JP2006252808A - Transfer method of film, and manufacturing method of film transfer device and plasma display panel - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To improve freedom of line design and product design through shortening of the time needed for processing, contraction of a device scale, and to improve the utilization efficiency of the materials. <P>SOLUTION: The film transfer device 110 for transferring a transfer film of a sheet material of a three-layer structure of a support film, a transfer film and a protective film to a substrate 1, is provided with a transfer film removal means 20, forming the transfer film left on the support film into a desired transfer pattern by removing a part of the transfer film, after the protective film has been peeled off over the width direction for each given interval in the feeding direction; means 117A, 117B for transferring the transfer film formed into the transfer pattern to the substrate 1; and a means 119 of peeling off the support film from the transfer film already transferred. A transfer movement of one transfer film and the peeling movement of a support film from that transfer film are carried out with an overlapping timing. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a film transfer method, a film transfer apparatus, and a plasma display panel manufacturing method.

  Conventionally, a sheet material from a sheet supply roll formed by winding a sheet material having a three-layer structure of a transfer film transferred to a substrate, a protective film covering the transfer film, and a support film supporting the transfer film. Is known in which a sheet transfer film is transferred onto a substrate (for example, Patent Documents 1, 2, and 3).

  As shown in FIG. 11, the film transfer apparatus disclosed in Patent Document 1 includes a sheet supply roll 1001 formed by winding a sheet material 1000 having a three-layer structure, and a sheet material 1000 rewound from the sheet supply roll 1001. Protective film at the front end and rear end positions corresponding to positions between a plurality of guide rollers 1002 for guiding the substrate 100 and the substrate 1005 conveyed on the conveyance path at regular intervals (only one substrate 1005 is shown in FIG. 11). And a cutting device 1003 that cuts the transfer film, a protective film removing device 1004 that peels off the protective film of the portion transferred to the substrate at two cutting positions by the cutting device 1003, a substrate 1005, and a sheet material 1000. A pair of thermocompression-bonding rollers 1006 that press-bond them together and a protective film removing device 10 4 and a tension adjusting roller 1007 for applying a constant tension to the sheet material 1000 in the sheet material conveying path between the heat pressing roller 1006 and a protective film removing device 1004 and the tension adjusting roller 1007. And a misalignment detection device 1008 that detects a positional deviation of the material 1000 in the width direction.

  The film transfer apparatus of Patent Document 1 operates as follows.

  A protective film other than the portion corresponding to the portion between the substrates 1005 is cut between the substrate 1005 and the protective film of the three-layer structure sheet fed from the sheet supply roll 1001 and the transfer film, which are sequentially conveyed at regular intervals. After peeling off (that is, the protective film covering the portion to be transferred to the substrate 1005 later), the transfer film is transferred to the substrate 1005 by passing between the pair of pressure rollers 1006 together with the substrate without cutting the support film. . At this time, the position of the tension adjusting roller 1007 is adjusted while measuring with a tension measuring instrument so that the sheet maintains a constant tension between the cutting device 1003 and the pressure roller 1006. The transferred substrate 1005 is connected to the previously transferred substrate 1005 via a support film. Therefore, the support film between the substrates 1005 is cut to separate the front and rear substrates 1005 from each other.

  The film transfer apparatus disclosed in Patent Document 2 is substantially the same in structure and operation as that of Patent Document 1, and the main differences are as follows.

  In the case of Patent Document 2, a perforated cutter is used in the step of cutting the protective film and the transfer film. That is, as described in Patent Document 1, it is difficult to cut only two layers (two layers of a protective film and a transfer film) leaving only the support film, and in Patent Document 2, three layers are determined. Both have proposed a method of making perforations.

  The film transfer apparatus disclosed in Patent Document 3 is also similar in structure and operation to Patent Document 1, and the main differences are as follows.

  In removing an unnecessary portion corresponding to the space between the substrates in the transfer film, the protective film is peeled in advance and then the transfer film of the unnecessary portion is cut. Moreover, the cutting method and removal method of a transfer film are specifically mentioned. Furthermore, a plurality of transfer film cutting / removing units are provided for a multi-sided substrate.

  FIGS. 12A and 12B are plan views showing examples of transfer modes common to the above first to third patent documents, and transfer to two substrates 1005 whose processing order is before and after is completed. Shows the state.

  In the example of FIG. 12A, a plurality of transfer patterns 1100 (transfer film patterns) are formed on one substrate 1005 (multiple transfer patterns are taken).

  In FIG. 12A, the length A1 is the length of the transfer pattern 1100 (length in the feeding direction), the length B is the interval between the transfer patterns 1100 (interval in the feeding direction of the transfer film to be removed in advance), the length The length C is the length of the substrate 1005 (length in the feeding direction), and the length D is the interval between the substrates 1005 (interval in the feeding direction).

  In the example of FIG. 12B, one transfer pattern 1100 is formed on one substrate 1005.

  In FIG. 12B, the length A 2 is the length of the transfer pattern 1100, the length B is the interval between the transfer patterns 1100, the length C is the length of the substrate 1005, and the length D is the interval between the substrates 1005. .

  In the case of the transfer mode shown in FIG. 12A (in the case of three chamfering), there is a restriction of C = (A1 × 3) + (B × 3) −D, and the transfer shown in FIG. In the case of the aspect, there is a restriction of C = A2 + BD.

  As shown in FIG. 12A and FIG. 12B, at the stage where the transfer to the two substrates 1005 whose processing order is before and after is completed, the two substrates 1005 are connected to each other via a support film. It is.

  As described above, the transfer to the substrate 1005 in the subsequent processing order is performed while the two substrates 1005 in the processing order are connected via the support film, in order to maintain the tension of the transfer film.

  After the state shown in FIGS. 12A and 12B, the two substrates 1005 are separated by cutting a support film that extends between the two substrates 1005.

Further thereafter, the support film is peeled off from the transfer film pressure-bonded onto the substrate 1005.
Japanese Patent Laid-Open No. 9-174797 JP 2000-141577 A JP 2002-343713 A

  However, the above prior art has the following common problems.

  The first problem is that it is necessary to perform a support film peeling step after the transfer step, and thus the time required for the treatment becomes long.

  The reason for causing the first problem is that the tension of the transfer film is maintained by connecting the support film on the substrate transferred immediately before to the film transferred to the next substrate without cutting.

  The second problem is that the scale of the apparatus becomes large because at least one substrate needs to be retained in the apparatus.

  The reason for causing the second problem is that the previous substrate is stopped until the transfer of the next substrate is completed without cutting the support film of the substrate transferred immediately before in order to maintain the tension of the transfer film. It is to keep.

  The third problem is that a substrate once put into the facility must be transferred even if transfer is not required. For this reason, for example, since it has to be transferred to a defective pattern portion (a surface that is known to be a defective surface in advance) at the time of multi-surface processing, the utilization efficiency of the material is deteriorated.

  The reason for causing the third problem is that the transfer film of the film is preliminarily cut (streaks or perforations) before pasting, and the transfer is continuously performed across a plurality of substrates, and then the substrates are cut (separated). This is because the transfer cannot be interrupted.

  The fourth problem is that, as shown in FIG. 12, the length A1 (A2) of the transfer pattern 1100, the distance B between the transfer patterns 1100, the length C of the substrate 1005, and the distance D between the substrates 1005. There is a problem that the degree of freedom in line design and product design has been deprived. That is, for example, in the case of the transfer mode shown in FIG. 12A (in the case of three chamfering), a restriction of C = (A1 × 3) + (B × 3) −D occurs, and FIG. In the case of the transfer mode shown, the constraint that C = A2 + BD is generated.

  The reason for the fourth problem is that the distance between the substrates is set to a constant size and the transfer is continuously performed on a plurality of substrates. This is because the transfer position is deviated, and transfer can be performed only with the dimensions restricted as described above.

  The present invention has been made to solve the above-described problems, and shortens the time required for processing, reduces the scale of the apparatus, improves the material utilization efficiency, and increases the freedom of line design and product design. It is an object of the present invention to provide a film transfer method, a film transfer apparatus, and a plasma display panel manufacturing method capable of improving the above.

  In order to solve the above-mentioned problems, the film transfer method of the present invention is a method of transferring the transfer film in a sheet material having at least two layers of a transfer film transferred to a substrate and a support film supporting the transfer film to the substrate. In the transfer method for transferring to the sheet material, a sheet conveying step for conveying the sheet material in the feeding direction, and a part of the transfer film of the sheet material over the width direction of the transfer film at predetermined intervals in the feeding direction. A transfer film removing step for forming the transfer film left on the support film in a desired transfer pattern shape by removing, and a transfer step for transferring the transfer film formed in the transfer pattern shape to the substrate And a support film peeling step for peeling the support film from the transfer film that has been transferred to the substrate. For example, it is characterized by performing at a timing which overlaps the transfer step and the support film peeling step of one transfer film formed on the transfer pattern.

