JP2009061744A - Manufacturing device for laminated structure product - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing device for a laminated structure product which can easily discover a defective coating film prior to the completion of the laminated structure product, while facilitating the discovery of the defective laminated structured product. <P>SOLUTION: An inspection device 7 for inspecting the state of a coating film in a film laminate is provided in front of a cutting device 10. The inspection device 7, upon detecting a defective coating film, outputs an alarm signal AS indicating that a defective laminated structure product is in production. A marking device 8, when the alarm signal AS is outputted, displays a display indicating the presence of the defective laminated structure product on the film laminate. Then, a cutting machine 9 cuts off the laminated structure product from the film laminate. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to an apparatus for manufacturing a laminated structure product provided with a coating film PF between two substrates.

  A holographic display film, which is a kind of laminated structure product, has a structure in which a layer of a coating film PF of a photopolymerizable material is provided between two substrates. Japanese Patent Application Laid-Open No. 7-84504 (Patent Document 1) and Japanese Patent Application Laid-Open No. 2004-29476 (Patent Document 2) show a technique related to the structure of a laminated structure product such as a hologram display element and the flow prevention of a coating film PF. Has been. And regarding the lamination technique used when manufacturing a laminated structure product, for example, in JP 2007-815A, when a coating film PF is formed on a traveling film and the coating film PF is in a semi-dry state, , An apparatus for attaching the film to a substrate and then cutting the film and the substrate is disclosed.

When actually manufacturing a laminated structure product, first, a coating film material is applied on a film substrate by a coating film forming apparatus to form a coating film. Next, using a drying apparatus, the coating film formed on the surface of the film-like substrate is dried to such an extent that adhesive force remains on the surface portion. And another film-like board | substrate is bonded together on a coating film so that a coating film may be pinched | interposed with a film-form substrate bonding apparatus, and the film laminated body of a multilayer structure is formed. Finally, the film laminate is cut into a predetermined size by a cutting device to make a laminated structure product. When manufacturing a hologram display element, after performing the outflow prevention process for preventing the coating film in a film laminated body from flowing out, it cut | disconnects with a cutting device.
JP-A-7-84504 JP 2004-29476 A

  In the past, defective products were found by inspecting the finished laminated product. For this reason, it takes time to find defective products, and it also takes a lot of time to separate good products from defective products. There was also a problem that the yield of the product was considerably bad. In particular, in the case where the coating film has photosensitivity, such as a hologram display element, the production line must be kept in a light-shielded state until a product is completed. Therefore, the state of the coating film PF cannot be seen during the production of the product, and a laminated structure product having a defect in the coating film is easily produced.

  An object of the present invention is to provide a manufacturing apparatus for a laminated structure product that facilitates the discovery of a defective laminated structure product by making it possible to find defects in the coating film before the laminated structure product is completed. There is.

  Another object of the present invention is to provide an apparatus for manufacturing a laminated structure product that can easily distinguish good products from defective products.

  Another object of the present invention is to provide information on which device in which production line has the cause of the defect in the coating film PF, thereby adjusting the production device causing the defect at an early stage. An object of the present invention is to provide an apparatus for manufacturing a laminated structure product that makes it possible.

  The manufacturing apparatus for a laminated structure product of the present invention includes a coating film forming apparatus, a drying apparatus, a film-like substrate bonding apparatus, an outflow prevention processing apparatus, an inspection apparatus, and a cutting apparatus. The coating film forming apparatus forms a coating film by applying a coating material containing a volatile solvent on the surface of the film-like substrate. Although the structure of the coating film forming apparatus is arbitrary, what can apply | coat so that the film thickness of a coating film may become as uniform as possible is preferable. The film-like substrate is generally a synthetic resin film substrate, but the material is appropriately determined according to the type of the laminated structure product and is arbitrary. A composite film substrate in which a plurality of films are bonded may be used. Furthermore, the film-like substrate may be either light transmissive or light opaque depending on the type of laminated structure product. Incidentally, when the coating film has photosensitivity like a holographic display element, at least one of the two film-like substrates sandwiching the coating film has a light-transmitting property.

