JP2008268420A - Method for manufacturing liquid crystal display device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To easily superpose an optical sheet with high accuracy on each of a liquid crystal panel and a light guide plate. <P>SOLUTION: A method for manufacturing a liquid crystal display device includes: a first superposition step of superposing a liquid crystal panel base 10 on a first optical sheet base 21 by aligning with a first mask 15 and a second mark 25; a second superposition step of superposing a plurality of optical sheet bases 21, 22, 23, 24 on one another by aligning with the second marks 25; and a third superposition step of superposing a light guide plate base 26 on the second optical sheet base 24 by aligning with the second mark 25 and a third mark 32. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a liquid crystal display device.

  Conventionally, liquid crystal display devices are widely known as displays for mobile phones, digital cameras, and the like. This liquid crystal display device includes a liquid crystal panel having a liquid crystal layer formed between a pair of substrates, and a backlight unit that irradiates the liquid crystal panel with light from one surface side of the liquid crystal panel.

  The backlight unit has a direct type in which a number of light sources are installed directly on the back of the liquid crystal panel, and a predetermined pattern such as a diffraction grating or dot shape is formed on the back of the liquid crystal panel via at least one optical sheet. There is known a side edge type in which light guide plates are stacked and a light source is installed on at least one side surface of the light guide plate. It is difficult to reduce the thickness of the direct type backlight unit due to its structure. On the other hand, in the side edge type backlight unit, since the light guide plate contributes to the thickness, it is possible to reduce the thickness by thinning the light guide plate.

  Further, the backlight unit is required to uniformly extract light from the light source through the liquid crystal panel so that luminance unevenness does not occur. However, the uniformity of the light extracted from the side-edge type backlight unit is affected by the accuracy of a predetermined pattern formed on the light guide plate. Is likely to occur.

Therefore, Patent Document 1 that improves the accuracy of a predetermined pattern in a light guide plate is known. In Patent Document 1, a photosensitive reflection type resin is applied to a film substrate, and then the film substrate is exposed and developed to form a light guide plate. As a result, a dot-shaped resin having a predetermined pattern is accurately formed on the film substrate.
JP-A-6-333407

  By the way, since the backlight unit is superimposed and bonded to the liquid crystal panel only by rough alignment such as pin alignment, the accuracy of the optical sheet overlapping with the liquid crystal panel is relatively low. As a result, the pattern of the pixels of the liquid crystal panel and the optical sheet interfere with each other and moire tends to occur.

  In addition, since the optical sheet and the light guide plate are overlapped only by rough alignment, the accuracy of the optical sheet overlap with the light guide plate is low, and even with the light guide plate of Patent Document 1, the light from the light source is made uniform. It is difficult to take it out of the backlight unit, and uneven brightness tends to occur.

  Thus, when the accuracy of overlaying the optical sheet on at least one of the liquid crystal panel and the light guide plate is low, the display quality of the liquid crystal display device is degraded. In order to overlay the optical sheet on each of the liquid crystal panel and the light guide plate with high accuracy, after the optical sheet and the liquid crystal panel or the light guide plate are overlaid, the optical sheet is arranged at a desired position with respect to the liquid crystal panel or the light guide plate. Therefore, it is necessary to adjust the position of the optical sheet. Therefore, it takes time and effort to accurately overlay the optical sheet on the liquid crystal panel and the light guide plate.

  The present invention has been made in view of these points, and an object of the present invention is to easily and accurately superimpose at least one optical sheet on each of a liquid crystal panel and a light guide plate. .

  In order to achieve the above object, a method of manufacturing a liquid crystal display device according to the present invention includes a liquid crystal panel base material including a plurality of liquid crystal panels arranged in a matrix and a light guide plate base material. And a plurality of optical sheet base materials including the second optical sheet base material, the first optical sheet base material being adjacent to the surface of the liquid crystal panel base material, and the second optical sheet base material Is a method of manufacturing a liquid crystal display device by dividing the laminated body adjacent to the surface of the light guide plate base material for each liquid crystal panel, wherein the first mark forms a first mark on the liquid crystal panel base material Forming step, a second mark forming step of forming a second mark on each of the plurality of optical sheet base materials, a third mark forming step of forming a third mark on the light guide plate base material, For one optical sheet base material, the above liquid A first superimposing step of aligning and superimposing the panel base material with the first mark and the second mark, and superposing the plurality of optical sheet base materials with each other by the second mark A second superposition step, and a third superposition step in which the light guide plate base material is aligned and superposed on the second optical sheet base material by the second mark and the third mark.

  Further, a laminated body configured by laminating a liquid crystal panel base material including a plurality of liquid crystal panels arranged in a matrix and a light guide plate base material through an optical sheet base material is divided for each liquid crystal panel. A first mark forming step of forming a first mark on the liquid crystal panel base material, and a second mark forming step of forming a second mark on the optical sheet base material. And a third mark forming step of forming a third mark on the light guide plate base material, and the liquid crystal panel base material is aligned with the optical sheet base material by the first mark and the second mark. And a second superimposing step of aligning and superimposing the light guide plate base material on the optical sheet base material with the second mark and the third mark. Including.

  In the second mark forming step, the optical sheet base material is formed at the same time as the optical sheet base material by punching out a base material including at least one optical sheet base material for each of the optical sheet base materials. It is preferable to form the second mark.

  In the third mark forming step, it is preferable to form the third mark at the same time as forming a diffraction grating on the light guide plate base material.

  In the third mark forming step, the resin member is cured in a state where a mold is pressed against an uncured resin member applied to the film substrate base material, whereby the first mark is formed on one surface of the film substrate base material. 3 marks and the diffraction grating may be formed.

  The film substrate base material may be formed of acrylic carbonate or cycloolefin.

  The plurality of optical sheet base materials may be two diffusion sheet base materials and two prism sheet base materials.