  In the film transfer method of the present invention, it is preferable to further include a support film winding and collecting step of winding and collecting the support film peeled off in the support film peeling step.

  In the film transfer method of the present invention, it is preferable that the support film is wound at a constant tension in the support film winding and collecting step.

  In the film transfer method of the present invention, in the transfer step, the sheet material is moved by moving a sheet pressure roller, which can be brought into and out of contact with the substrate, with the sheet material. The sheet material is pressed against the substrate by the sheet pressure roller while being in contact with the substrate, and the sheet pressure roller is applied to the substrate via the sheet material before the transfer step. It is preferable to provide a tension maintaining step for maintaining the tension of the sheet material constant during the contact operation.

  In the film transfer method of the present invention, the tension maintaining step includes a first tension roller that engages with the sheet material in the vicinity of the sheet pressure roller and upstream of the sheet pressure roller in the feeding direction; and the sheet It is preferable to move or rotate a second tension roller that engages with the sheet material in the vicinity of the pressure roller and downstream of the sheet pressure roller in the feeding direction.

  The film transfer method of the present invention may include a front end position adjusting step of adjusting a front end of the transfer film formed in a desired transfer pattern shape by the transfer film removing step to a transfer start position with respect to the substrate. preferable.

  In the film transfer method of the present invention, the transfer step is performed by pressing the sheet material against the substrate with a sheet pressing roller, and the front end position adjusting step is performed by transferring the transfer film formed in a transfer pattern shape. The front end of the sheet pressing roller has reached a predetermined position on the circumferential surface of the sheet pressing roller, and a predetermined amount of the sheet material is detected based on the detection timing of the front end position adjustment position detection step and the front end position adjustment position detection step. It is preferable to provide a constant amount feeding step for feeding only in the feeding direction.

  In the film transfer method of the present invention, the constant amount feeding step includes a first tension roller that engages with the sheet material in the feeding direction upstream side of the sheet pressing roller in the vicinity of the sheet pressing roller; It is preferable to perform this by moving or rotating a second tension roller that engages with the sheet material in the vicinity of the sheet pressure roller and downstream of the sheet pressure roller in the feeding direction.

  The film transfer method of the present invention preferably includes a pattern length adjusting step for adjusting the length of the transfer film formed in the transfer pattern shape.

  In the film transfer method of the present invention, the pattern length adjusting step includes a pattern length adjusting position detecting step of detecting a front end of the transfer film formed in the transfer pattern shape by a sensor, and the pattern length adjusting position. A calculation step of calculating a feed amount Y of the sheet material between the detection in the detection step and the removal operation in the transfer film removal step based on the rotation amount of a roller that guides the sheet material; The total amount of the calculated feed amount Y and the distance N between the position detected by the sensor and the position where the removal operation is performed in the transfer film removal step is set to the desired transfer pattern length L. It is preferable to include a removal operation position adjustment step of adjusting a position where the removal operation is performed in the transfer film removal step.

  In the film transfer method of the present invention, in the removal operation position adjustment step, correction is performed in consideration of the amount of elongation of the sheet material due to the tension applied to the sheet material, and the removal operation is performed in the transfer film removal step. It is preferable to adjust the position to perform.

  In the film transfer method of the present invention, when the transfer film is transferred to each of a plurality of transfer locations on one substrate, the transfer film is not transferred to a transfer location that is known to be defective in advance, and is not transferred to a transfer location that is not defective. It is preferable to selectively transfer only.

  In the film transfer method of the present invention, the transfer step includes a first sheet pressing roller disposed on the upstream side in the feeding direction, and a second sheet disposed on the downstream side of the first sheet pressing roller. It is preferable that the sheet material is pressed against the substrate by a sheet pressing roller.

  The film transfer apparatus of the present invention is a film transfer apparatus for transferring the transfer film in a sheet material having at least two layers of a transfer film transferred to a substrate and a support film supporting the transfer film to the substrate. In the sheet conveying means for conveying the sheet material in the feeding direction, and removing a part of the transfer film of the sheet material at a predetermined interval in the feeding direction over the width direction of the transfer film, A transfer film removing means for forming the transfer film left on the support film into a desired transfer pattern shape; a transfer means for transferring the transfer film formed in the transfer pattern shape to the substrate; and Supporting film peeling means for peeling the support film from the transferred transfer film. And transferring operation of one of the transfer film formed in a pattern shape, it is characterized in that performed at the timing of overlapping the peeling operation of the supporting film from the transfer film, the.

  In the film transfer apparatus of the present invention, it is preferable that the film transfer apparatus further includes a support film take-up and collection unit that winds and collects the support film peeled off by the support film peeling unit.

  In the film transfer apparatus of the present invention, it is preferable that the support film take-up and recovery unit winds the support film with a constant tension.

  In the film transfer apparatus of the present invention, the transfer unit is configured to be able to contact and separate from the substrate via the sheet material, and moves along with the sheet material to move the substrate via the sheet material. A sheet pressing roller that presses the sheet material against the substrate in contact with the substrate, and the film transfer device further causes the sheet pressing roller to contact the substrate via the sheet material before the transfer operation. It is preferable that a tension maintaining means for maintaining the tension of the sheet material constant during operation is provided.

  In the film transfer apparatus of the present invention, the tension maintaining means includes a first tension roller that engages with the sheet material in the vicinity of the sheet pressure roller and upstream of the sheet pressure roller, in the feeding direction; A second tension roller that engages with the sheet material on the downstream side in the feeding direction with respect to the sheet pressure roller in the vicinity of the roller, and by moving or rotating the first and second tension rollers, It is preferable to keep the tension of the sheet material constant.

  In the film transfer apparatus of the present invention, it is preferable that the film transfer apparatus further includes a front end position adjusting unit that adjusts a front end of the transfer film formed in a desired transfer pattern shape by the transfer film removing unit to a transfer start position with respect to the substrate. .

  In the film transfer apparatus of the present invention, the transfer unit includes a sheet press roller that presses the sheet material against the substrate, and the front end position adjusting unit includes a front end of the transfer film formed in the transfer pattern shape. The sheet material is fed by a predetermined amount from the front end position adjusting position detection sensor that detects that the predetermined position on the circumferential surface of the sheet pressing roller has been reached, and the detection timing of the front end position adjusting position detection sensor. It is preferable to include a fixed amount feeding means for feeding to the head.

  In the film transfer apparatus of the present invention, the fixed amount feeding means includes a first tension roller that engages with the sheet material in the vicinity of the sheet pressing roller and upstream of the sheet pressing roller in the feeding direction, and the sheet A second tension roller that engages with the sheet material on the downstream side of the sheet pressure roller in the feeding direction in the vicinity of the pressure roller, and by moving or rotating the first and second tension rollers, It is preferable to feed the sheet material in a feeding direction by a certain amount.

  In these cases, the position detection sensor for adjusting the front end position is preferably a light reflection sensor or a laser reflection sensor.

  In this case, the radius of the pressure roller is R, the length of the portion removed in the transfer film removal process is B, the circumference is π, and the previous transfer is completed from the center of the pressure roller. When the angle formed between the line connecting the rear end position of the transfer film and the optical axis of the front end position adjusting position detection sensor is θ, the front end position adjusting position detection sensor is configured such that the angle θ is θ < It is necessary to arrange at a position satisfying (B / πR) × 180 °.

  In the film transfer apparatus of this invention, it is preferable to provide the pattern length adjustment means which adjusts the length of the said transfer film formed in the said transfer pattern shape.

  In the film transfer apparatus of the present invention, the pattern length adjustment means includes a pattern length adjustment position detection sensor for detecting a front end of the transfer film formed in the transfer pattern shape, and the pattern length adjustment position detection sensor. A calculating means for calculating a feed amount Y of the sheet material after detection is performed until a removal operation is performed by the transfer film removing means, based on a rotation amount of a roller for guiding the sheet material; and the transfer film Removing means position adjusting means for adjusting the position of the removing means in the feeding direction of the sheet material, the removing means position adjusting means being detected by the calculated feed amount Y and the pattern length adjusting position detection sensor. The total value of the distance N between the position and the position where the removal operation is performed by the transfer film removing means is a desired transfer pattern length L. In so that, by adjusting the position of the transfer film removing means, said transfer film removing means, it is preferable to carry out the removal operation of the transfer film in the adjusted position.

  In the film transfer apparatus of the present invention, the removal means position adjustment means adjusts the position of the transfer film removal means by performing correction in consideration of the elongation amount of the sheet material due to the tension applied to the sheet material. It is preferable.

  In the film transfer apparatus of the present invention, the transfer unit includes a sheet pressure roller disposed on the upstream side in the feeding direction, and a plurality of cooling rollers disposed on the downstream side of the sheet pressure roller, It is preferable that the transfer operation is performed by pressing the sheet material against the substrate by a sheet pressing roller and the plurality of cooling rollers.