  The drying device evaporates the volatile solvent from the coating film formed on the surface of the film-like substrate and dries it to the extent that the adhesive force remains on the surface portion of the coating film. When the undried coating film contains a volatile solvent, if the surface of the coating film dries early, the volatilized volatile solvent may form pores on the coating film surface, resulting in irregularities on the surface. In addition, voids may be formed inside the coating film. Therefore, it is preferable to select a drying apparatus that does not dry the surface of the coating film until it is heated from inside the coating film and all the volatile solvent in the coating film is volatilized. For example, it is possible to heat from the inside of the coating film by irradiating the coating film with infrared rays using an infrared heater having a predetermined wavelength.

  Next, the film-like substrate laminating apparatus bonds another film-like substrate on the coating film so as to sandwich the dried coating film so that the adhesive force remains on the surface. Next, the outflow prevention processing device performs outflow prevention processing for preventing the coating film in the film laminate from flowing out. When a coating film has photosensitivity like a holographic display element, the light which exposes a photopolymerizable material is irradiated from the exposure apparatus around the area | region used as an element. If it does in this way, only the coating-film part which received light will solidify, a dam part will be formed, and it can prevent effectively that the coating film inside it flows out (moves). Moreover, the solidified coating film portion also functions as a joining means for joining two film-like substrates. A coating film is formed on a film-like substrate at intervals, and another film-like substrate is stacked on the coating film, and then the two film-like substrate portions facing each other around the coating film are heat-welded. It is possible to prevent the outflow of the coating film by using them. The outflow prevention processing technique to be used is arbitrary.

  In this invention, the test | inspection apparatus which test | inspects the state (the presence or absence of a defect) of the coating film in a film laminated body is provided in front of a cutting device. The cutting device cuts the film laminate into predetermined dimensions to make a laminated structure product. When the inspection apparatus detects that the coating film is defective, the inspection apparatus outputs an alarm signal indicating that a defective laminated structure product is manufactured. The alarm signal is used for the purpose of distinguishing and excluding defective laminated structure products, the purpose of adjusting the device that causes the defect, and the purpose of notifying the operator of the occurrence of the defect. The configuration of the inspection device is arbitrary, and can be configured using various measuring devices such as an image recognition measuring device using infrared rays and a thickness measuring device that measures the thickness of the film laminate. The inspection apparatus has a function of comprehensively judging the measurement result of the measuring instrument to be used and judging whether or not the coating film has a defect. Such a function can be easily realized by using a computer.

  As the cutting device, it is preferable to use a cutting device having a marking function for displaying an indication that the laminated structure product has a defect before and after the cutting operation or simultaneously with the cutting operation. In this way, it is easy to distinguish between non-defective products and defective products simply by checking whether there is a display indicating that there is a defect in the laminated structure product coming out of the cutting device. It can be carried out. Note that this display determination may be performed using an image recognition device to automatically reject defective products. The marking may be printed, but a cut having a specific shape may be made at the time of cutting, and the cut itself may be used as the marking. Of course, even if the marking function is not provided, the laminated structure product cut after the alarm signal is output may be regarded as a defective product without exception, and may be excluded.

  As in the case of manufacturing a holographic display element, when the work line from the coating film forming device to the cutting device has to be shielded from light, the work situation cannot be confirmed visually. Therefore, in such a case, the inspection device includes information indicating which of the coating film forming device, the drying device, the film-like substrate bonding device, and the outflow prevention processing device is the cause of the defect in the alarm signal. It is preferable that an output function is further provided. If such information is included in the alarm signal, the operator can manually adjust the problematic device based on this information. However, at least one of the coating film forming device, the drying device, the film-like substrate laminating device, and the outflow prevention processing device performs the automatic adjustment necessary to eliminate the occurrence of the defect based on the information included in the warning signal. If the automatic adjustment function is provided, it is possible to stop the occurrence of defects without bothering the operator. Ideally, the coating film forming apparatus, the drying apparatus, the film-like substrate bonding apparatus, and the outflow prevention processing apparatus are all preferably equipped with an automatic adjustment function. However, even with the highest probability, an apparatus that generates an adjustment deviation has an automatic adjustment function.

  When the coating material contains a photopolymerizable material, such as a holographic display element, the spill prevention treatment device applies light to the coating film portion at the cutting position of the film laminate that is cut by at least the cutting device. When configured to include an exposure apparatus that irradiates, the inspection apparatus preferably has a function of inspecting defects in the coating film PF including the exposure result of the exposure apparatus.

