JP2009186987A - Optical display unit manufacturing method and optical display unit manufacturing system - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an optical display unit manufacturing method and an optical display unit manufacturing system for performing bonding while maintaining cleanliness, in bonding an optical member onto a substrate. <P>SOLUTION: In the optical display unit manufacturing method and the optical display unit manufacturing system to manufacture the optical display unit by bonding the optical member which includes a polarizer, onto the substrate with an adhesive, the optical display unit manufacturing system is characterized in that the surface of the substrate W is brought into the upright state and the optical member is bonded onto at least one surface thereof. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to an optical display unit manufacturing method for manufacturing an optical display unit by bonding an optical member having a polarizer to a substrate via an adhesive, and a manufacturing system thereof.

  FIG. 14 conceptually shows a method for manufacturing an optical display unit mounted on a conventional liquid crystal display device. First, an optical member manufacturer manufactures a long sheet-shaped product having an optical member as a raw roll (# 1). Examples of the “long sheet-like product” include a polarizing plate original used for a liquid crystal display device, a laminated film original made of a polarizing plate and a retardation plate, and the like. Next, the roll material is slit into a predetermined size (a size according to the size of the substrate) (# 2). Next, the slit raw material is cut to a fixed length in accordance with the size of the substrates to be bonded (# 3). Next, an appearance inspection is performed on the sheet product that has been cut into pieces (# 4). Next, the finished product is inspected (# 5). Next, end surfaces of the four end surfaces of the sheet product are processed (# 6). This is performed to prevent the adhesive or the like from protruding from the end face during transportation. Next, in a clean room environment, the single-sheet product is clean-wrapped (# 7). Next, packaging for transportation (transport packaging) (# 8). As described above, a sheet product is manufactured and transported to a panel processing manufacturer.

  The panel processing manufacturer packs and disassembles the sheet product that has been transported (# 11). Next, an appearance inspection is performed in order to inspect for scratches, dirt, etc. that occur during transportation or at the time of unpacking (# 12). The single-sheet product that has been determined to be non-defective in the inspection is conveyed to the next process. Note that this appearance inspection may be omitted. A substrate (for example, a glass substrate in which a liquid crystal cell is sealed) on which a single sheet product is bonded is manufactured in advance, and the substrate is cleaned before the bonding step (# 13).

  A single sheet product and a substrate are bonded together to form an optical display unit (# 14). The release film is peeled off from the sheet product leaving the adhesive, and the adhesive is bonded to one surface of the substrate as a bonding surface. Further, it can be similarly bonded to the other surface of the substrate. Next, the bonded state inspection and defect inspection are performed (# 15). The optical display unit determined to be non-defective in this inspection is transported to the mounting process and mounted on the liquid crystal display device (# 16). On the other hand, the optical display unit determined to be defective is subjected to a rework process (# 17). The optical member is peeled from the substrate by the rework process. An optical member is newly bonded to the reworked substrate (# 14).

  In the above manufacturing process, end face processing, packaging of single sheet products, packaging disassembly, etc. are necessary because the optical film manufacturer and the panel processing manufacturer exist in different places. . However, there are problems in increasing manufacturing costs due to multiple processes, problems such as scratches, dust, and dirt caused by multiple processes and transportation, the necessity of inspection processes associated therewith, and storage of other types of single-sheet products as stock.・ There is a problem that it must be managed.

  As a method for solving this problem, the present applicant has created an invention described in Japanese Patent Application Laid-Open No. 2007-140046 (Patent Document 1). According to this invention, the sheet product is pulled out from the roll on which the sheet product having the optical member is wound, and a defect of the sheet product is detected. Based on the detection result, the sheet product is cut and processed into a sheet product. Next, after the release film is peeled off, the sheet product is bonded to the liquid crystal cell substrate. Since the above processes are arranged on a continuous production line, in the past, sheet products were punched, the punched sheet products were strictly packed, and delivered to the panel processing manufacturer. The wrapped sheet product can be directly packed and delivered. On the other hand, as disclosed in Japanese Patent Application Laid-Open No. 2005-37416 (Patent Document 2), the release film is left out of the sheet product, and other members (for example, polarizing plates) are cut. There has been proposed a continuous manufacturing method in which continuity is maintained and a sheet product is bonded to a substrate via an adhesive while peeling the release film.