  In addition, the liquid crystal panel and the light guide plate are configured to be stacked via a plurality of optical sheets including a first optical sheet and a second optical sheet, the first optical sheet is adjacent to the surface of the liquid crystal panel, and the first A method of manufacturing a liquid crystal display device in which two optical sheets are adjacent to the surface of the light guide plate, the first mark forming step of forming a first mark on the liquid crystal panel, and a first mark forming step for each of the plurality of optical sheets. A second mark forming step of forming a second mark, a third mark forming step of forming a third mark on the light guide plate, and the liquid crystal panel with respect to the first optical sheet. A first superimposing step of aligning and superimposing by the second mark, a second superimposing step of aligning and superimposing the plurality of optical sheets by the second mark, and the above For two optical sheets, and a third superimposing step superposed with the light guide plate aligned with the second mark and the third mark.

  A method of manufacturing a liquid crystal display device in which a liquid crystal panel and a light guide plate are laminated via an optical sheet, the first mark forming step of forming a first mark on the liquid crystal panel, A second mark forming step of forming a second mark on the optical sheet; a third mark forming step of forming a third mark on the light guide plate; and the liquid crystal panel with respect to the optical sheet. And a first superimposing step of aligning and superimposing with the second mark, and a second superimposing and aligning the light guide plate with the second mark and the third mark on the optical sheet. And a superimposing step.

  The plurality of optical sheets may be two diffusion sheets and two prism sheets.

-Action-
According to the method for manufacturing a liquid crystal display device according to the present invention, the liquid crystal panel base material and the light guide plate base material are laminated by sandwiching a plurality of optical sheet base materials for each liquid crystal panel. In the mark forming step, a first mark is formed on the liquid crystal panel base material. In the second mark forming step, a second mark is formed on each of the plurality of optical sheet base materials. In the third mark forming step, a third mark is formed on the light guide plate base material.

  In the first superimposing step, the liquid crystal panel base material is aligned and superposed on the first optical sheet base material by the first mark and the second mark, so that the first optical sheet base material is placed at a desired position. The liquid crystal panel base material is quickly and accurately superimposed. In the second overlapping step, the plurality of optical sheet base materials are aligned and overlapped with each other by the second mark, so that the plurality of optical sheet base materials are overlapped with each other with high accuracy. In the third superimposing step, the light guide plate base material is aligned and superposed on the second optical sheet base material by the second mark and the third mark, so that the second optical sheet base material is placed at a desired position. The light guide plate base material is quickly and accurately superimposed.

  Accordingly, the plurality of optical sheet base materials are quickly and accurately superimposed on the liquid crystal panel base material, respectively, and the plurality of optical sheet base materials are quickly and accurately superimposed on the light guide plate base material, respectively. In addition, the time required for accurate overlaying of the plurality of optical sheet base materials on each of the light guide plate base materials is shortened. As a result, a plurality of optical sheets can be easily and accurately superimposed on each of the liquid crystal panel and the light guide plate.

  In the second mark forming step, a base material having at least one optical sheet base material is punched for each optical sheet base material, thereby forming the optical sheet base material and simultaneously forming a second mark on the optical sheet base material. In some cases, it is not necessary to perform the second mark forming step separately from the step of forming the optical sheet base material. Therefore, it is possible to prevent the manufacturing process from increasing by forming the second mark on the optical sheet base material.

  In the third mark forming step, when forming the third mark at the same time as forming the diffraction grating on the light guide plate base material, it is not necessary to perform the step of forming the diffraction grating separately from the third mark forming step. In other words, it is not necessary to perform the third mark forming step separately from the step of forming the diffraction grating. Therefore, it is possible to prevent the manufacturing process from increasing by forming the third mark on the light guide plate base material.

  In addition, according to the method for manufacturing a liquid crystal display device according to the present invention, the liquid crystal panel base material and the light guide plate base material are laminated via the optical sheet base material, and the liquid crystal display device according to the present invention divides the laminate into each liquid crystal panel. In the mark forming step, a first mark is formed on the liquid crystal panel base material. In the second mark forming step, a second mark is formed on the optical sheet base material. In the third mark forming step, a third mark is formed on the light guide plate base material.

  In the first superimposing step, the liquid crystal panel base material is aligned and superposed on the optical sheet base material by the first mark and the second mark. Further, in the second superimposing step, the light guide plate base material is aligned and superposed on the optical sheet base material by the second mark and the third mark, so that the light guide plate is placed at a desired position on the optical sheet base material. The base materials are quickly and accurately superimposed. Therefore, the optical sheet can be easily and accurately superimposed on each of the liquid crystal panel and the light guide plate.

  In addition, according to the method of manufacturing a liquid crystal display device according to the present invention for manufacturing a liquid crystal display device in which a liquid crystal panel and a light guide plate are laminated via a plurality of optical sheets, the first mark forming step includes a liquid crystal panel. A first mark is formed on the substrate. In the second mark forming step, a second mark is formed on each of the plurality of optical sheets. In the third mark forming step, a third mark is formed on the light guide plate.

  In the first superimposing step, the liquid crystal panel is aligned with the first optical sheet by the first mark and the second mark so that the liquid crystal panel is accurately and quickly placed at a desired position on the first optical sheet. Is superimposed. In the second superimposing step, the plurality of optical sheets are aligned with each other by the second mark and superimposed, so that the plurality of optical sheets are superimposed on each other with high accuracy. Further, in the third superimposing step, the light guide plate is superposed on the second optical sheet by the second mark and the third mark, so that a plurality of optical sheets are easily and accurately placed on the liquid crystal panel and the light guide plate, respectively. It becomes possible to superimpose.