  In the film transfer apparatus of the present invention, the transfer means is disposed at a position facing the sheet pressing roller with the sheet and the sheet material sandwiched between the sheet pressing roller for pressing the sheet material to the substrate. And a substrate-side pressure roller.

  The method for manufacturing a plasma display panel according to the present invention is a method for manufacturing a plasma display panel including first and second substrates, wherein at least one of the first and second substrates is provided. It is characterized by comprising a step of transferring a transfer film by the film transfer method of the present invention.

  In the method for manufacturing a plasma display panel according to the present invention, the dielectric layer of the plasma display panel is preferably formed by the transfer film.

  According to the present invention, when transferring a transfer film to a substrate (for example, a glass substrate or a resin substrate), the transfer operation of one transfer film formed in a transfer pattern shape, and the support film from the transfer film are transferred. Since the peeling operation is performed at the overlapping timing, the transfer operation of the transfer film and the operation of peeling the support film from the transfer film are completely compared with the prior art (Patent Documents 1 to 3). The time required for processing can be shortened.

  Further, after removing a part of the transfer film of the sheet material after the protective film is peeled off (that is, a part corresponding to the interval between the transfer patterns) by the transfer film removing means in advance, the transfer operation of one transfer film and the transfer Since the peeling operation of the support film from the film is performed at an overlapping timing, the transfer process can be executed for each substrate without retaining the transferred substrate in the apparatus. Therefore, the apparatus scale can be reduced.

  Furthermore, in the case of the present invention, since only the transfer film of the three layers constituting the sheet material is transferred onto the substrate, the transfer process can be performed individually for each transfer pattern. Therefore, it is possible not to transfer to a portion where transfer is not required (for example, a defective pattern portion in multi-surface drawing), and it is possible to improve the utilization efficiency of the transfer material.

  In addition, since the transfer position with respect to the substrate can be adjusted for each transfer pattern, the degree of freedom in line design and product design can be improved.

  In the prior art, the transfer film is continuously transferred to a plurality of substrates to maintain the stability of the tension of the transfer film, whereas in the present invention, the support film is wound at a constant tension. By taking it, the stability of the tension of the transfer film can be maintained.

  Furthermore, since the pattern length adjusting means for adjusting the length of the transfer film is provided, a desired pattern length can be set for each transfer film. Therefore, for example, when multiple patterns are formed in one substrate (a plurality of patterns are formed), the pattern length can be set for each pattern.

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

[First Embodiment]
1 is a side view showing a film transfer apparatus 110 according to the first embodiment, FIG. 2 is a plan view of the film transfer apparatus 110, and FIG. 3A is a sheet formed by winding a sheet material 160 having a transfer film 162. 3 is a perspective view showing the supply roll 170, FIG. 3B is a cross-sectional view showing the layer structure of the sheet material 160, and FIGS. 4A and 4B are plan views showing examples of the transfer mode of the film to the substrate. FIG. 5 is a side view showing the vicinity of the first transfer film detection sensor 40 and the transfer film removal unit 20 of the film transfer apparatus 110. FIG. 5A shows the transfer film removal unit 20 at the reference position. FIG. 5B shows a state where the transfer film removal unit 20 has moved from the reference position. FIG. 6 is a side view showing the vicinity of the second transfer film detection sensor 50 of the film transfer apparatus 110. FIG. 7 is a series of process diagrams for explaining the transfer operation by the film transfer device 110, and is a side view showing the vicinity of the pressure rollers 117A and 117B of the film transfer device 110, respectively.

  As shown in FIG. 3B, the sheet material 160 includes a support film 163 that supports the transfer film 162, a transfer film 162 that is transferred onto the substrate by the film transfer device 110, and a protective film that covers the transfer film 162. 161 is laminated in this order.

  As shown in FIG. 3A, the sheet supply roll 170 is configured by winding a sheet material 160 into a roll shape, and supplies the sheet material 160 when the sheet material 160 is rewound.

  As shown in FIGS. 4A and 4B, the substrate 1 has alignment marks 1A for detecting the posture of the substrate 1, for example, two diagonal positions or four corners (4 ).

  For example, as shown in FIG. 4A, one transfer pattern (transfer film 162) is transferred to such a substrate 1, or as shown in FIG. 4B. A plurality of (for example, three) transfer patterns (transfer film 162) are transferred.

  As shown in FIG. 1, the film transfer device 110 includes a substrate transport unit 100A that transports the substrate 1 to which the transfer film 162 is transferred, a film transfer unit 100B that transfers the transfer film 162 to the substrate 1, It is configured with.

  The film transfer unit 100B includes an operation of unwinding and supplying the sheet material 160 from the sheet supply roll 170, an operation of peeling the protective film 161 from the rewound sheet material 160, and a sheet material 160 (support film after the peeling). 163 and the transfer film 162 of the support film 163), an operation of forming the transfer film 162 in a desired pattern shape, an operation of transferring the transfer film 162 formed in the desired pattern shape onto the substrate 1, An operation of peeling the support film 163 from the transfer film 162 transferred onto the substrate 1 and an operation of winding up and collecting the peeled support film 163 are performed. In particular, the operation of transferring the transfer film 162 onto the substrate 1 and the operation of peeling the support film 163 from the transfer film 162 transferred onto the substrate 1 by the operation are performed at overlapping timing (performed in parallel). .

  In order to perform these operations, the film transfer unit 100B is held by the sheet supply roll holding unit 111 that rotatably holds the sheet supply roll 170 and the sheet supply roll holding unit 111, as shown in FIG. A pair of guide rollers 112 and 113 for guiding the sheet material 160 supplied (rewinded) from the sheet supply roll 170 to be sandwiched, and protection separated from the sheet material 160 at the position of the guide roller 113 A part of the transfer film 162 (consisting of the support film 163 and the transfer film 162 on the support film 163) from which the protection film 161 is peeled off and the remaining sheet material 160 from which the protection film 161 has been peeled off. The transfer film 162 is removed by removing a portion corresponding to between the transfer patterns). A transfer film removal unit 20 formed in a desired transfer pattern shape, a removal unit moving mechanism 30 for adjusting the transfer pattern shape and correcting the elongation of the sheet material 160 by moving the transfer film removal unit 20, and a transfer A guide roller 115 that guides the sheet material 160 having the transfer film 162 formed in a pattern shape and changes the drawing direction of the sheet material 160 from, for example, a horizontal direction to a vertical direction, and a transfer film formed in a transfer pattern shape Transfer film detection sensors (for example, first and second transfer film detection sensors 40 and 50 described later) installed at a plurality of locations downstream of the transfer film removal unit 20 in the feeding direction. And the sheet material 160 and the sheet material 1 The first tension roller 116 for adjusting the tension (tension) of 0 and the sheet material 160 and guiding the transfer film 162 included in the sheet material 160 to the substrate 1 positioned below are transferred. The upper press roller 117A and the upper press roller 117A are disposed to face each other via the sheet material 160 and the substrate 1, and transferred to the substrate 1 and the lower press roller 117B that presses the substrate 1 against the sheet material 160 ( A second tension roller 118 that guides the support film 163 peeled from the transfer film 162 (transferred) and adjusts the tension of the support film 163, and winds the support film 163 with a constant winding torque. And a support film take-up roller 119 to be recovered by The

  Here, as shown in FIG. 1, the sheet material 160 is drawn in advance along a predetermined path in the film transfer unit 100B.

  That is, the sheet material 160 rewound from the sheet supply roll 170 passes through the gap between the pair of guide rollers 113 and 112, and the guide roller 115, the first tension roller 116, the upper pressure roller 117A, and the second The tension roller 118 is bridged in this order, and one end is fixed to the support film take-up roller 119.

  Note that the sheet material 160 is routed so that the support film 163 is positioned on the lower side and the transfer film 162 is positioned on the upper side of the position from the time when the sheet is rewound from the sheet supply roll 170 to the guide roller 115. Has been.

  Of the three layers of the film constituting the sheet supply roll 170, only the protective film 161 is peeled off when passing through the pair of guide rollers 113 and 112, and the remaining two layers (the support film 163 and the transfer film 162). It is collected by a different route. That is, the protective film 161 is folded back along the peripheral surface of the guide roller 113, travels toward the protective film take-up roller 114, and is taken up by the protective film take-up roller 114.

  The protective film take-up roller 114 takes up and collects the protective film 161 in synchronization with the supply operation of the sheet material 160 from the sheet supply roll 170. Thereby, the protective film 161 of the sheet material 160 is peeled off by the amount supplied from the sheet supply roll 170.

  Therefore, only the two-layer film (the support film 163 and the transfer film 162) excluding the protective film 161 is drawn from the pair of guide rollers 113 and 112.