Japanese Patent Laid-Open No. 2007-140046 JP 2005-37416 A

  However, in the case of Patent Documents 1 and 2, the environment when the sheet-like product (for example, a laminated structure of a surface protective film, a pressure-sensitive adhesive layer, a polarizing plate, a pressure-sensitive adhesive layer, and a release film) is bonded to the substrate is mixed with foreign matter. In order to keep clean from the viewpoint of prevention, it is necessary to keep the entire installation site of the manufacturing system clean. That is, it is necessary to install the entire manufacturing system in a so-called clean room (for example, class 10,000 or less). In addition, due to recent demands for improving the image display quality of optical display devices, it is necessary to make the clean environment of a clean room, for example, class 1000 or lower. However, when the entire manufacturing system is installed in a clean room, the construction cost and running cost of the clean room are high, and the workability in the clean room may be poor, so improvement is desired.

  The present invention has been made in view of the above circumstances, and an object of the present invention is to provide an optical display unit manufacturing method and an optical device capable of performing bonding while maintaining cleanliness when bonding an optical member to a substrate. It is to provide a display unit manufacturing system.

  As a result of intensive studies in order to solve the above problems, the present invention has been completed.

The method for producing an optical display unit of the present invention is a method for producing an optical display unit for producing an optical display unit by bonding an optical member having a polarizer to a substrate via an adhesive,
The surface of the substrate is in a vertical state, and an optical member is bonded to at least one surface.

  According to this configuration, since the bonding surfaces of the substrate and the optical member are in the vertical state, no falling foreign matter adheres to the bonding surface, so that no foreign matter is mixed in the bonding process. For example, when the substrate and the optical member are laid down in a plan view, it is considered that the bonded surface becomes the upper surface and foreign matter is mixed due to dropping. However, according to the configuration of the present invention, there is no concern. Also, the bonding device and the conveyance process are isolated from the outside, and the substrate and optical members are laid down in plan view in a bonding environment where clean air is applied to maintain high cleanliness. In such a state, the air flow of clean air is blocked, and air stays, which is not preferable. However, according to the configuration of the present invention, since the flow of clean air is not blocked by the optical member or the like, it can be rectified, and no air stays. Therefore, since the cleanliness of the bonding surfaces of the substrate and the optical member is maintained, contamination of foreign matters on the bonding surfaces can be suitably suppressed, and the optical display unit can be manufactured with high quality.

The optical display unit manufacturing system of the present invention includes:
An optical display unit manufacturing system for manufacturing an optical display unit by bonding an optical member having a polarizer to a substrate via an adhesive,
An isolation structure that at least isolates the bonding process of the substrate and the optical member;
A blower that generates an air current acting on the optical member and the substrate;
A first laminating device that causes the surface of the substrate to be in a vertical state while causing the airflow to act on the optical member and the substrate, and bonds the first optical member to at least one surface;
It is the structure which has.

  According to this configuration, in the optical display unit manufacturing system, at least the bonding process of the substrate and the optical member is performed in the isolation structure in order to maintain cleanliness. More preferably, the entire manufacturing system is isolated within an isolation structure. The isolation structure is not particularly limited, but a transparent plastic panel is preferable so that it can be seen from the outside. In addition, from the viewpoints of maintenance of each part of the apparatus, installation of the roll raw material, conveyance entrance / exit of the optical display unit, workability, and the like, an opening portion that can be opened and closed and a conveyance passage portion are provided at appropriate positions.

  The blower is preferably installed on the ceiling surface side of the isolation structure, and has a structure in which an airflow hole is provided on the floor side or the lower wall surface of the isolation structure through a filter so that the airflow passes from the floor side or the lower part of the isolation structure wall. . Furthermore, the structure which the airflow ventilated from the air blower circulates through a predetermined | prescribed pipe from an airflow hole can also be made. A well-known device can be applied as the blower device as long as it generates a clean airflow. As the blower, for example, a device in which a HEPA filter is incorporated can be suitably applied. With the isolation structure and the blower, the manufacturing system can be kept clean, the entire manufacturing site does not have to be a clean room structure, and the cost advantage is great.