  Further, according to the method of manufacturing a liquid crystal display device according to the present invention for manufacturing a liquid crystal display device in which a liquid crystal panel and a light guide plate are laminated via an optical sheet, the first mark forming step includes 1 mark is formed. In the second mark forming step, a second mark is formed on the optical sheet. In the third mark forming step, a third mark is formed on the light guide plate.

  In the first superimposing step, the liquid crystal panel is aligned and superposed on the optical sheet by the first mark and the second mark. Further, in the second superimposing step, the light guide plate is aligned with the optical sheet by the second mark and the third mark, and the optical sheet is easily and accurately placed on each of the liquid crystal panel and the light guide plate. It becomes possible to superimpose.

  According to the present invention, the first optical sheet base material can be quickly and accurately superimposed on the liquid crystal panel base material by the first superposition step. Further, the second and third superposition steps allow the plurality of optical sheet base materials to be quickly and accurately overlapped with each other, and the second optical sheet base material is quickly and accurately overlapped with the light guide plate base material. Since they can be combined, the time required for accurate overlaying of the plurality of optical sheet base materials on the liquid crystal panel base material and the light guide plate base material can be reduced. As a result, a plurality of optical sheets can be easily and accurately superimposed on each of the liquid crystal panel and the light guide plate.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. The present invention is not limited to the following embodiment.

Embodiment 1 of the Invention
1 to 12 show Embodiment 1 of the present invention. 1-11 is a figure for demonstrating the manufacturing method of the liquid crystal display device S. FIG. FIG. 12 is a cross-sectional view schematically showing the liquid crystal display device S. In FIG. 9, the diffraction grating 31 formed on the light guide plate base material 26 is not shown.

  First, the liquid crystal display device S manufactured by the liquid crystal display device manufacturing method of Embodiment 1 will be described.

  As shown in FIG. 12, the liquid crystal display device S includes a liquid crystal panel 50 formed by bonding a pair of substrates 51 and 52 to each other, and a liquid crystal panel 50 disposed on one surface of the liquid crystal panel 50 so as to emit uniform light. And a backlight unit 40 that emits light. The liquid crystal panel 50 is sealed with a sealing member between the element substrate 51 and the counter substrate 52, although not illustrated, the element substrate 51, a counter substrate 52 disposed opposite to the element substrate 51, and illustration thereof are omitted. And a liquid crystal layer.

  Although not shown, the element substrate 51 has a plurality of pixels on the surface on the liquid crystal layer side, and a TFT and a pixel electrode are formed in each pixel. The element substrate 51 is provided with an alignment film (not shown) on the surface on the liquid crystal layer side, and a polarizing plate 53 is laminated on the surface opposite to the liquid crystal layer.

  Although not shown, the counter substrate 52 has a common electrode made of a color filter and ITO on the surface on the liquid crystal layer side. The counter substrate 52 is provided with an alignment film (not shown) on the surface on the liquid crystal layer side, and a polarizing plate 54 is laminated on the surface opposite to the liquid crystal layer.

  In addition, in the region on one side of the element substrate 51, the surface on the liquid crystal layer side is partially exposed from the counter substrate 52 when viewed from the direction perpendicular to the surface of the liquid crystal panel 50. A terminal portion (not shown) connected to each pixel electrode is formed on the surface of the element substrate 51 exposed from the counter substrate 52, and the first FPC is connected to the terminal portion and applies a voltage to the liquid crystal layer. (Flexible printed wiring board) 55 is provided.

  The backlight unit 40 includes a plurality of optical sheets 41, 42, 43, 44 laminated on the surface of the liquid crystal panel 30 on the element substrate 31 side, and a plurality of optical sheets 41, 42, 43, 44 through the plurality of optical sheets 41, 42, 43, 44. 30, a second FPC 46 having a light source lamp such as an LED (light emitting diode) disposed on one side of the light guide plate 45, these optical sheets 41, 42, 43, 44, A frame 47 having a substantially concave cross section for storing and supporting the optical plate 45 and the second FPC 46 is provided. The backlight unit 40 is a side edge type backlight unit.

  The plurality of optical sheets 41, 42, 43, 44 include two diffusion sheets, a first diffusion sheet 41 that is a first optical sheet and a second diffusion sheet 44 that is a second optical sheet, and a first prism sheet 42. And two prism sheets of the second prism sheet 43. The first diffusion sheet 41 is adjacent to the surface of the liquid crystal panel 50 on the element substrate 51 side. Here, the term “adjacent” means that the first diffusion sheet 41 and the liquid crystal panel 50 may be in contact with each other, and a slight gap may be formed between the first diffusion sheet 41 and the liquid crystal panel 50. means.

  The first diffusion sheet 41 and the second diffusion sheet 44 are superposed via the first prism sheet 42 and the second prism sheet 43. The first prism sheet 42 is stacked adjacent to the first diffusion sheet 41, and the second prism sheet 43 is stacked adjacent to the second diffusion sheet 44. The plurality of optical sheets 41, 42, 43, 44 are formed in a region that does not overlap the display region (liquid crystal layer) of the liquid crystal panel 30 when viewed from the direction perpendicular to the surface of the liquid crystal panel 30, and are made of, for example, acrylic resin Are bonded together by being overlapped with each other via an adhesive layer (not shown).

  The light guide plate 45 is adjacent to the surface of the second diffusion sheet 44 on the side opposite to the liquid crystal panel 50, and is overlapped and bonded via an adhesive layer in the same manner as the plurality of optical sheets 41, 42, 43, 44. ing. The light guide plate 45 is a wedge-shaped light guide plate.

  That is, the light guide plate 45 is formed with a diffraction grating 31 composed of a plurality of prism grooves 30 extending in a direction perpendicular to the incident direction of light from the light source lamp on the surface opposite to the second diffusion sheet 44. Yes. The prism grooves 30 are formed in a V-shaped cross section and are continuously formed at a predetermined interval in the incident direction of light from the light source lamp. The light guide plate 45 has a thickness that gradually decreases with respect to the light guide direction, and is formed so as to move away from the light source lamp and increase the total number of reflections and the total reflection angle on the surface of the prism groove 31. ing.