  Further, the sheet material 160 is changed along the circumferential surface of the guide roller 115 (for example, from the horizontal direction to the vertical direction), and reaches the upper pressure roller 117A.

  Furthermore, since the transfer film 162 of the sheet material 160 is transferred onto the substrate 1 by the transfer operation by the upper and lower pressure rollers 117A and 117B, only the support film 163 is drawn from the upper pressure roller 117A.

  As shown in FIG. 1, the transfer film removing unit 20 is disposed along a sheet material 160 positioned between the pair of guide rollers 113 and 112 and the guide roller 115.

  This transfer film removal unit 20 is configured to include a pair of cutters 21 which are long in the depth direction of FIG. 1 and are arranged in parallel to each other, and are formed into two layers after peeling off the protective film 161. A part of the transfer film 162 in 160 is cut by the cutter 21 over the width direction of the transfer film 162 at predetermined intervals in the feeding direction, and the transfer film 162 in the portion located between the cutters 21 is cut into the sheet material 160. The transfer film 162 on the support film 163 is formed into a transfer pattern shape.

  That is, the transfer film removal unit 20 divides the front and rear transfer films 162 in the feed direction from each other at a desired interval in the feed direction, and as a result, the transfer film left on the support film 163 of the sheet material 160. 162 is formed in a desired transfer pattern shape.

  Therefore, the sheet material 160 at the portion removed by the transfer film removing unit 20 is only the support film 163.

  The distance between the pair of cutters 21 is constant, and therefore the length (dimension) in the feeding direction of the portion removed by the transfer film removing unit 20 is always constant.

  In this way, the transfer film 162 is cut and removed with a constant feed direction dimension in order to (1) maintain the linearity of the front end and rear end of the transfer pattern, and (2) clarify the front end position of the transfer pattern. (3) During the transfer operation to one substrate 1, the transfer film 162 is prevented from being transferred to the substrate 1 to be processed next. In addition, the dimension (feed direction dimension) of the part to be cut and removed is set to a minimum dimension that can achieve the objects (1) to (3).

  The removal unit moving mechanism 30 moves and positions the transfer film removal unit 20 to an arbitrary position in the feeding direction (the left-right direction in FIG. 1 at the position of the transfer film removal unit 20).

  In the state where the position of the transfer film removal unit 20 is adjusted by the removal unit moving mechanism 30, the transfer film 162 is cut and removed by the transfer film removal unit 20 as described above, whereby the transfer direction of the transfer film 162 to be a transfer pattern The dimension (transfer pattern length) can be adjusted, and the transfer film 162 on the support film 163 can be formed into a desired transfer pattern shape.

  That is, by adjusting the position of the transfer film removal unit 20 by the removal unit moving mechanism 30, by adjusting the interval between the two portions of the transfer film 162 that are removed by the transfer film removal unit 20 in time. The transfer pattern length can be adjusted.

  For example, as shown in FIG. 5, the removal unit moving mechanism 30 includes a holding unit 31 that holds the transfer film removal unit 20, a guide unit 32 that guides the transfer film removal unit 20 together with the holding unit 31 in the moving direction, And a drive mechanism (not shown) that moves the holding portion 31 along the guide portion 32.

  Further, as shown in FIG. 1, the first transfer film detection sensor 40 is located between the pair of guide rollers 113 and 112 and the guide roller 115 on the downstream side of the transfer film removing unit 20. Are arranged along.

  The first transfer film detection sensor 40 includes, for example, a light reflection sensor or a laser reflection sensor, and detects the front end position of the transfer film 162 formed in the transfer pattern shape, for example, before the guide roller 115. In other words, the first transfer film detection sensor 40 includes a single layer portion in which the transfer film 162 is removed and only one layer of the support film 163, and two layers in which the transfer film 162 formed in the transfer pattern shape remains. The boundary with the part is detected optically.

  Note that the transfer film removing unit 20 has a transfer film at a position upstream of the detection pattern by the transfer pattern length after the front end position of the transfer film 162 is detected by the first transfer film detection sensor 40. The removal operation 162 is performed.

  Here, the operation of adjusting the transfer pattern length will be described with reference to FIG.

  The transfer pattern length adjustment operation described below is performed in the second and subsequent cut and removal operations by the transfer film removal unit 20 performed on the transfer film 162 of the series of sheet materials 160. The first removal cutting operation on the sheet material 160 may be performed on an arbitrary position of the sheet material 160.

  As shown in FIG. 5B, the transfer pattern length is L, and the distance from the first transfer film detection sensor 40 (detection position by the transfer film) to the reference position of the transfer film removal unit 20 (position of FIG. 5A). The distance is N, the moving distance of the transfer film removal unit 20 from the reference position is ΔN, and the removal operation by the transfer film removal unit 20 after the first transfer film detection sensor 40 detects the front end position of the transfer film 162. Assuming that the feed amount of the sheet material 160 until Y is Y, the length L of the transfer pattern is N + ΔN + Y.

  Of these, the distance N (the distance from the first transfer film detection sensor 40 to the reference position of the transfer film removal unit 20) is obtained in advance by measurement and stored in the film transfer device 110. Therefore, it is not necessary to calculate the distance N every time the transfer pattern length is adjusted.

  Further, since the moving distance ΔN is the moving distance of the transfer film removing unit 20 by the removing unit moving mechanism 30, it can be accurately recognized.

  Further, the feed amount Y is, for example, the amount of rotation of the guide roller 115 from when the front end position of the transfer film 162 is detected by the first transfer film detection sensor 40 until the removal operation by the transfer film removal unit 20 is performed. Calculated based on (rotation angle). The calculation means for performing this calculation is not shown.

  The removal unit moving mechanism 30 calculates the total value of the calculated feed amount Y, the known distance N, and the moving distance ΔN (which changes according to the transfer pattern length L), and the calculated total The position of the transfer film removal unit 20 is adjusted in the feed direction so that the value becomes a desired transfer pattern length L, and the transfer film removal unit 20 removes the transfer film 162 at the adjusted position. Perform the action. In addition, illustration is also abbreviate | omitted about the calculation means of the total value of feed amount Y, distance N, and movement distance (DELTA) N.

  Conventionally, the length is measured based on the rotation amount of the guide roller over the entire length of the transfer pattern length L, but this method has a problem that the error becomes large. On the other hand, in the case of this embodiment, since the calculation is performed based on the rotation amount (rotation angle) of the guide roller 115 by the distance Y that is a very small part of the entire length of the transfer pattern length L, the transfer pattern length is increased. It becomes possible to adjust the accuracy.

  Further, since tension is applied to the sheet material 160 conveyed in the film transfer unit 100B, the transfer film 162 being conveyed is longer than the actual length.

  Therefore, the removal unit moving mechanism 30 adjusts the position of the transfer film removal unit 20 by performing correction in consideration of the amount of elongation of the sheet material 160 due to the tension applied to the sheet material 160. That is, the transfer pattern length L shown in FIG. 5 is larger than the actual transfer pattern length of the transfer film 162 when transferred onto the substrate 1 by the amount of elongation due to the tension. The correction amount increases as the transfer pattern length L increases.

  By performing such correction, the transfer pattern length of the transfer film 162 that is actually transferred onto the substrate 1 can be accurately controlled.

  The pressure rollers 117A and 117B are configured as, for example, a pair of upper and lower rollers having a lifting function and a pressure adjusting function. The pressure rollers 117A and 117B are specifically, for example, those obtained by applying a certain thickness of rubber coating to a metal roller.

  While the substrate 1 and the sheet material 160 are held together by the pressure rollers 117A and 117B, the substrate 1 passes through the space between the pressure rollers 117A and 117B at a constant speed, whereby the transfer film 162 is pressure-transferred to the substrate 1. The

  These pressure rollers 117A and 117B transfer the transfer film 162 to the substrate 1 by, for example, thermocompression bonding.

  Further, the first tension roller 116 is disposed on the upstream side of the upper pressure roller 117A in the feeding direction of the sheet material 160, and the second tension roller 118 is disposed on the downstream side of the upper pressure roller 117A in the feeding direction of the sheet material 160. Has been.

  More specifically, the first tension roller 116 engages with the sheet material 160 between the guide roller 115 and the upper press roller 117A, and the second tension roller 118 includes the upper press roller 117A and the support film take-up roller. 119 is engaged with the sheet material 160, and tension is applied to the sheet material 160, respectively.

  The first and second tension rollers 116 and 118 have a function of maintaining a constant tension of the sheet material 160 when the upper press roller 117A is moved up and down, and both the rollers 116 and 118 in the horizontal direction or the vertical direction in FIG. Has a function of performing a minute feed of the sheet material 160 (an operation for finely adjusting the front end position of the transfer film 162 by feeding only a minute distance).

  Specifically, the first tension roller 116 has a function of moving in the left-right direction in FIG. 1 and a function of rotating counterclockwise in FIG. 1, and the second tension roller 118 has a function of moving up and down in FIG. The movement function to a direction and the clockwise rotation function of FIG. 1 are provided.