  The 1st bonding apparatus is installed in the isolation | separation structure, the air current by the air blower is acting on the optical member and the board | substrate, and can keep both clean. In particular, the present invention has a configuration in which the surface of the substrate is in a vertical state and the first optical film is also in a vertical state, and each is bonded to each other. There is no contamination of falling foreign matter on the optical member side. In addition, since there is nothing to block the flow of clean air, airflow acts on the substrate and the optical member, foreign matter does not accumulate, and the cleanliness of the bonding processing environment is maintained high.

In the present invention, a cutting device for cutting the first optical member and the first pressure-sensitive adhesive layer, leaving a release film formed on the first optical member via the first pressure-sensitive adhesive layer,
Before the treatment by the first laminating device, a peeling device for peeling the release film,
It further has these.

  According to this structure, the 1st optical member and the 1st adhesive layer are cut | disconnected, leaving the release film formed in the 1st optical member through the 1st adhesive layer, By the 1st bonding apparatus Prior to the bonding process, the release film is peeled from the optical member. That is, since the bonding surface of the optical member is not exposed until just before the bonding, no foreign matter is mixed into the bonding surface of the optical film. Moreover, the cutting method by the cutting device may be a state in which the first optical member is laid down in a plan view or may be in a vertical state.

Moreover, in the said invention, before the cutting process by the said cutting device, The peeling apparatus which peels the release film formed in the said 1st optical member through the 1st adhesive layer,
An inspection device for inspecting defects of the first optical member after the release film is peeled;
It further has a release film laminating device for laminating a release film to the first optical member via a first pressure-sensitive adhesive layer after the defect inspection.

  According to this configuration, it is possible to perform a defect inspection of the optical member by removing the release film. Therefore, it is not necessary to consider the phase difference inherent in the release film and the defects such as foreign matter and scratches attached to or existing in the release film, and the defect inspection of the optical member can be performed. The method of defect inspection will be described later. Further, the inspection method using the inspection apparatus may be a state in which the first optical member is laid down in a plan view, or may be in a vertical state.

  In this defect inspection, when a defect is detected and a defective product is determined, it is cut into a predetermined size in a cutting process (sometimes referred to as a skip cut) so as to avoid the portion of the optical member containing the defect. The portion including the defect can be removed or bonded to a member that is not a substrate, and the non-defective optical member that has been cut to a predetermined size can be bonded to the substrate. Thereby, the yield of the optical display unit is greatly improved.

  In the present invention described above, the apparatus further includes a second bonding apparatus that bonds the second optical member to a surface opposite to the one surface where the first optical member of the substrate is bonded. The bonding process here may be configured such that the surface of the substrate is in the vertical state and the second optical member is also in the vertical state, and the two optical members are bonded together in a state in which the substrate is laid in a plan view. May be. When the first optical member and the second optical member are bonded to the substrate in a vertical state, the size in the width direction in the transport direction of the manufacturing system can be reduced, which is preferable.

  According to this configuration, the second optical member can be bonded to the surface where the optical member is not bonded. Before bonding, the substrate is rotated 90 degrees, and a rotation mechanism is provided in the transport mechanism so that the polarizer of the first optical member and the polarizer of the second optical member have a crossed Nicols relationship. In addition, since the substrate surface, which is a bonding surface, faces the ceiling, it is kept clean by the action of airflow. Further, for example, since the bonding surfaces of the substrate and the second optical member are in a vertical state, or the bonding surface of the second optical member faces the floor surface, contamination with foreign matters can be greatly suppressed. Accordingly, an optical display unit in which the first optical member is bonded to one surface of the substrate and the second optical member is bonded to the other surface and the optical members are provided on both surfaces is manufactured by a method that suppresses the mixing of foreign matters as much as possible. Can do. The obtained optical display unit is incorporated into the liquid crystal display device so that the second optical member is on the backlight side of the liquid crystal display device so that the first optical member is on the viewing side of the liquid crystal display device, for example.