  According to the present invention, since an alarm signal indicating the occurrence of a defect is issued from the inspection apparatus, the alarm signal is used to distinguish and exclude defective laminated structure products, or an apparatus that is the cause of the occurrence of a defect Can be adjusted and the operator can be informed of the occurrence of a defect.

  In particular, when a warning signal is output as a cutting device, a device having a marking function that indicates that the laminated structure product has a defect before or after the cutting operation or simultaneously with the cutting operation is used. It is possible to distinguish between non-defective products and defective products simply by looking at whether or not there are indications indicating that there are defects in the laminated product that comes out. .

  Hereinafter, an example of an embodiment of the present invention will be described in detail with reference to the drawings. FIG. 1 is a block diagram showing a configuration of an example of an embodiment in which a manufacturing apparatus for a laminated structure product of the present invention is applied when manufacturing a holographic display element. 2A to 2F are schematic views for explaining a product obtained in the manufacturing process in the manufacturing apparatus of FIG.

  In this manufacturing apparatus, first, a film (hereinafter referred to as a film-like substrate) in which a protective layer made of an acrylic UV-based cured resin having a thickness of 4 μm is formed on both sides of a transparent polycarbonate film having a thickness of about 100 μm is wound in a roll shape. The film-like substrate FS1 is pulled out from the film roll 1 and supplied to the coating film forming apparatus 2. The coating film forming apparatus 2 forms a coating film PF by applying a hologram recording material (hereinafter referred to as a coating film material) containing a photopolymerizable material and a volatile solvent on the surface of the film-like substrate FS1. The hologram recording material is a photopolymerizable compound (acrylic or styrene monomer), a photopolymerization initiator, a sensitizing dye that activates the photopolymerization initiator, and a volatile solvent.

  Although the structure of the coating film forming apparatus 2 is arbitrary, what can apply | coat a coating material so that the film thickness of the coating film PF may become as uniform as possible is preferable. In the present embodiment, the coating film forming apparatus 2 applies the hologram recording material (coating material) on the film substrate FS1 so that the thickness of the coating film PF is about 75 μm. FIG. 2A schematically shows a state in which an undried coating film PF is formed on the film-like substrate FS1.

  Next, the drying device 3 evaporates the volatile solvent from the coating film PF formed on the surface of the film-like substrate FS1 and dries it to the extent that the adhesive force remains on the surface portion of the coating film PF. As in the present embodiment, when the coating film PF in an undried state contains a volatile solvent, if the surface of the coating film PF is dried at an early stage, the volatilized volatile solvent is formed in the surface of the coating film PF. May form irregularities on the surface. In such a case, a void may be formed inside the coating film PF. Therefore, it is preferable to select a drying device for coating so that the surface portion of the coating film PF is not dried until all the volatile solvents in the coating film PF are volatilized by heating from the inside of the coating film PF. Therefore, in the present embodiment, a drying apparatus including a front-side infrared irradiation device on the front side of the film-like substrate FS1 passing through the furnace and a rear-side infrared irradiation device on the back side of the film-like substrate FS1 is used. . The wavelength of the infrared rays applied to the coating film from the surface side infrared irradiation device does not polymerize the photopolymerizable material in the coating film, and the volatile solvent is volatilized from the coating film by heating the coating film from the inside of the coating film. The wavelength can be determined. In this Embodiment, the wavelength of the infrared rays irradiated to a coating film from the surface side infrared irradiation apparatus is 2 micrometers-20 micrometers. In addition, the wavelength of infrared rays irradiated from the back side infrared irradiation device to the back surface of the film-like substrate does not polymerize the photopolymerization material, and most of the heat input to the photopolymerizable coating film by the surface side infrared irradiation device is The wavelength at which the film-like substrate is heated to a temperature that contributes to the drying of the coating film is determined. In this Embodiment, the wavelength of the infrared rays irradiated to the back surface of the film substrate from the back side infrared irradiation device is set to 2 μm to 20 μm. As a result of using such a drying apparatus 3, in the present embodiment, the thickness of the undried coating film PF can be reduced to about 35 μm to about 35 μm. Moreover, adhesive force remained on the surface of the dried coating film PF ′. FIG. 2B schematically shows the state of the coating film PF ′ whose thickness is reduced by drying.