  Although not shown, the light guide plate 45 includes a film substrate and a resin member formed on one surface of the film substrate, and the plurality of prism grooves 30 are formed in the resin member. The film substrate is made of, for example, acrylic carbonate or cycloolefin.

  Thus, in the backlight unit 40, light incident on the inside of the light guide plate 45 from the side surface of the light guide plate 45 by the light source lamp of the second FPC 46 propagates through the inside of the light guide plate 45 to face the second diffusion sheet 44 from the side. Further, the light emitted from the light guide plate 45 is made uniform through the second diffusion sheet 44, the second prism sheet 43, the first prism sheet 42, and the first diffusion sheet 41 in order, and the backlight unit 40. The light is emitted from the surface on the liquid crystal panel 30 side.

  In addition, a reflection sheet (not shown) is provided between the light guide plate 45 and the frame 47 to reflect the light leaking to the opposite side of the light guide plate 45 from the first diffusion sheet 44 to the light guide plate 45. As a result, the light from the light source lamp is more efficiently emitted to the liquid crystal panel 50 via the light guide plate 45 and the plurality of optical sheets 41, 42, 43, 44.

  The backlight unit 40 is integrally formed with the liquid crystal panel 30 because the surface of the first diffusion sheet 41 is superimposed on the surface of the liquid crystal panel 30 via an adhesive layer. Thus, the liquid crystal display device S irradiates the liquid crystal panel 50 with uniform light by the backlight unit 40 and controls the orientation of the liquid crystal molecules in the liquid crystal layer to perform a desired display.

-Manufacturing method-
The manufacturing method of the liquid crystal display device S includes a liquid crystal panel base material forming step, an optical sheet base material forming step, a light guide plate base material forming step, a first bonding step, a second bonding step, and a third. A bonding process and a cutting process are included.

  In the liquid crystal panel base material forming step, a TFT substrate and a pixel electrode are formed on the surface of one glass substrate base material of a pair of glass substrate base materials, and an element substrate base including a plurality of element substrates 31 arranged in a matrix form A material 11 is formed. Further, a color filter and a common electrode are formed on the surface of the other glass substrate base material to form the counter substrate base material 12 including a plurality of counter substrates 32 arranged in a matrix.

  Next, the element substrate base material 11 and the counter substrate base material 12 are bonded together so that each element substrate 31 and each counter substrate 32 are arranged to face each other with a liquid crystal layer therebetween, and then the element substrate base material. The liquid crystal panel base material 10 is formed by laminating polarizing plate base materials 13 and 14 on the surface of the substrate 11 and the counter substrate base material 12 opposite to the liquid crystal layer. A known method for forming the liquid crystal panel base material 10 can be applied to the liquid crystal panel base material forming step.

  This liquid crystal panel base material forming step includes a first mark forming step of forming a first mark 15 on the liquid crystal panel base material 10 as shown in FIG. In this first mark forming step, simultaneously with the formation of the pixel electrodes on one glass substrate base material, first marks 15 that are metal layers having a predetermined shape are formed at the four corners of the glass substrate base material.

  In the optical sheet base material forming step, two diffusion sheet base materials 21, a first diffusion sheet base material 21 that is a first optical sheet base material and a second diffusion sheet base material 24 that is a second optical sheet base material, 24 and two prism sheet base materials 23, 24 of the first prism sheet base material 22 and the second prism sheet base material 24, respectively, are formed. The optical sheet base material forming step includes a second mark forming step of forming the second mark 25 on each of the plurality of optical sheet base materials 21, 22, 23, and 24.

  Regarding the formation of the first diffusion sheet base material 21 in the optical sheet base material formation step, first, as shown in FIG. 2, the base material 20 including at least one first diffusion sheet base material 21 is formed by a known method. To do. Next, a second mark forming process is performed. In the second mark formation step, the first diffusion sheet base material 21 is formed by punching the base material 20 of the first diffusion sheet base material 21 for each first diffusion sheet base material 21 to form the first diffusion sheet base material 21 at the same time. Second marks 25, which are through holes of a predetermined shape, are formed at the four corners of the base material 21. That is, the second mark 25 is formed by punching the base material for each first diffusion sheet base material 21 and simultaneously punching part of the four corners of the first diffusion sheet base material 21 into a predetermined shape. Then, as shown in FIG. 3, the first diffusion sheet base material 21 in which the second marks 25 are formed at the four corners is formed.

  The second diffusion sheet base material 24, the first prism sheet base material 22 and the second prism sheet base material 23 are each formed in the same manner as the first diffusion sheet base material 21 after forming a base material by a known method. The second diffusion sheet base material 24, the first prism sheet base material 22 and the second prism sheet base material 23 are formed at the same time by punching each base material with a die, respectively. Second marks 25 are formed at the four corners of the first prism sheet base material 22 and the second prism sheet base material 23, respectively.

  In the light guide plate base material forming step, the light guide plate base material 26 having the diffraction grating 31 on one surface and including a plurality of light guide plates 45 arranged in a matrix is formed. The light guide plate base material forming step includes a third mark forming step of forming the third mark 32 on the light guide plate base material 26.

  In this light guide plate base material forming step, first, as shown in FIG. 4, an uncured resin member 26b is formed on one surface of a film substrate base material 26a formed of acrylic carbonate or cycloolefin by a printing method or the like. Apply. Next, a third mark forming step is performed. In the third mark forming step, as shown in FIG. 5, the mold 27 is pressed against the uncured resin member 26b applied to the film substrate base material 26a. In the mold 27, a plurality of protrusions having a V-shaped cross section are continuously formed in one direction on the surface pressed against the resin member 26b. Moreover, the convex part of a predetermined shape is provided in the surface of the metal mold | die 27 pressed against the four corners of the resin member 26b. 5 denotes a direction in which the mold 27 is pressed.