In addition, in the bonding of the second optical member, the second optical member and the second pressure-sensitive adhesive layer are formed without cutting the release film formed on the second optical member via the second pressure-sensitive adhesive layer. Cutting device for cutting,
It has further a peeling apparatus which peels the said release film before the process by a said 2nd bonding apparatus, It is characterized by the above-mentioned. The effect of this structure is the same as the above.

Moreover, in the above-mentioned present invention, before the cutting treatment by the cutting device, a peeling device for peeling the release film formed on the second optical member via the second pressure-sensitive adhesive layer;
An inspection device for inspecting defects of the second optical member after the release film is peeled;
It further has a release film laminating device for laminating a release film to the second optical member via a second pressure-sensitive adhesive layer after the defect inspection. The effect of this structure is the same as the above.

  Examples of the substrate of the present invention include a glass substrate of a liquid crystal cell and an organic EL light emitting substrate. Further, it is preferable that the substrate is cleaned in advance before being bonded to the optical member.

Moreover, in the manufacturing method of the optical display unit of the present invention described above,
The method further includes an inspection step of inspecting the bonding state after the optical member is bonded to one side or both sides of the substrate, and each of the steps is performed on a continuous production line. “Inspection of bonding state” includes, for example, inspection for misalignment, twisting, bubble mixing, and the like between the optical member and the substrate.

Moreover, in the manufacturing method of the optical display unit of the present invention described above,
After the optical member is bonded to one side or both sides of the substrate, an inspection process for inspecting a defect after the bonding is further included, and each of the processes is performed on a continuous production line. "Defects" means, for example, surface or internal dirt, scratches, special defects such as dents that bite foreign objects (sometimes called nicks), bubbles, foreign objects, etc. Yes.

(Embodiment 1)
Embodiment 1 of the present invention will be described below. FIG. 1 shows a flowchart of a method for manufacturing the optical display unit of the first embodiment. FIG. 3 shows the configuration and plan layout of the optical display unit manufacturing system in the first embodiment. The manufacturing system of the first embodiment includes first and second pre-inspection peeling devices 13 and 23 and first and second release film sticking devices 15 and 25 in the configuration of the manufacturing system of the second embodiment to be described later. There is no configuration example. Further, as another embodiment of the manufacturing system of the first embodiment, a configuration that does not include the first and second defect inspection apparatuses 14 and 24 can be exemplified. In addition, the planar arrangement of the manufacturing system of Embodiments 1 and 2 is not limited to this.

(Substrate of members constituting the optical display unit)
Examples of the substrate include a glass substrate of a liquid crystal cell, an organic EL light emitter substrate, and the like.

(Optical member)
The optical member has at least a polarizer film. The optical member is exemplified by a structure in which one or more optical films such as a retardation film, a viewing angle compensation film, and a brightness enhancement film are laminated on a polarizer film. A protective polarizer protective film may be laminated on one side or both sides of the polarizer film. Moreover, an adhesive is formed on one surface of the optical member so as to be attached to the substrate, and a release film for protecting the adhesive is provided. Further, a surface protection member is provided on the other surface of the optical member via an adhesive. Hereinafter, the optical member on which the surface protection member and the release film are laminated may be referred to as a sheet product.

(Adhesive)
The polarizing plate and the optical member are provided with an adhesive layer for adhering to other members such as a substrate (for example, a liquid crystal cell). The pressure-sensitive adhesive layer is not particularly limited, but can be formed of an appropriate pressure-sensitive adhesive such as an acrylic type. Low moisture absorption and heat resistance due to prevention of foaming and peeling phenomenon due to moisture absorption, deterioration of optical characteristics due to thermal expansion difference, prevention of liquid crystal cell warpage, and formation of a high-quality and durable image display device. It is preferable that it is an adhesive layer excellent in property. Moreover, it can be set as the adhesion layer etc. which contain microparticles | fine-particles and show light diffusivity. The adhesive layer may be provided on a necessary surface as necessary. For example, when referring to a polarizing plate composed of a polarizer and a polarizer protective film layer, one or both surfaces of the polarizer protective layer as required. An adhesive layer may be provided on the surface.