  The first tension roller 116 increases the tension of the sheet material 160 by moving to the left side in FIG. 1, while relaxing the tension of the sheet material 160 by moving to the right side.

  On the other hand, the second tension roller 118 increases the tension of the sheet material 160 by moving to the upper side in FIG. 1, while relaxing the tension of the sheet material 160 by moving to the lower side.

  Further, the film transfer device 110 performs a leading-out operation (front end position adjusting operation) for adjusting the front end of the transfer film 162 formed in a desired transfer pattern shape to the transfer start position with respect to the substrate 1 as follows. It is configured as follows.

  In order to minimize the shift amount of the transfer position of the transfer film 162 with respect to the substrate 1, it is necessary to recognize the front end of the transfer film 162 at a location closest to the transfer start position.

  Therefore, as shown in FIG. 6, at a position where it can be detected that the front end of the transfer film 162 formed in the transfer pattern shape has reached a predetermined position (detection position S) on the peripheral surface of the upper press roller 117A. A second transfer film detection sensor 50 is installed.

  In addition, the 2nd transfer film detection sensor 50 also consists of a light reflection type sensor or a laser reflection type sensor like the 1st transfer film detection sensor 40, for example.

  Here, since it is inconvenient if the next transfer pattern is already detected by the second transfer film detection sensor 50 at the end of the transfer operation of the transfer film 162 (transfer pattern) to the substrate 1, the second transfer film. The installation position of the detection sensor 50 is defined in detail as follows.

  That is, as shown in FIG. 6, a line F connecting the rear end position T of the transfer film 162 where the previous transfer is completed and the center E of the upper press roller 117A, and the optical axis G of the second transfer film detection sensor 50. The second transfer film detection sensor 50 is installed at a position where the angle θ formed by the above satisfies the following expression (1).

  In the following equation (1), R is a radius of the upper press roller 117A, B is a dimension in the feed direction of a portion of the transfer film 162 cut and removed by the transfer film removing unit 20, and π is a circumference ratio. is there.

θ <(B / πR) × 180 ° (1)
In order to move the transfer film 162 constituting the next transfer pattern to the detection position S by the second transfer film detection sensor 50 after the transfer operation of the transfer film 162 to the substrate 1 is completed, the first tension roller 116 is moved. The sheet material 160 is gradually moved by rotating the upper pressure roller 117A counterclockwise in FIG. 1 while moving the second tension roller 118 in the upward direction in FIG. 1 while moving it in the right direction in FIG. send. Eventually, the front end of the transfer film 162 is detected by the second transfer film detection sensor 50.

  After the front end of the transfer film 162 is detected by the second transfer film detection sensor 50, the length M of the sheet material 160 from the detection position S to the position above the transfer start position P (FIG. 7C) ( Send in the feed direction only (not shown).

  Thereby, the front end position of the transfer film 162 can be accurately aligned with the position above the transfer start position P.

  Here, since the sheet length M from the detection position S to the position above the transfer start position P is always constant, it is assumed that the sheet length M is measured in advance and stored in the film transfer apparatus 110.

  Note that the front end positioning of the transfer film 162 formed in the transfer pattern shape and the cutting and removal operation of the transfer film 162 by the transfer film removal unit 20 can be performed independently (in parallel) (transfer). When not in operation).

  The substrate transport unit 100A advances the substrate 1 in synchronization with the operation of receiving the substrate 1 from the previous process equipment and aligning it at a predetermined position and the operation of transferring the transfer film 162 onto the substrate 1 by thermocompression bonding. The operation and the operation of unloading the substrate 1 onto which the transfer film 162 has been transferred to the subsequent process equipment are performed.

  In order to perform these operations, the substrate transport unit 100A has a transport device (generally not shown in the drawing: FIG. 2) configured to include a large number of transport rollers 60 for supporting and transporting the substrate 1, as shown in FIGS. 2, reference numerals are given only to a part of the transport rollers 60), a plurality of alignment cameras 70 for recognizing the alignment mark 1 A attached on the substrate 1, and the substrate 1 for alignment. Based on the recognition result by the drive mechanism 80 and the alignment camera 70 that changes the posture of the substrate 1, the amount of deviation from the predetermined position of the substrate 1 conveyed from the previous process is calculated, and the operation for correcting this deviation amount is performed. 80, and a control unit (not shown).

  Here, as shown in FIGS. 2 and 4, the alignment marks 1A on the substrate 1 are formed, for example, at two diagonal positions or four corners (four positions) of the substrate 1, and recognize these alignment marks 1A. Therefore, each alignment camera 70 is also arranged at that position.

  The drive mechanism 80 changes the posture of the substrate 1 based on the recognition result by the alignment camera 70 under the control of the control unit. For example, one drive mechanism 80 is provided on each of the left and right sides of the substrate 1 as shown in FIG. Is provided.

  Each drive mechanism 80 includes, for example, a first drive unit 81 that moves one end side of the substrate 1 in the left-right direction (vertical direction in FIG. 2) in the transport direction (arrow A direction in FIG. 2) and the opposite direction. A second drive unit 82 that moves the front part (front part in the transport direction) of the substrate 1 in the left-right direction (vertical direction in FIG. 2) and the rear part (rear part in the transport direction) of the substrate 1 in the left-right direction (vertical direction in FIG. And a third drive unit 83 that is moved to the position.

  The posture of the substrate 1 can be corrected by appropriately adjusting the drive amount by each of the drive units 81 to 83 according to the recognition result by the alignment camera 70.

  Further, as described above, the front end position of the transfer film 162 is aligned with the upper position of the transfer start position P (leading out), and after the substrate 1 is transported to the transfer start position, the upper pressure roller 117A is moved. While lowering, lower press roller 117B is raised.

  As a result, the front end position of the transfer film 162 is aligned with the transfer start position P, and the substrate 1 and the sheet material 160 are held together by the press rollers 117A and 117B.

  In this state, the transfer film 162 is transferred onto the substrate 1 by passing the substrate 1 and the sheet material 160 between the press rollers 117A and 117B in the right direction of FIGS.

  Here, the second tension roller 118 positioned at the rear stage of the upper press roller 117A is spaced from the substrate 1 and positioned above the substrate 1 even during such a transfer operation.

  For this reason, the support film 163 is continuously peeled from the transfer film 162 that has been transferred onto the substrate 1 by the transfer operation in conjunction with the transfer operation.

  That is, the operation of transferring the transfer film 162 onto the substrate 1 and the operation of peeling the support film 163 from the transfer film 162 transferred onto the substrate 1 by the operation are performed at the same timing (in parallel). )

  Further, the support film 163 thus peeled off is taken up by the support film take-up roller 119 via the second tension roller 118.

  Here, the support film take-up roller 119 performs the take-up operation of the support film 163 by the same amount as the conveyance in synchronization with the conveyance of the sheet material 160 and the substrate 1. The winding operation is always performed with a constant tension.

  Furthermore, the substrate transport unit 100A carries out the substrate 1 on which the transfer of the transfer film 162 has been completed to equipment in a subsequent process.

  Next, a series of transfer operations will be described with reference to FIG.

  First, as shown in FIG. 7A, the substrate 1 carried in from the previous step is aligned (aligned) at a predetermined position by the substrate transport unit 100A.

  Next, as shown in FIG. 7B, while feeding the sheet material 160 until the front end of the transfer film 162 crosses the optical axis G of the second transfer film detection sensor 50 (until the detection position S is reached), The substrate 1 is advanced.

  Next, as shown in FIG. 7C, the front end position of the transfer film 162 is moved by the predetermined feed amount M (not shown) from the timing when the front end of the transfer film 162 reaches the detection position S. Positioning is performed (leading out) so as to be positioned above the transfer start position P. In this leading-out, the first and second tension rollers 116 and 118 are moved in the direction of loosening the tension of the sheet material 160, and the upper pressure roller 117A is slightly rotated counterclockwise in FIG. 7C. That is, the first tension roller 116 is moved in the right direction in FIG. 7C, while the second tension roller 118 is moved in the upper direction in FIG. 7C, and the upper pressure roller 117A is moved. FIG. 7C is performed by slightly rotating counterclockwise. On the other hand, the substrate 1 is further advanced and set at the transfer start position (the position of the substrate 1 in FIG. 7C).

  Next, as shown in FIG. 7D, the upper pressure roller 117A is lowered while the lower pressure roller 117B is raised, so that the substrate 1 and the sheet material 160 are held together by the pressure rollers 117A and 117B. To do.