  Subsequently, the resin member 26b is cured by irradiating the resin member 26b with ultraviolet rays from the side opposite to the mold 27 of the film substrate base material 26a in a state where the mold 27 is pressed against the resin member 26b. Reference numeral 26 in FIG. 5 indicates an irradiation direction of ultraviolet rays. As a result, as shown in FIGS. 6 and 7, a plurality of prism grooves 30 are formed in the resin member 26b provided on one surface of the film substrate base material 26a to form the diffraction grating 31, and at the same time, the film substrate base material. Third marks 32 that are concave portions of a predetermined shape are formed in the resin members 26b at the four corners of the material 26a. Then, the third mark 32 and the diffraction grating 31 are formed on one surface of the film substrate base material 26a, and the light guide plate base material 26 is formed by integrally forming the film substrate base material 26a and the resin member 26b. Form.

  In the first superposition step to be performed next, as shown in FIG. 8, the liquid crystal panel base material 10 is aligned with the first mark 15 and the second mark 25 with respect to the first diffusion sheet base material 21. Overlapping. At this time, the first diffusion sheet base material 21 and the liquid crystal panel base material 10 are bonded to each other by being overlaid on the surface of the liquid crystal panel base material 10 via an adhesive layer formed in advance. 21 is adjacent to the surface of the liquid crystal panel base material 10.

  In the second superposition step to be performed next, the plurality of optical sheet base materials 21, 22, 23, and 24 are aligned with each other by the second mark 25 and superposed. At this time, adjacent optical sheet base materials are overlapped and bonded to each other via an adhesive layer.

  That is, first, after an adhesive layer is formed on the surface of the first diffusion sheet base material 21 bonded to the liquid crystal panel base material 10, the first diffusion sheet base material 21 and the first prism sheet base material 22 are mutually connected. The second mark 25 is aligned and overlapped through the adhesive layer. Next, after forming an adhesive layer on the surface of the first prism sheet base material 22 opposite to the first diffusion sheet base material 21, the first prism sheet base material 22, the second prism sheet base material 23, Are aligned with each other by the second mark 25 and overlapped through the adhesive layer. Next, after the adhesive layer is formed on the surface of the second prism sheet base material 23 opposite to the first prism sheet base material 22, the second prism sheet base material 23, the second diffusion sheet base material 24, Are aligned with each other by the second mark 25 and overlapped through the adhesive layer.

  In the third superimposing step to be performed next, as shown in FIG. 9, the light guide plate base material 26 is aligned with the second mark 25 and the third mark 32 to adhere to the second diffusion sheet base material 24. Overlay through layers.

  That is, after an adhesive layer is formed on the surface of the second diffusion sheet base material 24 opposite to the second prism sheet base material 23, the second diffusion sheet base material 24 and the light guide plate base material 26 are overlapped. Then, the second diffusion sheet base material 24 is adjacent to the surface of the light guide plate base material 26. Then, by bonding the second diffusion sheet base material 24 and the light guide plate base material 26, as shown in FIG. 10, the liquid crystal panel base material 10 and the light guide plate base material 26 include a plurality of optical sheet base materials. A stacked body A is formed by stacking through 21, 22, 23, and 24.

  Next, as shown in FIG. 11, the laminate A is divided at the dividing line 60 for each liquid crystal panel 50, so that the liquid crystal panel 50 and the light guide plate 45 have a plurality of optical sheets 41, 42, 43, 44. A plurality of individual laminates formed by stacking through the layers are formed. At this time, the counter substrate 52 and the polarizing plate 54 that cover the terminal portions of the element substrate 51 are divided and removed, so that the terminal portions provided on the element substrate 51 are exposed from the counter substrate 52.

  After that, the first FPC 55 having a light source lamp is installed on the side surface of the light guide plate 45, and the second FPC 46 is connected to the terminal portion of the element substrate 51, so that the plurality of optical sheets 41, 42, 43, 44, the light guide plate 45 and the first The 2FPC 46 is stored in advance in a frame 47 in which a reflection sheet is disposed on the bottom surface. In this manner, the liquid crystal panel base material 10 and the light guide plate base material 26 are laminated for each of the liquid crystal panels 50 by laminating the plurality of optical sheet base materials 21, 22, 23, and 24. A liquid crystal display device S is manufactured.

-Effect of Embodiment 1-
Therefore, according to the first embodiment, in the first superimposing step, the liquid crystal panel base material 10 is aligned and superposed on the first diffusion sheet base material 21 by the first mark 15 and the second mark 25. Therefore, the liquid crystal panel base material 10 can be quickly and accurately superimposed on a desired position of the first diffusion sheet base material 21. Further, in the second superimposing step, the plurality of optical sheet base materials 21, 22, 23, 24 are aligned with each other by the second mark 25 and are superposed. 24 can be quickly and accurately superimposed on each other. In addition, in the third superimposing step, the second diffusion sheet base material 24 is aligned and superposed on the light guide plate base material 26 by the second mark 25 and the third mark 32, so that the second diffusion The light guide plate base material 26 can be quickly and accurately superimposed on a desired position of the sheet base material 24.

  Accordingly, the plurality of optical sheet base materials 21, 22, 23, and 24 can be quickly and accurately superimposed on the liquid crystal panel base material 10 and the light guide plate base material 26, respectively. The time required for accurate overlaying of the plurality of optical sheet base materials 21, 22, 23, 24 on each of the materials 26 can be shortened. As a result, the plurality of optical sheets 41, 42, 43, 44 can be easily and accurately superimposed on the liquid crystal panel 50 and the light guide plate 45, respectively.

