut by the separation cutter 216, the substrate 206 is taken out, and the front plate on which the film sheet 201 is laminated is completed.

  The laminated film sheet 200 after being cut is wound around the winding roller 211 using the winding auxiliary roller 212.

  Next, when the film sheet 201 starts traveling, the position of the side end surface of the film sheet 201 or the base film 203 and the position of the side end surface of the substrate 206 are determined by position detection means (position detection sensor) or relative position detection means (relative). Is measured by a CCD camera 213 serving as a position detection sensor) and sent as an image to the image processing device 214. The side end surfaces of the film sheet 201 and the substrate 206 are recognized as line segments, and the angle θ formed by each line segment is Calculated. When the angle θ is not 0, that is, when the side end surface of the film sheet 201 and the side end surface of the substrate 206 are not parallel, the angle θ is set to 0 by the rotary motor 215 serving as a travel control unit that moves the winding roller 211. Thus, the winding roller 211 is moved in the axial direction which is a direction perpendicular to the traveling direction. Further, along with the angle θ, the shift amount of the distance of the film sheet 201 from the side end surface of the substrate 206 is also measured, and the film sheet 201 is moved to a predetermined position. The axial movement of the take-up roller 211 is performed while sequentially calculating the position based on the image processing information while the take-up rotation of the laminated film sheet 200 is performed. Also good.

  In the present embodiment, in order to clarify the positional relationship, the state where the film sheet 201 is wound around the winding roller 211 while being crimped to the substrate 206 is shown, but the laminated film sheet 200 is actually wound up. When being wound around the roller 211, the substrate 206 and the laminated film sheet 200 are kept in a state where they are not pressure-bonded. Further, when the position of the film sheet 201 is adjusted after the series of work steps is completed, the winding roller 211 is moved in a state where the substrate 206 is not inserted between the upper pressure roller 209 and the lower pressure roller 210. Is done.

(Second Embodiment)
FIG. 3 is a perspective view showing a laminating apparatus according to the second embodiment of the present invention. In this embodiment mode, a case is shown in which a base film 302 wound and supplied by a film roller 301 is directly bonded to a substrate. Further, the state of FIG. 3 shows a state where the crimping to a series of substrates has been completed and the substrate has already been ejected from the process. In this embodiment, the position correction of the base film 302 is performed using two laser beam irradiators 303 and 304 and laser beam receivers 305 and 306 instead of the image processing apparatus shown in the first embodiment. Is going. When the base film 302 is in the normal position, the light emitted from the left and right laser light irradiators 303 and 304 and the amount of light incident on the laser light receivers 305 and 306 are constant, but the light is incident on the base film 302. When the deviation occurs, the amount of incident light changes. The amount of change is analyzed by the arithmetic processing unit 307, and the winding roller 309 is moved by the axial movement stepping motor 308 which is a driving unit of the traveling control unit. Since the movement of the winding roller 309 is performed while being rotated by the drive motor 310, the movement of the base film 302 can be sequentially controlled, and the base film 302 can be returned to the normal position very quickly. In addition, this method has an advantage that the apparatus cost is very low since the apparatus configuration is simple and image processing is not necessary, as compared with the first embodiment.

(Third embodiment)
FIG. 4 is a perspective view showing the film sheet running direction control means of the laminating apparatus according to the third embodiment of the present invention. In this embodiment, the amount of deviation of the film sheet 403 from the normal position is mechanically measured by the two actuators 404 and 405, and the deviation angle θ of the film sheet 403 is calculated from the amount of change, and the winding roller 406. Is moved to return the angle θ to 0. Other configurations are the same as those of the first embodiment. One end of the winding roller 406 is connected to the motor by a universal joint (not shown). The other end has a structure in which the winding roller 406 can be displaced in the radial direction by a movable bearing 407. For this reason, the take-up roller 406 can be slightly tilted, and an equal tension can be applied to the film sheet 403. As a result, when the film sheet 403 is wound around the winding roller 406, the film sheet 403 can be wound without wrinkles and quickly returned to the normal position. In addition, since a mechanical sensor is used, it is more resistant to dust and has a longer lifespan than an optical sensor.

  In the second embodiment and the third embodiment, two measuring devices are used for detecting the film position, but the accuracy may be reduced to one. Needless to say, the position may be measured at three or more locations if the cost permits.

(Fourth embodiment)
FIG. 5 is a front view showing a laminating apparatus according to the fourth embodiment of the present invention. As shown in FIG. 5, the main components of the laminating apparatus are the same as those in the first embodiment shown in FIG. 2, and the same components are denoted by the same reference numerals.

  The fourth embodiment is different from the first embodiment in that a measurement step of measuring a relative position between the substrate 206 and the film sheet 201 after the film sheet 201 is attached to the substrate 206 and the base film 203 is peeled off. And having a relative position detecting means 500 therefor. Further, based on the information of the relative position detecting means 500, a removal process for removing a predetermined area of the film sheet 201 in order to form the film sheet 201 having a predetermined shape is controlled. Specifically, an auxiliary cutter unit 501 that controls the removal region based on information from the relative position detection unit 500 is provided.