  Here, when the upper and lower pressure-bonding rollers 117A and 117B are moved up and down, the first tension roller 116 moves in the direction to loosen the tension of the sheet material 160, while the second tension roller 118 moves the tension of the sheet material 160. Move it in the direction of increasing. That is, the first tension roller 116 is moved in the right direction in FIG. 7D, while the second tension roller 118 is moved in the downward direction in FIG. Accordingly, the tension of the sheet material before and after the operation of FIG. 7D can be maintained constant, and the front end position of the transfer film 162 on the peripheral surface of the upper press roller 117A can be prevented from moving. it can. Therefore, the leading end position of the transfer film 162 can be prevented from shifting from the transfer start position P, and the front end position of the transfer film 162 can be very accurately aligned with the transfer start position P.

  Subsequently, as shown in FIGS. 7D to 7E, a transfer operation is performed.

  At this time, the sheet material 160 and the substrate 1 are conveyed by the same amount in synchronization with each other. Further, the first tension roller 116 and the upper pressure roller 117A roll counterclockwise, and the second tension roller 118 and the lower pressure roller 117B roll clockwise.

  As a result, the transfer film 162 is transferred onto the substrate 1 and a transfer pattern is formed on the substrate 1.

  When the transfer operation is completed, as shown in FIG. 7 (F), the upper pressure roller 117A is raised while the lower pressure roller 117B is lowered, so that the substrate 1 and the sheet material 160 of the both pressure rollers 117A and 117B are lowered. Release the pinched state.

  Also at this time, the first and second tension rollers 116 and 118 are moved in order to maintain the sheet material 160 at a constant tension. That is, the first tension roller 116 is moved leftward and the second tension roller 118 is moved upward.

  Thereafter, the transfer film 162 can be individually and sequentially transferred to the plurality of substrates 1 by repeatedly performing the operation of FIG.

  In addition, when forming a transfer pattern with respect to each of a plurality of locations on one substrate 1, the operations shown in FIGS. 7A to 7F are repeated.

  Here, examples of the transfer film include a dielectric film and a resist film (photosensitive film).

  Of these, when the dielectric film is transferred, it is baked after being transferred onto the substrate.

  In the case of a resist film, after transferring on a substrate, exposure and development are performed in this order. Furthermore, when the resist film is left as a film on the substrate 1, baking is performed after development. On the other hand, when performing an etching process etc. by using a resist film as a mask, an etching process is performed after image development, and after that, a resist film is peeled and baked.

  Next, an example in which the film transfer device 110 is used in the plasma display panel manufacturing process will be described.

  In the present embodiment, for example, an example in which a dielectric layer of a plasma display panel is formed by transfer by a film transfer device 110 will be described.

  FIG. 8 is an exploded perspective view showing the structure of a plasma display panel (hereinafter referred to as PDP).

  As shown in FIG. 8, the PDP 150 includes two substrates, a front substrate 10 and a rear substrate 11 that are arranged in parallel to each other.

  Transparent scanning electrodes 14 and transparent sustaining electrodes 15 are formed on the front substrate 10 facing the rear substrate 11 so as to extend in the row direction of the PDP 150 (left and right in FIG. 8).

  Further, the front substrate 10 is formed with a dielectric layer 19A covering the scan electrodes 14 and the sustain electrodes 15 and a protective layer 18 made of magnesium oxide or the like for protecting the dielectric layer 19A from discharge.

  Among these, the dielectric layer 19A is transferred onto the front substrate 10 by the film transfer apparatus 110 according to the present embodiment.

  On the side of the rear substrate 11 facing the front substrate 10, when viewed from the direction perpendicular to the surface direction of the PDP 150, the column direction perpendicular to the scanning electrodes 14 and the sustain electrodes 15 (in FIG. The data electrode 16 is formed so as to extend in the direction toward the surface.

  Further, on the rear substrate 11, a dielectric layer 19B covering the data electrode 16 and a partition wall 12 extending in the column direction on the dielectric layer 19B and partitioning the display cells in the row direction are provided from the dielectric layer 19B. It is formed into a standing wall shape that stands vertically.

  Among these, the dielectric layer 19B is transferred onto the back substrate 11 by the film transfer device 110 according to the present embodiment.

  In addition, a phosphor layer 17 that converts ultraviolet rays generated by the discharge of the discharge gas into visible light is formed on the side surfaces of the barrier ribs 12 and the surface of the dielectric layer 19B.

  Thus, a discharge space 13 partitioned by the barrier ribs 12 is formed in the space between the front substrate 10 and the rear substrate 11.

  The discharge space 13 is filled with a discharge gas.

  In PDP 150, display cells are arranged in a matrix so as to include one closest point between scan electrode 14 and data electrode 16 and one closest point between sustain electrode 15 and data electrode 16. Accordingly, the PDP 150 includes (n × m) display cells.

  The PDP 150 manufactured by the manufacturing method as described above includes the dielectric layers 19A and 19B transferred with high accuracy by the film transfer apparatus 110 according to the present embodiment, and therefore has high quality.

  Next, with reference to FIG. 9, a preferred example of a plasma display device configured to include the PDP 150 described above will be described.

  FIG. 9 is a schematic block diagram showing a preferred example of the plasma display device according to the present embodiment.

  The plasma display device 100 shown in FIG. 9 is schematically configured to include an analog interface 120 and a PDP module 130.

  The PDP module 130 includes a plasma display panel 150 (hereinafter referred to as “PDP 150”) manufactured as described above.

  The analog interface 120 includes a Y / C separation circuit 121 having a chroma decoder, an A / D conversion circuit 122, a synchronization signal control circuit 123 having a PLL circuit, an image format conversion circuit 124, and an inverse γ (gamma). ) Conversion circuit 125, system control circuit 126, and PLE control circuit 127.

  In general, the analog interface 120 has a function of converting a received analog video signal into a digital signal and supplying the digital signal to the PDP module 130.

  For example, an analog video signal input from a TV tuner is decomposed into luminance signals of R (red), G (green), and B (blue) in the Y / C separation circuit 121, and then an A / D conversion circuit. In 122, it is converted into a digital signal.

  Thereafter, when the pixel configuration of the PDP module 130 and the pixel configuration of the video signal are different from each other, the image format conversion circuit 124 performs necessary image format conversion processing.

  The A / D conversion circuit 122 performs A / D (analog / digital) conversion of the video signal, and then the inverse γ conversion circuit 125 performs inverse γ conversion on the video signal to restore the linear characteristics. A digital video signal is generated. The digital video signal generated in this way is output to the PDP module 130 as an RGB video signal.

  A PLL (phase-locked loop) circuit built in the synchronization signal control circuit 123 generates a sampling clock signal and a data clock signal based on a horizontal synchronization signal supplied simultaneously with the analog video signal, and supplies it to the PDP module 130. Output.

  The PLE control circuit 127 of the analog interface 120 performs brightness control of the PDP. Specifically, the display brightness is controlled to increase when the average brightness level is equal to or lower than a predetermined value, and the display brightness is controlled to decrease when the average brightness level exceeds a predetermined value.

  The system control circuit 126 outputs various control signals to the PDP module 130.

  The PDP module 130 includes a digital signal processing / control circuit 131, a panel unit 132, and an in-module power supply circuit 133 incorporating a DC / DC converter. The digital signal processing / control circuit 131 includes an input interface signal processing circuit 134, a frame memory 135, a memory control circuit 136, and a driver control circuit 137.

  The input interface signal processing circuit 134 includes various control signals transmitted from the system control circuit 126, RGB video signals transmitted from the inverse γ conversion circuit 125, synchronization signals transmitted from the synchronization signal control circuit 123, and transmission from the PLL circuit. Receive a data clock signal.

  The average luminance level of the video signal input to the input interface signal processing circuit 134 is calculated by an input signal average luminance level calculation circuit (not shown) in the input interface signal processing circuit 134 and is output as, for example, 5-bit data. . Further, the PLE control circuit 127 sets PLE control data according to the average luminance level and supplies it to a luminance level control circuit (not shown) in the input interface signal processing circuit 134.

  In the digital signal processing / control circuit 131, these various signals are processed in the input interface signal processing circuit 134 and then a control signal is transmitted to the panel unit 132. At the same time, the memory control circuit 136 transmits a memory control signal and the driver control circuit 137 transmits a driver control signal to the panel unit 132, respectively.

  The panel unit 132 includes a PDP 150, a scan driver 138 that drives the scan electrodes of the PDP 150, a data driver 139 that drives the data electrodes of the PDP 150, a high-voltage pulse circuit 140 that supplies a pulse voltage to the PDP 150 and the scan driver 138, and a high voltage And a power recovery circuit 141 that recovers surplus power from the pulse circuit 140.

  The PDP 150 is configured to have pixels arranged in, for example, 1365 × 768. In the PDP 150, the scan driver 138 controls the scan electrodes, and the data driver 139 controls the data electrodes (address electrodes), thereby controlling lighting or non-lighting of predetermined pixels among these pixels. The image is displayed.

  Since such a plasma display device 100 includes the PDP 150, a high-quality plasma display device can be obtained.