  Further, in the second mark forming step, the optical sheet base material 21 is formed by punching out the base materials of the plurality of optical sheet base materials 21, 22, 23, 24 for each of the optical sheet base materials 21, 22, 23, 24. , 22, 23, 24 are formed at the same time as the second mark 25 is formed on each of the optical sheet base materials 21, 22, 23, 24, so that the optical sheet base materials 21, 22, 23, 24 are formed. There is no need to perform the process and the second mark forming process separately. Accordingly, it is possible to prevent an increase in the manufacturing process due to the formation of the second mark 25 on each of the plurality of optical sheet base materials 21, 22, 23, 24.

  In the third mark forming step, the diffraction grating 31 is formed on the light guide plate base material 26 and the third mark 32 is formed at the same time. Therefore, the step of forming the diffraction grating 31 needs to be performed separately from the third mark forming step. There is no. That is, since it is not necessary to perform the third mark forming step separately from the step of forming the diffraction grating 31, it is possible to prevent an increase in manufacturing steps due to the formation of the third mark 32 on the light guide plate base material 26.

<< Embodiment 2 of the Invention >>
In the following embodiments, the same parts as those in FIGS. 1 to 12 are denoted by the same reference numerals, and detailed description thereof is omitted.

  In the first embodiment, the liquid crystal panel base material 10 and the light guide plate base material 26 are separated from each other by laminating the laminated body A formed by laminating the plurality of optical sheet base materials 21, 22, 23, and 24. Although the display device S is manufactured, in the second embodiment, the liquid crystal panel base material 10, the light guide plate base material 26, and the plurality of optical sheet base materials 21, 22, 23, and 24 are respectively divided in advance 1 The liquid crystal display device S is manufactured by superimposing the two liquid crystal panels 50, the light guide plate 45, and the plurality of optical sheets 41, 42, 43, and 44 on each other.

  The manufacturing method of the liquid crystal display device according to the second embodiment includes a liquid crystal panel forming step, a light guide plate forming step, an optical sheet forming step, a first overlapping step, a second overlapping step, and a third overlapping step. Process.

  In the liquid crystal panel forming step, the liquid crystal panel base material 10 is formed in the same manner as in the first embodiment, and then the liquid crystal panel base material 10 is divided into the liquid crystal panels 50 to form the liquid crystal panel 50. This liquid crystal panel forming step includes a first mark forming step of forming the first mark 15 on the liquid crystal panel 50. In the first mark forming step, the pixel electrode is formed on the surface of the glass substrate base material, and at the same time, the first mark 15 that is a metal layer having a predetermined shape is formed at each of the four corners of each liquid crystal panel 50. Thus, first marks 15 are formed at the four corners of the liquid crystal panel 50.

  In the optical sheet forming step, a plurality of first diffusion sheet base material 21, first prism sheet base material 22, second prism sheet base material 23, and second diffusion sheet base material 24 are provided as in the first embodiment. After the optical sheet base material is formed, the first diffusion sheet 41, the first prism sheet 42, the second prism sheet 43, and the second diffusion sheet are divided by dividing the optical sheet base materials 21, 22, 23, and 24, respectively. 44 optical sheets are formed.

  This optical sheet forming step includes a second mark forming step of forming the second mark 25 on each of the plurality of optical sheets 41, 42, 43, 44. In the second mark forming step, each optical sheet base material 21, 22, 23, 24 is formed by punching each base material of the plurality of optical sheet base materials 21, 22, 23, 24 with a mold, The optical sheets 41, 42, 43, and 44 are partially punched into a predetermined shape by the above molds to form the optical sheets 41, 42, 43, and 44. Second marks 25 are formed respectively.

  In the light guide plate forming step, the light guide plate base material 26 is formed in the same manner as in the first embodiment, and then the light guide plate base material 26 is divided into light guide plates 45 to form the light guide plate 45. This light guide plate forming step includes a third mark forming step of forming the third mark 32 on the light guide plate 45. In the third mark forming step, the diffraction grating 31 is formed by pressing the mold 27 against the resin member 26b, and at the same time, the third marks 32 that are concave portions of a predetermined shape are formed at the four corners of each light guide plate 45. That is, the mold 27 of the second embodiment has a plurality of protrusions similar to those of the first embodiment, and convex portions having predetermined shapes at the four corners of the light guide plate 26 on the surface pressed against the resin member 26b. ing.

  In the first superposition process to be performed next, the liquid crystal panel 50 is aligned with the first diffusion sheet 41 by the first mark 15 and the second mark 25, and the adhesive layer is formed on the liquid crystal panel 10 in advance. Overlapping. Then, the first diffusion sheet 41 and the liquid crystal panel 50 are bonded together.

  In the second superposition process to be performed next, the plurality of optical sheets 41, 42, 43, 44 are aligned and superposed with each other by the second mark 25. At this time, in the plurality of optical sheets 41, 42, 43, 44, the first prism sheet 42, the second prism sheet 43, and the second diffusion sheet 44 are sequentially laminated on the first diffusion sheet 41, and the same as in the first embodiment. Further, they are bonded together by being overlapped via an adhesive layer. Thereafter, an adhesive layer is formed on the surface of the second diffusion sheet 44 opposite to the second prism sheet 43.

  In the third superimposing step to be performed next, the second light guide plate 45 is aligned with the second diffusion sheet 44 by the second mark 25 and the third mark 32 and superposed via the adhesive layer, so that the second The diffusion sheet 44 and the light guide plate 45 are bonded together. Thereafter, the first FPC 55 is provided connected to the terminal portion, and the second FPC 46 is installed on the side surface of the light guide plate 45 so that the plurality of optical sheets 41, 42, 43, 44, the light guide plate 45 and the second FPC 46 are provided in advance on the bottom surface. Is stored in the arranged frame 47.