(Release film)
On the exposed surface of the adhesive layer, a release film is temporarily attached and covered for the purpose of preventing contamination until it is put to practical use. Thereby, it can prevent contacting an adhesion layer in the usual handling state. As a release film, for example, a suitable thin leaf body such as a plastic film, rubber sheet, paper, cloth, nonwoven fabric, net, foamed sheet or metal foil, laminate thereof, if necessary, silicone-based or long-chain alkyl-based, Appropriate ones according to the prior art such as those coated with an appropriate release agent such as fluorine-based or molybdenum sulfide can be used.

(Surface protection member)
A surface protection member is formed on the optical member opposite to the surface provided with the release film, for example, via a weak adhesive. Its main purpose is to prevent scratches and pollution. As the surface protection member, for example, a suitable thin leaf body such as a plastic film, rubber sheet, paper, cloth, nonwoven fabric, net, foamed sheet or metal foil, laminate thereof, if necessary, silicone-based or long-chain alkyl-based, Appropriate ones according to the prior art such as those coated with an appropriate release agent such as fluorine-based or molybdenum sulfide can be used.

(Manufacturing flowchart)
(1) 1st roll original fabric preparation process (FIG. 1, S1). A long first sheet product is prepared as a first roll. The width | variety of a 1st roll original fabric is dependent on the bonding size with a board | substrate. As shown in FIG. 13, the laminated structure of the first sheet product F1 includes a first optical member F11, a first release film F12, and a surface protective film F13. The first optical member F11 includes a first polarizer F11a, a first film F11b having an adhesive layer (not shown) on one side thereof, and a second film having an adhesive layer (not shown) on the other side. F11c.

  The first and second films F11b and F11c are, for example, polarizer protective films (for example, triacetyl cellulose film, PET film, etc.). The second film F11c is bonded to the optical display unit surface side via the first adhesive F14. A surface treatment can be applied to the first film F11b. Examples of the surface treatment include a hard coat treatment, an antireflection treatment, a treatment for the purpose of prevention of sticking, diffusion or antiglare, and the like. The first release film F12 is provided via the second film F11c and the first pressure-sensitive adhesive layer F14. Moreover, the surface protection film F13 is provided through the 1st film F11b and the adhesive layer F15. Specific configurations of the first and second films F11b and F11c will be described later. Hereinafter, a laminated structure of a polarizer and a polarizer protective film may be referred to as a polarizing plate.

  The following steps are performed in an isolation structure isolated from the factory, and the cleanliness is maintained. In particular, it is important that the cleanliness is maintained in the bonding step of bonding the optical film to the optical display unit.

  (2) Transport process (FIG. 1, S2). The first sheet material F1 is fed out from the first roll stock prepared and installed, and is conveyed downstream. The first conveying device 12 that conveys the first sheet product F1 is configured by, for example, a nip roller pair, a tension roller, a rotation driving device, an accumulating device A, a sensor device, a control device, and the like. In particular, in the configuration of the present embodiment, the first and second sheet products F1 and F2 are conveyed in a vertical state as shown in FIG. 5A. When these sheet products are conveyed in a vertical state, they may be slackened downward due to the influence of gravity, so the first and second conveying devices 12 and 22 are configured to convey the sheet products while suppressing the slack. .

  (3) First inspection step (FIG. 1, S3). The first sheet product F1 is inspected for defects using the first defect inspection device 14. In the present embodiment, since the first sheet product F1 is conveyed in a vertical state, the defect inspection is also performed in accordance with the first sheet product F1.

  As a defect inspection method, both sides of the first sheet product F1 are imaged and processed by transmitted light and reflected light, and the inspection polarizing film is an inspection object between the CCD camera and the inspection object. A method of photographing and processing an image by arranging it so that it is in crossed Nicols with the polarization axis of the polarizing plate (sometimes referred to as 0 degree cross), and inspecting the polarizing film for inspection between the CCD camera and the inspection object A method of taking an image and processing the image by arranging (sometimes referred to as an x degree cross) so as to be at a predetermined angle (for example, a range of greater than 0 degrees and within 10 degrees) with the polarization axis of the target polarizing plate. It is done. Note that a known method can be applied to the image processing algorithm, and for example, a defect can be detected by density determination by binarization processing.