  In the present embodiment, the relative position detection unit 500 includes a detection sensor 502 and a processing device 503, and the positional relationship between the substrate 206 and the film sheet 201 at the rear end 504 in the traveling direction of the substrate 206 is detected by the detection sensor 502. Measuring. When the film sheet 201 is formed at a position other than the predetermined position of the substrate 206 determined in advance, the removal area of the removal process is adjusted. A signal from the processing device 503 of the relative position detecting unit 500 is transmitted to the auxiliary cutter unit 501. For example, when the film sheet 201 is pasted from the normal position at the rear end portion 504 of the substrate 206, it is removed by the film sheet removal cutter 207 of the previous process by the auxiliary cutter unit 501 and has a predetermined length. The rear end portion 505 in the running direction of the film sheet 201 can be cut with the adjustment cutter 506 to adjust the length of the film sheet 201 attached to the substrate 206.

  Although FIG. 5 shows an example in which the auxiliary cutter unit 501 is provided separately from the film sheet removal cutter 207, information on the relative position detecting means 500 can be fed back to the film sheet removal cutter 207 to control the removal area. It is. Further, by adopting a configuration in which the two film sheet removal cutters 207 are moved independently, it is possible to adjust and control the state of the film sheet 201 attached to the rear end portion 504 or the front end portion of the substrate 206.

  In the above-described embodiment, a method and an apparatus have been described in which a substrate processed into a predetermined size is run one by one and a film sheet that is continuously conveyed is pasted to each substrate. However, the present invention can also be applied to a so-called multi-sided manufacturing method and manufacturing apparatus in which a plurality of film sheets are formed on a large plate substrate from which a plurality of substrates can be taken. It is suitable for the method and apparatus to do.

  Further, in the embodiment shown here, the substrate is made of glass and has a rectangular shape, but the substrate as shown in the conventional example is a long metal plate or a thick substrate. Needless to say, the present invention exhibits an effective effect even with a box-shaped substrate.

  According to the laminating apparatus according to the present invention, when the film sheet starts traveling, the position in the traveling direction of the side end surface of the film sheet is controlled, so that the accuracy of the position where the film sheet is adhered to the substrate can be ensured and uniform. It can be applied with tension, and is useful for laminating apparatuses that can be applied to various substrates such as glass, plastic, and metal such as liquid crystal displays, PDPs, and printed circuit boards.

The perspective view of the laminating apparatus in the 1st Embodiment of this invention Front view of the laminator The perspective view of the laminating apparatus in the 2nd Embodiment of this invention. The fragmentary perspective view of the laminating apparatus in the 3rd Embodiment of this invention. The front view of the laminating apparatus in the 4th Embodiment of this invention Perspective view and partial enlarged sectional view of the front plate of the PDP Front view of conventional laminating equipment Front view of conventional laminating equipment Front view of conventional laminating equipment

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Front glass substrate 3 Bus electrode 5 Dielectric layer 6 Dielectric protective layer 200 Laminated film sheet 201,403 Film sheet 202 Cover film 203,302 Base film 204,301 Film roller 205 Cover film roller 206 Substrate 207 Film sheet removal cutter 208 Film sheet removal area 209 Upper pressure roller 210 Lower pressure roller 211, 309, 406 Winding roller 212 Winding auxiliary roller 213 CCD camera 214 Image processing device 215 Rotating motor 216 Separating cutter 303 Laser beam irradiator (left)
304 Laser beam irradiator (right)
305 Laser receiver (left)
306 Laser receiver (right)
307 Arithmetic processing device 308 Axial moving stepping motor 310 Drive motor 404, 405 Actuator 407 Movable bearing 500 Relative position detecting means 501 Auxiliary cutter unit 502 Detection sensor 503 Processing device 504 Rear end portion of substrate 505 Direction of travel of film sheet 506 Adjustment cutter

Claims (5)

A laminating device for attaching a sheet material formed on a continuous film onto a substrate,
Film running means for continuously running at least the film;
Winding means for winding up the running direction start end of the film;
Affixing means for affixing the sheet material to the substrate;
Position detecting means for detecting the position of the side end face of the film;
A travel control means for controlling the travel direction position of the side end face of the film based on information from the position detection means,
The laminating apparatus, wherein the travel control means includes a drive means for displacing the winding means. The laminating apparatus according to claim 1, wherein the winding means is a winding roller, and the driving means moves the winding roller in a direction perpendicular to the running direction of the film. The laminating apparatus according to claim 1, wherein the winding means is a winding roller, and the driving means displaces at least one of the end portions of the winding roller. The laminating apparatus according to claim 1, wherein the position detecting means mechanically or optically detects a displacement amount of the side end face of the film from a predetermined position at least at two or more points in the running direction of the film. A laminating apparatus that pastes the sheet material on a substrate while running the sheet material formed on a continuous film,
A film running roller for continuously running at least the film;
A removal cutter unit that removes a predetermined region of the sheet material formed on the film and processes it into a predetermined shape,
A pressure roller for attaching the sheet material to the substrate;
A relative position detection sensor for measuring a relative position between the sheet and the substrate;
An auxiliary cutter unit that controls a removal region of the removal cutter unit based on information of the relative position detection sensor;
A laminating apparatus comprising:

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