-Effect of Embodiment 2-
Therefore, according to the second embodiment, the liquid crystal panel 50 can be accurately and quickly overlapped at a desired position of the first diffusion sheet 41 by the first overlapping step. Further, the plurality of optical sheets 41, 42, 43, and 44 can be quickly and accurately overlapped with each other by the second overlapping step. In addition, the light guide plate 45 can be quickly and accurately overlapped at a desired position of the second diffusion sheet 44 by the third overlapping step. As a result, the same effect as in the first embodiment can be obtained.

<< Other Embodiments >>
In the first embodiment, the liquid crystal panel base material 10 and the light guide plate base material 26 are separated from each other by laminating the laminated body A formed by laminating the plurality of optical sheet base materials 21, 22, 23, and 24. Although the display device S is manufactured, the present invention is not limited to this, and a laminated body configured by laminating the liquid crystal panel base material 10 and the light guide plate base material 26 via one optical sheet base material, The liquid crystal display device S may be manufactured by being divided for each liquid crystal panel 50, and a first mark forming step for forming the first mark 15 on the liquid crystal panel base material 10 and a second mark on the optical sheet base material. In contrast to the second mark forming step for forming 25, the third mark forming step for forming the third mark 32 on the light guide plate base material 26, and the first mark 15 for the liquid crystal panel base material 10 relative to the optical sheet base material. And alignment by the second mark 25 A second superimposing step of superimposing and a second superimposing step of aligning and superimposing the light guide plate base material 26 with the second mark 25 and the third mark 32 with respect to the optical sheet base material may be included. .

  Also by this method of manufacturing the liquid crystal display device S, the optical sheet base material can be quickly and accurately superimposed on each of the liquid crystal panel base material 10 and the light guide plate base material 26, and thus the same effects as those of the first embodiment are obtained. be able to.

  In the second embodiment, the liquid crystal panel 50 and the light guide plate 45 are overlapped via the plurality of optical sheets 41, 42, 43, and 44 to manufacture the liquid crystal display device S. However, the present invention is not limited to this, The liquid crystal display device S may be manufactured by superimposing the liquid crystal panel 50 and the light guide plate 45 via a single optical sheet, and a first mark forming step of forming the first mark 15 on the liquid crystal panel 50; A second mark forming step for forming the second mark 25 on the optical sheet; a third mark forming step for forming the third mark 32 on the light guide plate 45; and the liquid crystal panel 50 with respect to the optical sheet. A first superimposing step of aligning and superimposing the light guide plate 15 and the second mark 25, and aligning and superimposing the light guide plate 45 with the second mark 25 and the third mark 32 on the optical sheet. Second superimposing step and may include that.

  Also by this method of manufacturing the liquid crystal display device S, the optical sheet can be quickly and accurately superimposed on each of the liquid crystal panel 50 and the light guide plate 45, so that the same effect as in the first embodiment can be obtained.

  In the first embodiment, the plurality of optical sheet base materials are the two diffusion sheet base materials 21 and 24 and the two prism sheet base materials 22 and 23, and the present invention is not limited to this. The sheet base material may be another optical sheet base material.

  In the first embodiment, the light guide plate base material 26 is superposed on the second diffusion sheet base material 24 after the plurality of optical sheet base materials 21, 22, 23, and 24 are superposed in order on the liquid crystal panel base material 10. The present invention is not limited to this, and after the plurality of optical sheet base materials 24, 23, 22, 21 are sequentially stacked on the light guide plate base material 26, the liquid crystal panel base material 10 is placed on the first diffusion sheet base material 21. The liquid crystal panel base material 10, the first diffusion sheet base material 21, the first prism sheet base material 22, the second prism sheet base material 23, the second diffusion sheet base material 24, and the light guide plate base material 26 may be stacked. Can form the layered product A by overlapping in any order. Also in the second embodiment, the liquid crystal panel 50, the first diffusion sheet 41, the first prism sheet 42, the second prism sheet 43, the second diffusion sheet 44, and the light guide plate 45 can be stacked in any order. .

  In the first embodiment, the light guide plate base material 26 is formed by curing the resin member 27 in a state where the mold 27 is pressed against the resin member 26b applied to the surface of the film substrate base material 26a. However, the light guide plate base material 26 may be formed by a known method such as injection molding.

  In the first embodiment, the second mark 25 is formed simultaneously with the formation of the optical sheet base materials 21, 22, 23, and 24 in the second mark forming step. In the third mark forming step, the third mark 32 is formed simultaneously with the formation of the diffraction grating 31 of the light guide plate base material 26. However, the present invention is not limited to this, and the second mark forming step is performed for each optical sheet. The step of forming the base materials 21, 22, 23, and 24 may be performed separately, and the third mark formation step may be performed separately from the formation of the diffraction grating 31 of the light guide plate base material 26.

  In the first embodiment, the first mark forming step is included in the liquid crystal panel base material forming step, and the first mark 15 is formed simultaneously with the formation of the pixel electrode on one glass substrate base material. The first mark 15 may be formed simultaneously with the formation of the color filter of the other glass substrate base material, and the first mark forming step may be performed separately from the liquid crystal panel base material forming step.

  In the first embodiment, the light guide plate 45 is a wedge-shaped light guide plate. However, the present invention is not limited to this, and another light guide plate such as a mat light guide plate or a lens light guide plate is applied to the light guide plate 45. It is possible.

  As described above, the present invention is useful for a method of manufacturing a liquid crystal display device, and is particularly suitable when at least one optical sheet is accurately superimposed on each of a liquid crystal panel and a light guide plate.