  In the image capturing / image processing method using transmitted light, foreign matter inside the first sheet product F1 can be detected. In the image photographing / image processing method using the reflected light, the adhered foreign matter on the surface of the first sheet product F1 can be detected. In the image photographing / image processing method using the 0-degree cross, mainly surface foreign matter, dirt, internal foreign matter, etc. can be detected as bright spots. In the image photographing / image processing method using the x-degree cross, a nick can be mainly detected.

  The defect information obtained by the first defect inspection apparatus 14 is linked together with the position information (for example, position coordinates), transmitted to the control apparatus 1, and contributes to a cutting method by the first cutting apparatus 16 described later. be able to.

  (4) 1st cutting process (FIG. 1, S4). The first cutting device 16 cuts the surface protective film F13, the pressure-sensitive adhesive layer F15, the first optical member F11, and the first pressure-sensitive adhesive layer F14 into a predetermined size while leaving the first release film F12. In the present embodiment, since the first sheet material F1 is conveyed in a vertical state, the cutting process is configured to cut in a state corresponding to the cutting process.

  Examples of the cutting means include a laser device, a cutter, and other known cutting means. Based on the defect information obtained by the first defect inspection apparatus 14, the cutting is performed so as to avoid the defect. Thereby, the yield of the first sheet product F1 is greatly improved. The first sheet product F1 including the defect is excluded by a first rejection device 19 described later, and is configured not to be attached to the substrate W.

  (5) The 1st optical member bonding process (Drawing 1, S5). While removing the first release film F12 using the first peeling device 17, the first optical member F11 from which the first release film F12 has been removed using the first bonding device 18 is used as the first adhesive. It is bonded to the substrate W through the layer F14. At the time of bonding, as will be described later, the first optical member F11 and the substrate W are sandwiched between roll pairs (181, 182) and are bonded together.

    In the present embodiment, since the substrate W and the first sheet product F1 are conveyed in a vertical state, the bonding process is also performed in a vertical state in a state corresponding to the substrate (see the side view of the production line in FIG. 6A). . As a result, no foreign matter is dropped on the bonding surface of the substrate W, and no foreign matter is dropped on the first optical member F11 side of the bonding surface. In addition, since there is nothing that blocks the flow of clean air, an airflow acts on the substrate W and the first optical member F11, and foreign matter does not accumulate, so that the bonding process can be executed in a high cleanliness environment.

  (6) Cleaning step (FIG. 1, S6). As shown in FIG. 3, the surface of the substrate W is cleaned by the polishing cleaning device 10 and the water cleaning device 11. The cleaned substrate W is transported to the first bonding apparatus 18 by the transport mechanism R. The transport mechanism R includes, for example, a transport roller, a transport direction switching mechanism, a rotation drive device, a sensor device, and a control device. In particular, the present embodiment is configured to clean the substrate W in a vertical state and transport it to the bonding position. A specific configuration of the transport mechanism R will be described later. The polishing cleaning device 10 and the water cleaning device 11 will be described later.

  It is preferable that each of these 1st roll original fabric preparation processes, a 1st inspection process, a 1st cutting process, the bonding process of a 1st optical member, and the washing | cleaning process is performed by the continuous manufacturing line. In the series of manufacturing steps described above, the first optical member F11 was bonded to one surface of the substrate W. Below, the manufacturing process which bonds the 2nd optical member F21 on another surface is demonstrated.

  (7) 2nd roll original fabric preparation process (FIG. 1, S11). A long second sheet product F2 is prepared as a second roll material. As shown in FIG. 13, the laminated structure of the second sheet product F2 has the same configuration as that of the first sheet product F1, but is not limited thereto. The second sheet product F2 includes a second optical member F21, a second release film F22, and a surface protection film F23. The second optical member F21 includes a second polarizer 21a, a third film F21b having an adhesive layer (not shown) on one side thereof, and a fourth film having an adhesive layer (not shown) on the other side. F21c.