  According to the embodiment as described above, when transferring a thin film pattern made of the transfer film 162 to the substrate (for example, a glass substrate or a resin substrate) 1, the transfer of one transfer film 162 formed in the transfer pattern shape is performed. Since the operation and the peeling operation of the support film 163 from the transfer film 162 are performed at the same timing, the transfer operation of the transfer film 162 and the operation of peeling the support film 163 from the transfer film 162 are completely separate. Compared with the prior art (Patent Documents 1 to 3 etc.) performed at the timing, the time required for processing can be shortened.

  In addition, after the protective film 161 is peeled off, a part of the transfer film 162 of the sheet material 160 (that is, a part corresponding to the interval between the transfer patterns) is removed in advance by the transfer film removing unit 20, and then the one transfer film 162 is transferred. Since the transfer operation and the peeling operation of the support film 163 from the transfer film 162 are performed at the same timing, the transferred substrate 1 is not retained in the film transfer device 110 and is transferred to each substrate 1. Transfer processing can be executed. Therefore, the scale of the film transfer device 110 can be reduced.

  Further, in the present embodiment, since only the transfer film 162 of the three layers constituting the sheet material 160 is transferred onto the substrate 1, the transfer process can be performed for each transfer pattern 162. Therefore, it is possible not to transfer to a portion where transfer is not required (for example, a defective pattern portion in multi-surface drawing), and it is possible to improve the utilization efficiency of the transfer material. In other words, it is preferable to selectively transfer only a non-defective portion among a plurality of transfer portions.

  In addition, since the transfer position with respect to the substrate 1 can be adjusted for each transfer pattern 162, the degree of freedom in line design and product design can be improved.

  In the prior art, the transfer film is continuously transferred to the plurality of substrates 1 to maintain the stability of the tension of the transfer film, whereas in the present embodiment, the support film 163 is fixed. By winding with the tension, the stability of the tension of the transfer film 162 can be maintained.

  Furthermore, since the length of the transfer film 162 can be adjusted, a desired pattern length can be set for each transfer film 162. Therefore, for example, when multiple patterns are formed in one substrate 1 (a plurality of patterns are formed), the pattern length can be set for each pattern.

[Second Embodiment]
Next, a film transfer apparatus 200 according to the second embodiment will be described with reference to FIG.

  FIG. 10 is a side view showing a film transfer apparatus 200 according to the second embodiment.

  The film transfer apparatus 200 differs from the film transfer apparatus 100 according to the first embodiment only in the points described below, and is otherwise configured in the same manner as the film transfer apparatus 100. Of these constituent elements, the same constituent elements as those of the film transfer apparatus 100 are denoted by the same reference numerals, and the description thereof is omitted.

  In the case of the first embodiment, the support film 163 is peeled off from the transferred transfer film 162 immediately after the transfer film 162 is transferred to the substrate 1 by the upper press roller 117A. However, in this case, the fixing of the transfer film 162 to the substrate 1 becomes worse because the support film 163 is peeled off from the transfer film 162 when the transfer film 162 is not sufficiently cooled on the substrate 1. there is a possibility.

  Therefore, the film transfer apparatus 200 according to the second embodiment includes, as shown in FIG. 10, in addition to the components of the film transfer apparatus 100 according to the first embodiment, the latter stage (sheet material 160). A plurality of (for example, two) upper cooling rollers 201 arranged on the downstream side in the feed direction) and a lower cooling roller 202 disposed opposite to each upper cooling roller 201 with the sheet material 160 and the substrate 1 interposed therebetween. I have.

  Unlike the upper pressure roller 117A and the lower pressure roller 117B, the upper cooling roller 201 and the lower cooling roller 202 preferably include a cooling mechanism for cooling the transfer film 162 (and the substrate 1). In this case, among the plurality of the upper cooling roller 201 and the lower cooling roller 202, those that are located farther from the pressure rollers 117A and 117B are set to a lower temperature so that the cooling is performed stepwise and efficiently. It can be performed. The upper cooling roller 201 and the lower cooling roller 202 may not be provided with a cooling mechanism, and may simply press the transfer film 162 against the substrate 1 without heating.

  The upper cooling roller 201 performs the same operation as that of the upper pressure roller 117A in synchronization with the upper pressure roller 117A. The lower cooling roller 202 performs the same operation as that of the lower pressure roller 117B in synchronization with the lower pressure roller 117B.

  Therefore, after the transfer film 162 is transferred to the substrate 1 by the upper pressure roller 117A and the lower pressure roller 117B, the transfer film 162 is further transferred to the substrate 1 by the plurality of upper cooling rollers 201 and lower cooling rollers 202. Securely crimped.

  Further, during the pressure-bonding operation by the upper cooling roller 201 and the lower cooling roller 202, the transfer film 162 is cooled even when both the pressure-bonding rollers 201 and 202 are not provided with a cooling mechanism. The fixing of 162 to the substrate 1 becomes good.

  According to the second embodiment as described above, the fixing of the transfer film 162 to the substrate 1 is better than in the case of the first embodiment.

  In the second embodiment described above, an example in which two upper cooling rollers 201 and two lower cooling rollers 202 are provided has been described. However, the present invention is not limited to this example. You may make it provide more than.

It is a side view which shows the film transfer apparatus which concerns on 1st Embodiment. It is a top view which shows the film transfer apparatus which concerns on 1st Embodiment. (A) is a perspective view which shows a sheet | seat supply roll, (B) is sectional drawing which shows the layer structure of a sheet | seat material. It is a top view which shows the example of the transfer aspect of the film with respect to a board | substrate. It is a side view which shows the vicinity of the 1st transfer film detection sensor and transfer film removal unit of a film transfer apparatus, (A) is the state in which the transfer film removal unit is located in a reference position, (B) is a transfer film The state where the removal unit has moved from the reference position is shown. It is a side view which shows the vicinity of the 2nd transfer film detection sensor of a film transfer apparatus. FIG. 7 is a series of process diagrams for explaining a transfer operation by the film transfer device, and FIGS. 7A to 7F are side views each showing the vicinity of the pressure roller of the film transfer device. It is a disassembled perspective view which shows the structure of a plasma display panel. It is a block diagram which shows the structure of a plasma display apparatus. It is a side view which shows the film transfer apparatus which concerns on 2nd Embodiment. It is a side view which shows the conventional film transfer apparatus. It is a top view which shows the example of the transfer aspect of the film with respect to the board | substrate by the conventional film transfer apparatus.

Explanation of symbols

110 Film transfer device 112 Guide roller (sheet conveying means)
113 Guide roller (sheet conveying means)
115 Guide roller (sheet conveying means)
114 Protective film take-up roller (protective film peeling means, protective film take-up collecting means)
20 Transfer film removal unit (transfer film removal means)
117A Upper pressure roller (transfer means, sheet pressure roller, first sheet pressure roller)
117B Lower pressure roller (transfer means, substrate pressure roller)
119 Support film take-up roller (support film peeling means, support film take-up recovery means)
116 First tension roller (tension maintaining means, front end position adjusting means, fixed amount feeding means)
118 Second tension roller (support film peeling means, tension maintaining means, front end position adjusting means, fixed amount feeding means)
50 Second transfer film detection sensor (front end position adjusting means, front end position adjusting position detection sensor)
30 Removal unit moving mechanism (pattern length adjusting means, removing means position adjusting means)
40 Second transfer film detection sensor (pattern length adjustment means, position detection sensor for pattern length adjustment)
10 Front substrate (substrate)
11 Back substrate (substrate)
150 Plasma display panel 19 Dielectric layer 200 Film transfer device 201 Second upper pressure roller (second sheet pressure roller)
202 Second lower pressure roller

Claims (29)