It is a front view which shows a liquid crystal panel base material typically. It is a figure which shows typically the base material of the 1st diffusion sheet base material. It is a figure which shows a 1st diffusion sheet base material typically. It is sectional drawing which shows the film substrate base material of the state by which the resin member was apply | coated to one surface. It is sectional drawing which shows the film substrate base material of the state by which the metal mold | die was pressed on the resin member apply | coated to one surface. It is a front view which shows a light-guide plate base material roughly. It is a figure which shows schematically the VII-VII line cross section of FIG. It is a perspective view which shows typically the liquid crystal panel base material of the state in which a some optical sheet base material is laminated | stacked. It is a perspective view which shows typically the 2nd diffusion sheet base material of the state on which a light-guide plate base material is piled up. It is sectional drawing which shows schematically the laminated body comprised by laminating | stacking a liquid crystal panel base material and a light-guide plate base material through the some optical sheet base material. It is a front view which shows roughly the laminated body parted for every liquid crystal panel. It is sectional drawing which shows the structure of a liquid crystal display device roughly.

Explanation of symbols

S liquid crystal display device A laminate 10 liquid crystal panel base material 15 first mark 20 base material 21 first diffusion sheet base material (first optical sheet base material)
22 First prism sheet base material 23 Second prism sheet base material 24 Second diffusion sheet base material (second optical sheet base material)
25 Second mark 26 Light guide plate base material 26a Film substrate base material 26b Resin member 27 Mold 31 Diffraction grating 32 Third mark 40 Backlight unit 41 First diffusion sheet (first optical sheet)
42 First prism sheet 43 Second prism sheet 44 Second diffusion sheet (second optical sheet)
45 Light guide plate 50 LCD panel

Claims (10)

A liquid crystal panel base material including a plurality of liquid crystal panels arranged in a matrix and a light guide plate base material are stacked via a plurality of optical sheet base materials including a first optical sheet base material and a second optical sheet base material. The laminated body in which the first optical sheet base material is adjacent to the surface of the liquid crystal panel base material and the second optical sheet base material is adjacent to the surface of the light guide plate base material is divided for each liquid crystal panel. A method of manufacturing a liquid crystal display device,
A first mark forming step of forming a first mark on the liquid crystal panel base material;
A second mark forming step of forming a second mark on each of the plurality of optical sheet base materials;
A third mark forming step of forming a third mark on the light guide plate base material;
A first superimposing step of aligning and superimposing the liquid crystal panel base material on the first optical sheet base material by the first mark and the second mark;
A second superimposing step of aligning and superimposing the plurality of optical sheet base materials with the second mark,
A liquid crystal display device comprising: a third superposition step of aligning and superimposing the light guide plate base material on the second optical sheet base material by the second mark and the third mark. Manufacturing method. A liquid crystal panel base material including a plurality of liquid crystal panels arranged in a matrix and a light guide plate base material are laminated via an optical sheet base material, and a liquid crystal is obtained by dividing the liquid crystal panel into each liquid crystal panel. A method for manufacturing a display device, comprising:
A first mark forming step of forming a first mark on the liquid crystal panel base material;
A second mark forming step of forming a second mark on the optical sheet base material;
A third mark forming step of forming a third mark on the light guide plate base material;
A first superposition step of aligning and superimposing the liquid crystal panel base material on the optical sheet base material by the first mark and the second mark;
2. A liquid crystal display device manufacturing method comprising: a second superposition step of aligning and superimposing the light guide plate base material on the optical sheet base material by the second mark and the third mark. Method. In claim 1,
In the second mark forming step, the optical sheet base material is formed at the same time as the optical sheet base material by punching out a base material including at least one optical sheet base material for each of the optical sheet base materials. A method of manufacturing a liquid crystal display device, wherein the second mark is formed. In claim 1,
In the third mark forming step, the third mark is formed at the same time as forming a diffraction grating on the light guide plate base material. In claim 4,
In the third mark forming step, the resin member is cured in a state where a mold is pressed against an uncured resin member applied to the film substrate base material, whereby the first mark is formed on one surface of the film substrate base material. 3. A method of manufacturing a liquid crystal display device, wherein the mark 3 and the diffraction grating are formed. In claim 5,
The method for producing a liquid crystal display device, wherein the film substrate base material is formed of acrylic carbonate or cycloolefin. In claim 1,
The method for manufacturing a liquid crystal display device, wherein the plurality of optical sheet base materials are two diffusion sheet base materials and two prism sheet base materials. A liquid crystal panel and a light guide plate are formed by laminating a plurality of optical sheets including a first optical sheet and a second optical sheet, the first optical sheet is adjacent to the surface of the liquid crystal panel, and the second optical sheet is formed. A method of manufacturing a liquid crystal display device in which a sheet is adjacent to the surface of the light guide plate,
A first mark forming step of forming a first mark on the liquid crystal panel;
A second mark forming step of forming a second mark on each of the plurality of optical sheets;
A third mark forming step of forming a third mark on the light guide plate;
A first superposition step of aligning and superimposing the liquid crystal panel on the first optical sheet with the first mark and the second mark;
A second superimposing step of aligning and superimposing the plurality of optical sheets with each other by the second mark;
A method for manufacturing a liquid crystal display device, comprising: a third overlapping step of aligning and overlapping the light guide plate with the second mark and the third mark on the second optical sheet. A method of manufacturing a liquid crystal display device in which a liquid crystal panel and a light guide plate are laminated via an optical sheet,
A first mark forming step of forming a first mark on the liquid crystal panel;
A second mark forming step of forming a second mark on the optical sheet;
A third mark forming step of forming a third mark on the light guide plate;
A first superimposing step of aligning and superimposing the liquid crystal panel on the optical sheet with the first mark and the second mark;
A method for manufacturing a liquid crystal display device, comprising: a second overlapping step of aligning and overlapping the light guide plate with the second mark and the third mark on the optical sheet. In claim 8,
The method of manufacturing a liquid crystal display device, wherein the plurality of optical sheets are two diffusion sheets and two prism sheets.

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