  The third and fourth films F21b and F21c are, for example, polarizer protective films (for example, triacetylcellulose film, PET film, etc.). The fourth film F21c is bonded to the optical display unit surface side via the second pressure-sensitive adhesive layer F24. The third film F21b can be subjected to a surface treatment. Examples of the surface treatment include a hard coat treatment, an antireflection treatment, a treatment for the purpose of prevention of sticking, diffusion or antiglare, and the like. The second release film F22 is provided via the fourth film F21c and the second pressure-sensitive adhesive layer F24. Moreover, the surface protection film F23 is provided through the 3rd film F21b and the adhesive layer F25. Specific configurations of the third and fourth films F21b and F21c will be described later.

  (8) Transporting process (FIG. 1, S12). The second sheet material F2 is fed out from the prepared and installed second roll, and is conveyed downstream. The second conveying device 22 that conveys the second sheet product includes, for example, a nip roller pair, a tension roller, a rotation driving device, an accumulating device A, a sensor device, a control device, and the like. In the configuration of the present embodiment, the second sheet product F2 is configured to be conveyed in a vertical state.

  (9) Second inspection step (FIG. 1, S13). The second sheet material F2 is inspected for defects using the second defect inspection device 24. The defect inspection method here is the same as the method using the first defect inspection apparatus described above. In the present embodiment, since the second sheet product F2 is conveyed in a vertical state, the defect inspection is also performed in accordance with the second sheet product F2.

  (10) Second cutting step (FIG. 1, S14). The second cutting device 26 cuts the surface protective film F23, the pressure-sensitive adhesive layer F25, the second optical member F21, and the second pressure-sensitive adhesive layer F24 into a predetermined size, leaving the second release film F22. In the present embodiment, since the second sheet product F2 is conveyed in a vertical state, the cutting process is configured to be cut in a state corresponding to that.

  Examples of the cutting means include a laser device, a cutter, and other known cutting means. Based on the information on the defect obtained by the second defect inspection apparatus 24, it is configured to cut so as to avoid the defect. Thereby, the yield of the second sheet product F2 is greatly improved. The second sheet product F2 including the defect is excluded by a second rejection device 29 described later, and is not attached to the substrate W1.

  (11) A bonding step of the second optical member (FIG. 1, S15). Next, after the second cutting step, the second optical film from which the second release film F22 has been removed using the second laminating apparatus 28 while removing the second release film F22 using the second peeling apparatus 27. The member F21 is bonded to a surface different from the surface to which the first optical member F11 of the substrate W1 is bonded via the second pressure-sensitive adhesive layer F24. Before the second optical member F21 is bonded to the substrate W1, the substrate W1 is rotated 90 degrees by the transport direction switching mechanism of the transport mechanism R, and the polarizer of the first optical member F11 and the polarizer of the second optical member F21. In a crossed Nicol relationship. At the time of bonding, as will be described later, the second optical member F21 and the substrate W1 are sandwiched by a roll and are bonded.

  In the present embodiment, since the substrate W1 and the second sheet product F2 are conveyed in a vertical state, the bonding process is configured to be bonded in a vertical state corresponding to the bonding process. As a result, no foreign matter is dropped on the bonding surface of the substrate W1, and no foreign matter is dropped on the second optical member side of the bonding surface. In addition, since there is nothing that blocks the flow of clean air, an air flow acts on the substrate W1 and the second optical member, and foreign matter does not accumulate, so that the bonding process can be executed in a high cleanliness environment.

  (12) Optical display unit inspection process (FIG. 1, S16). The inspection device 30 inspects the optical display unit W12 in which the optical member is attached to both surfaces. Examples of the inspection method include a method of capturing an image and processing an image using reflected light on both surfaces of the optical display unit W12. As another method, a method of installing a polarizing film for inspection between the CCD camera and the inspection object is also exemplified. Note that a known method can be applied to the image processing algorithm, and for example, a defect can be detected by density determination by binarization processing. In this inspection step, the optical display unit W12 may be inspected in a vertical state, or may be inspected in a state where it is laid sideways (see FIG. 11). When the inspection is performed in the state of being laid sideways, the transport mechanism R includes a mechanism that causes the optical display unit W12 to be laid down from the vertical state to the side after the bonding process.