  Next, the film-like substrate bonding apparatus 4 bonds another film-like substrate FS2 on the coating film PF ′ so as to sandwich the coating film PF ′ dried to such an extent that the adhesive force remains on the surface. Another film-like substrate FS2 is made of the same material as the above-described film-like substrate FS1, and is pulled out from the film roll 5 and used in the same manner as the film-like substrate FS1. FIG. 3C schematically shows the structure of a film laminate FL formed by bonding another film substrate FS2 on the film PF ′. The film-like substrate laminating apparatus 4 has a plurality of rollers and guides, and the two film-like substrates FS1 and FS2 are subjected to the next outflow prevention process while being pressed in the thickness direction. It is conveyed to the device 6.

  The outflow prevention processing device 6 performs outflow prevention processing for preventing the coating film PF ′ in the film laminate FL from flowing out. In the holographic display element manufactured in the present embodiment, the coating film PF ′ has photosensitivity. Therefore, in the present embodiment, as shown in FIG. 2D, the photopolymerizability is obtained from the exposure apparatus disposed inside the area R1 surrounding the area R2 used as the holographic display element with respect to the coating film PF ′. Irradiate light to sensitize the material. In this embodiment mode, light having a wavelength in the near ultraviolet light to visible light region is irradiated. Specifically, light such as green LED light, laser light, and high-pressure mercury lamp can be used. In order to expose only a necessary portion, light irradiation is performed using a mask that irradiates only the region R1 on one side surface of the film laminate FL. Since the region R1 has a ring shape, necessary exposure is performed using a plurality of types of masks and a plurality of times of irradiation. As shown in FIG. 2D, in the present embodiment, the coating film PF ′ is formed so as to leave the non-application region R3 on both sides in the width direction of the film-like substrate FS1. This is to prevent the applied coating material from flowing in the lateral direction during conveyance and flowing down from above the film substrate FS1. As shown in FIG. 2D, when the region R1 in the coating film PF ′ is irradiated with light, only the coating film PF that has been exposed to light solidifies to form a weir portion. As a result, it is possible to effectively prevent the coating film in the region R2 from flowing out (moving). In addition, the solidified coating film PF portion (solidified portion in the region R1) thus functions also as a joining means for joining two film-like substrates.

  If the coating film does not contain a photopolymerizable material, the coating film PF ′ is formed on the film-like substrate at intervals, and another film-like substrate is overlaid on the coating film PF ′, and then the coating is performed. If the portions of the two film-like substrates facing each other around the film PF ′ are bonded using a thermal welding technique, the coating film PF ′ can be prevented from flowing out. In the outflow prevention processing device 6, the outflow prevention processing technique to be used may be arbitrarily determined according to the material of the coating film and the material of the film-like substrate.

  The film laminate FL exiting from the outflow prevention processing device 6 enters the inside of the inspection device 7. The inspection device 7 inspects the state (the presence or absence of defects) of the coating film PF ′ in the film laminate FL. When detecting that the coating film PF ′ is defective, the inspection device 7 has a function of outputting an alarm signal AS indicating that a defective laminated structure product is manufactured. In the present embodiment, an alarm signal AS is input to the marking device 8 in the cutting device 10, and an alarm signal AS is sent to the coating film forming device 2, the drying device 3, the film-like substrate bonding device 4, and the outflow prevention device 6. Is entered. When the alarm signal AS is output from the inspection device 7, in this embodiment, the marking device 8 gives a display indicating that the laminated structure product LG is defective to the film laminate FL before cutting [FIG. ) And (F)]. Thereafter, the film laminate FL is cut by the cutting machine 9 to produce a laminated structure product LG.

  In the present embodiment, a laser marking device is used as the Markin device 8. The display mode by the Markin device 8 may be any display mode such as characters, colors, symbols, and the like. For example, in the example of FIG. 2 (E), a strip-like color is displayed along one side of the film-like substrate FS2 as this display. In the example of FIG. 2F, the letter “O” is displayed on the film substrate FS2. It is preferable to use one having a marking function. In this way, it is possible to distinguish between non-defective products and defective products simply by checking whether or not there is a display indicating that there is a defect in the laminated structure product LG coming out of the cutting device 10. It can be done easily.