In a transfer method of transferring the transfer film in a sheet material having at least two layers of a transfer film transferred to a substrate and a support film supporting the transfer film to the substrate,
A sheet conveying step for conveying the sheet material in the feeding direction;
A part of the transfer film of the sheet material is removed at predetermined intervals in the feeding direction over the width direction of the transfer film, so that the transfer film left on the support film can be transferred to a desired transfer pattern. A transfer film removing step to be formed into a shape;
A transfer step of transferring the transfer film formed in the transfer pattern shape to the substrate;
A support film peeling step of peeling the support film from the transfer film transferred to the substrate;
With
A transfer method for a film, wherein the transfer step and the support film peeling step of one transfer film formed in the transfer pattern shape are performed at an overlapping timing.   The film transfer method according to claim 1, further comprising a support film winding and collecting step of winding and collecting the supporting film peeled in the supporting film peeling step.   The film transfer method according to claim 2, wherein in the support film winding and collecting step, the support film is wound with a constant tension. In the transfer step, the sheet pressing roller that can be brought into contact with and separated from the substrate through the sheet material is moved along with the sheet material to be in contact with the substrate through the sheet material. , By pressing the sheet material against the substrate by the sheet pressing roller,
2. A tension maintaining step of maintaining a constant tension of the sheet material in an operation of bringing the sheet pressing roller into contact with the substrate through the sheet material before the transfer step. 4. The method for transferring a film according to any one of items 1 to 3.   The tension maintaining step includes: a first tension roller that engages with the sheet material on the upstream side of the sheet pressure roller near the sheet pressure roller; and a sheet pressure roller near the sheet pressure roller. 5. The film transfer method according to claim 4, wherein the film is transferred or rotated by a second tension roller that engages with the sheet material on the downstream side in the feeding direction.   6. The film according to claim 5, further comprising a front end position adjusting step of adjusting a front end of the transfer film formed in a desired transfer pattern shape by the transfer film removing step to a transfer start position with respect to the substrate. Transfer method. The transfer step is performed by pressing the sheet material against the substrate with a sheet pressing roller,
The front end position adjusting step includes:
A front end position adjusting position detecting step for detecting that the front end of the transfer film formed in a transfer pattern shape has reached a predetermined position on the peripheral surface of the sheet pressing roller;
From the timing of detection by the front end position adjustment position detection step, a constant amount feeding step of feeding the sheet material in a feeding direction by a certain amount;
The film transfer method according to claim 6, further comprising:   The fixed amount feeding step includes: a first tension roller that engages with the sheet material at a position upstream of the sheet pressure roller near the sheet pressure roller; and a sheet pressure roller near the sheet pressure roller. The film transfer method according to claim 7, wherein the transfer is performed by rotating or rotating a second tension roller that engages with the sheet material further downstream in the feeding direction.   The film transfer method according to any one of claims 1 to 8, further comprising a pattern length adjustment step of adjusting a length of the transfer film formed in the transfer pattern shape. The pattern length adjusting step includes
A pattern length adjustment position detection step of detecting the front end of the transfer film formed in the transfer pattern shape by a sensor;
The feed amount Y of the sheet material from the detection in the pattern length adjustment position detection step to the removal operation in the transfer film removal step is based on the rotation amount of the roller that guides the sheet material A calculation step to calculate
The transfer amount is calculated so that a total value of the calculated feed amount Y and the distance N between the position detected by the sensor and the position where the removal operation is performed in the transfer film removal step becomes a desired transfer pattern length L. A removal operation position adjustment step for adjusting the position of the removal operation in the film removal step;
The film transfer method according to claim 9, further comprising:   In the removal operation position adjustment step, correction is performed in consideration of the amount of elongation of the sheet material due to the tension applied to the sheet material, and the position where the removal operation is performed in the transfer film removal step is adjusted. The film transfer method according to claim 10.   When transferring the transfer film to each of a plurality of transfer locations on one substrate, the transfer film is not transferred to a transfer location that is known to be defective in advance, but is selectively transferred only to a transfer location that is not defective. The film transfer method according to any one of claims 1 to 11.   In the transfer step, the sheet material is pressure-bonded to the substrate by a sheet pressure roller disposed on the upstream side in the feeding direction and a plurality of cooling rollers disposed on the downstream side of the sheet pressure roller. The film transfer method according to claim 1, wherein the transfer method is performed. In a film transfer apparatus for transferring the transfer film in a sheet material having at least two layers of a transfer film transferred to a substrate and a support film supporting the transfer film to the substrate,
Sheet conveying means for conveying the sheet material in the feeding direction;
A part of the transfer film of the sheet material is removed at predetermined intervals in the feeding direction over the width direction of the transfer film, so that the transfer film left on the support film can be transferred to a desired transfer pattern. A transfer film removing means to be formed into a shape;
Transfer means for transferring the transfer film formed in the transfer pattern shape to the substrate;
A support film peeling means for peeling the support film from the transfer film that has been transferred to the substrate;
And a transfer operation of one transfer film formed in the shape of the transfer pattern and a peeling operation of the support film from the transfer film are performed at an overlapping timing.   15. The film transfer apparatus according to claim 14, further comprising a support film take-up collecting unit that winds and collects the support film peeled off by the support film peeling unit.   The film transfer apparatus according to claim 15, wherein the support film winding and collecting unit winds the support film with a constant tension. The transfer means is configured to be able to contact with and separate from the substrate via the sheet material, and moves the sheet material along with the sheet material while being in contact with the substrate via the sheet material. A sheet pressing roller for pressing the substrate;
The film transfer device further includes:
2. A tension maintaining means for maintaining a constant tension of the sheet material during an operation of bringing the sheet pressing roller into contact with the substrate through the sheet material before a transfer operation. The film transfer apparatus according to any one of 14 to 16. The tension maintaining means includes
A first tension roller that engages with the sheet material on the upstream side of the sheet pressure roller in the feeding direction in the vicinity of the sheet pressure roller;
A second tension roller that engages with the sheet material at a position downstream of the sheet pressure roller in the feeding direction in the vicinity of the sheet pressure roller;
With
18. The film transfer apparatus according to claim 17, wherein the tension of the sheet material is maintained constant by moving or rotating the first and second tension rollers.   19. The film according to claim 18, further comprising front end position adjusting means for adjusting a front end of the transfer film formed in a desired transfer pattern shape by the transfer film removing means to a transfer start position with respect to the substrate. Transfer device. The transfer means includes a sheet pressing roller for pressing the sheet material to the substrate,
The front end position adjusting means includes
A front end position adjusting position detection sensor for detecting that the front end of the transfer film formed in the transfer pattern shape has reached a predetermined position on the peripheral surface of the sheet pressing roller;
From the timing of detection by the front end position adjustment position detection sensor, a constant amount feeding means for feeding the sheet material in the feeding direction by a certain amount;
The film transfer apparatus according to claim 19, comprising: The fixed amount feeding means is
A first tension roller that engages with the sheet material on the upstream side of the sheet pressure roller in the feeding direction in the vicinity of the sheet pressure roller;
A second tension roller that engages with the sheet material at a position downstream of the sheet pressure roller in the feeding direction in the vicinity of the sheet pressure roller;
With
21. The film transfer apparatus according to claim 20, wherein the sheet material is fed in a feeding direction by a predetermined amount by moving or rotating the first and second tension rollers. The front end position adjusting position detection sensor is a light reflection sensor or a laser reflection sensor,
Let R be the radius of the pressure roller,
The length in the feeding direction of the portion removed by the transfer film removal step is B,
Let pi be π,
When the angle between the line connecting the center of the pressure roller and the rear end position of the transfer film for which the previous transfer has been completed and the optical axis of the front end position adjusting position detection sensor is θ,
The film transfer according to claim 20 or 21, wherein the position detection sensor for front end position adjustment is arranged at a position where the angle θ satisfies θ <(B / πR) × 180 °. apparatus.   23. The film transfer apparatus according to claim 14, further comprising a pattern length adjusting unit that adjusts a length of the transfer film formed in the transfer pattern shape. The pattern length adjusting means is
A pattern length adjusting position detection sensor for detecting a front end of the transfer film formed in the transfer pattern shape;
The sheet material feed amount Y from the detection by the pattern length adjusting position detection sensor to the time when the transfer film removing means performs the removal operation is based on the rotation amount of the roller for guiding the sheet material. A calculating means for calculating;
Removing means position adjusting means for adjusting the position of the transfer film removing means in the feeding direction of the sheet material;
With
The removal means position adjustment means has a total value of the calculated feed amount Y, the distance N between the position detected by the pattern length adjustment position detection sensor and the position where the transfer film removal means performs the removal operation, The position of the transfer film removing unit is adjusted so that a desired transfer pattern length L is obtained, and the transfer film removing unit performs a transfer film removing operation at the adjusted position. 24. The film transfer apparatus according to 23.   25. The removal means position adjusting means adjusts the position of the transfer film removing means by performing correction in consideration of the amount of elongation of the sheet material due to the tension applied to the sheet material. The film transfer apparatus as described. The transfer means includes
A sheet pressure roller disposed on the upstream side in the feed direction;
A plurality of cooling rollers disposed downstream of the sheet pressing roller;
With
26. The film transfer apparatus according to claim 14, wherein a transfer operation is performed by pressing the sheet material against the substrate by the sheet pressing roller and the plurality of cooling rollers.   The transfer means includes: a sheet pressure roller for pressure bonding the sheet material to the substrate; and a substrate side pressure roller disposed at a position facing the sheet pressure roller with the substrate and the sheet material interposed therebetween. 27. The film transfer apparatus according to claim 14, wherein the film transfer apparatus is configured. A method for manufacturing a plasma display panel comprising first and second substrates, comprising:
14. A plasma display comprising a step of transferring a transfer film to at least one of the first and second substrates by the film transfer method according to any one of claims 1 to 13. Panel manufacturing method.   29. The method of manufacturing a plasma display panel according to claim 28, wherein the dielectric layer of the plasma display panel is formed by the transfer film.

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