  The configuration of the inspection device 7 is arbitrary. For example, various measuring devices such as an image recognition measuring device using infrared rays and a thickness measuring device for measuring the thickness of the film laminate FL can be used. The inspection device 7 comprehensively determines the measurement result of the measuring instrument to be used, and determines whether or not the coating film PF ′ is defective. The defect of the coating film means that the coating film in the region R2 has a recess or a cavity, the coating film in the region R2 has a photopolymerized part for some reason, or the coating film in the region R1. Is not solidified, or the amount of the coating film is small or too large (the thickness of the region is too thin or too thick).

  When the inspection device 7 outputs an alarm signal, in principle, the device (1 to 6) causing the defect is adjusted again without stopping the production. When manufacturing a holographic display element, the work line from the coating film forming apparatus 2 to the cutting apparatus 10 must be shielded from light. Therefore, the work situation cannot be confirmed visually. Therefore, in the present embodiment, the inspection device 7 uses the information IS indicating which of the coating film forming device 2, the drying device 3, the film-like substrate bonding device 4 and the outflow prevention processing device 6 is the cause of the defect. The alarm signal AS is included and output. It is possible to know in advance the relationship between the output of the measuring instrument in the inspection apparatus 7 and the cause of the defect by conducting tests and simulations in advance for the manufacture of the product. If such a relationship is known in advance, the cause of the defect can be identified and information for removing the cause can be easily identified based on the output of the measuring instrument in the inspection apparatus 7. it can. Therefore, in the present embodiment, the information IS relating to the cause of the defect is included in the alarm signal AS and output using the computer used in the inspection apparatus 7.

  In order to remove the cause of the defect in each equipment of the coating film forming device 2, the drying device 3, the film-like substrate laminating device 4 and the outflow prevention processing device 6 based on the information IS provided from the inspection device 7. In addition, an automatic adjustment function for performing automatic adjustment necessary for eliminating the occurrence of defects is provided. For example, the coating film forming apparatus 2 has a function of automatically adjusting the thickness of the coating film based on the information IS. The drying device 3 has a function of automatically adjusting the output of the infrared irradiation device based on the information IS. Further, the film-like substrate laminating device 4 has a function of automatically adjusting the tension of the film-like substrate FS2 based on the information IS and automatically adjusting the pressure applied by the transport roller. Furthermore, the outflow prevention processing device 6 has a function of automatically adjusting the output of the exposure device based on the information IS. Even if each facility does not have an automatic adjustment function, it is provided from the information display device if an information display device (lamp, display screen) for displaying the information IS provided from the inspection device 7 is provided in each facility. Based on the information, the operator can adjust each facility manually. As in the present embodiment, it is preferable that all of the coating film forming apparatus 2, the drying apparatus 3, the film-like substrate bonding apparatus 4 and the outflow prevention processing apparatus 6 have an automatic adjustment function. However, even with the highest probability, an apparatus that generates an adjustment deviation has an automatic adjustment function. Therefore, at least one of the coating film forming apparatus 2, the drying apparatus 3, the film-like substrate bonding apparatus 4, and the outflow prevention processing apparatus 6 eliminates the occurrence of defects based on the information IS included in the warning signal AS. If an automatic adjustment function for carrying out the automatic adjustment necessary for the operation is provided, the rate of trouble for the operator's hand is greatly reduced.

  In the present embodiment, marking is performed by the marking device 8 before the cutting work by the cutting machine 9. However, it is needless to say that marking may be performed by a marking device after cutting with the cutting machine 9. The marking may be printed, but a cut having a specific shape may be made at the time of cutting by the cutting machine 9, and the cut itself may be used as the marking. In that case, the cutting machine 9 has the function of a marking device.

  When the inspection device 7 detects a coating film defect and outputs an alarm signal AS, the laminated structure product LG that is cut after the alarm signal AS is output is regarded as a defective product without exception. Thus, a sorting device which is excluded may be installed after the cutting device. There are many products that can be sold as low-precision products even if the coating film has some defects. Therefore, even if it is judged as a defective product or a defective product, there are products that can be used satisfactorily depending on the application, and thus marking on the product is sufficiently meaningful.

  2E and 2F extend in the width direction of the film laminate FL in the solidified region R1 by light irradiation by an exposure device provided in the outflow prevention processing device. A film using a cutting blade die that can be divided into two along the dividing line PL and that can cut along two sides of the region R1 extending in the longitudinal direction of the film laminate FL and facing in the width direction. The laminate FL is manufactured by cutting into a predetermined dimension. The shape of the laminated structure product LG is arbitrary, and various cutting machines can be used as the cutting machine. For example, a laser cutting machine may be used as a cutting machine.

  In the above embodiment, the present invention is applied when manufacturing a holographic display element, but the manufacturing apparatus of the present invention can also be applied when manufacturing other laminated structure products. is there.

It is a block diagram which shows the structure of an example of embodiment which applied the manufacturing apparatus of the laminated structure product of this invention when manufacturing a holographic display element. (A) thru | or (F) is the schematic for demonstrating the product obtained in the manufacture process in the manufacturing apparatus of FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Film roll 2 Coating-film formation apparatus 3 Drying apparatus 4 Film-like board | substrate bonding apparatus 5 Film roll 6 Outflow prevention processing apparatus 7 Inspection apparatus 8 Marking apparatus 9 Cutting machine 10 Cutting apparatus

Claims (7)

A coating film forming apparatus for forming a coating film by applying a coating material containing a volatile solvent on the surface of the film substrate; and
A drying device that volatilizes the volatile solvent from the coating film formed on the surface of the film-like substrate and dries to the extent that the adhesive force remains on the surface portion of the coating film;
A film-like substrate laminating device for laminating another film-like substrate on the paint film so as to sandwich the dried paint film, and forming a multilayered film laminate;
An outflow prevention treatment apparatus for performing treatment for preventing the coating film in the film laminate from flowing out;
An inspection device for inspecting the state of the coating film in the film laminate;
The film laminate is configured to include a cutting device that cuts the film into predetermined dimensions to make a laminated structure product,
When the inspection device detects that the coating film is defective, the inspection device outputs an alarm signal indicating that a defective laminated structure product is manufactured.   When the warning signal is output, the cutting device has a marking function for attaching a display indicating that the laminated product is defective before or after the cutting operation or simultaneously with the cutting operation. The manufacturing apparatus of the laminated structure product according to claim 1. The work line from the coating film forming device to the cutting device is configured so that the work status cannot be confirmed visually,
The inspection apparatus includes the alarm signal including information indicating which of the coating film forming apparatus, the drying apparatus, the film-like substrate bonding apparatus, and the outflow prevention processing apparatus is the cause of the defect. The apparatus for manufacturing a laminated structure product according to claim 2, further comprising a function of:   At least one of the coating film forming apparatus, the drying apparatus, the film-like substrate laminating apparatus, and the outflow prevention processing apparatus is for eliminating the occurrence of the defect based on the information included in the warning signal. The apparatus for manufacturing a laminated structure product according to claim 3, further comprising an automatic adjustment function for performing automatic adjustment necessary for the manufacturing process. The coating material includes a photopolymerizable material,
The outflow prevention processing device is configured to include an exposure device that irradiates light to the coating film portion at the cutting position of the film laminate that is cut by at least the cutting device,
The manufacturing apparatus for a laminated structure product according to claim 1, wherein the inspection apparatus inspects defects of the coating film including an exposure result by the exposure apparatus. A film for producing a film laminate in which a photosensitive layer made of a photopolymerizable material is sandwiched between two long film-like substrates, and at least one of the two film-like substrates is transparent An apparatus for manufacturing a laminated structure product, comprising: a laminated body production line; and a cutting device that cuts the film laminate to a predetermined length to produce a laminated structure product,
An inspection device for inspecting the photosensitive layer for defects is provided between the cutting device and the laminate production line,
The laminate production line has a light shielding structure so that light is not applied to the photosensitive layer from the outside,
The inspection apparatus is configured to generate a warning signal when the defect is detected.   The cutting device is configured to include a marking unit that performs a display operation to display that the laminated structure product having the defect has the defect before the cutting operation when the warning signal is received. The manufacturing apparatus of the laminated structure product according to claim 6, wherein

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