  (13) The non-defective product of the optical display unit W12 is determined based on the defect information obtained by the inspection apparatus 30. The optical display unit W12 determined to be non-defective is conveyed to the next mounting process. If a defective product is determined, a rework process is performed, a new optical film is applied, and then inspected.If a good product is determined, the process proceeds to a mounting process. Discarded.

  In the above series of manufacturing steps, the optical display unit W12 can be suitably manufactured by executing the bonding step of the first optical member F11 and the second optical member F21 bonding step in a continuous production line. . In particular, the above steps are performed inside the isolation structure isolated from the factory, and the optical member can be bonded to the substrate in a high cleanliness environment by performing the bonding process between the substrate and the optical member in a vertical state. And a high quality optical display unit can be manufactured.

(Skip cut method)
Further, another embodiment of the first cutting step and the second cutting step will be described below. This embodiment is particularly effective when the first inspection process and the second inspection process are not provided. At one end in the width direction of the first and second rolls, defect information (defect coordinates, defect type, size, etc.) of the first and second sheet-like products in a predetermined pitch unit (for example, 1000 mm). It may be attached as code information (for example, QR code, barcode). In such a case, the code information is read and analyzed at a stage prior to cutting, and cut into a predetermined size in the first and second cutting steps (sometimes referred to as skip cut) so as to avoid the defective portion. Then, the part including the defect is removed or bonded to a member that is not a substrate, and the non-defective sheet-shaped product cut into a predetermined size is bonded to the substrate. Thereby, the yield of the optical display unit is greatly improved.

  In the above embodiment, the first and second sheet products F1 and F2 (first and second optical members F11 and F12) have been described as being transported in a vertical state, but the present invention is not particularly limited thereto. As another embodiment, the first and second sheet products F1 and F2 are fed out and laid sideways, the inspection process and the cutting process are performed in that state, and immediately before the bonding process, the first and second sheets The 1st, 2nd conveying apparatuses 12 and 22 can be constituted so that sheet products F1 and F2 may be made into a vertical state from the state where they were laid down horizontally.

(Embodiment 2)
Embodiment 2 of the present invention will be described below. FIG. 2 shows a flowchart of the manufacturing method of the optical display unit according to the second embodiment. FIG. 4 shows the configuration and plan layout of the optical display unit manufacturing system according to the second embodiment. A process similar to that of the first embodiment will be briefly described.

  (1) 1st roll original fabric preparation process (FIG. 2, S1). A long first sheet product F1 is prepared as a first roll material. The laminated structure of the first sheet product F1 is the same as that of the first embodiment shown in FIG.

  (2) Transport process (FIG. 2, S2). The first sheet material F1 is fed out from the first roll stock prepared and installed, and is conveyed downstream. The first sheet product F1 is conveyed in a vertical state as shown in FIG. 5A.

  (3) Release film removal process (FIG. 2, S23). The first pre-inspection peeling device 13 peels the release film F12 (H11 in FIG. 5) from the conveyed first sheet product F1. Details of the peeling mechanism will be described later. In the present embodiment, since the first sheet product F1 is conveyed in a vertical state, the release film removing process is also performed in accordance with the first film product F1.

  (4) First defect inspection step (FIG. 2, S24). The first defect inspection apparatus 14 inspects the defect of the first sheet product F1 after the release film removing step. It is not necessary to consider the phase difference inherent in the release film F12, foreign matter attached to the release film F12, etc., and the defect inspection of the first optical member F11 can be performed. The method of defect inspection is as described above. The first sheet product F1 including the defect is excluded by a first rejection device 19 described later, and is configured not to be attached to the substrate W. In the present embodiment, since the first sheet product F1 is conveyed in a vertical state, the defect inspection is also performed in accordance with the first sheet product F1.

  (5) Release film bonding process (FIG. 2, S25). The 1st release film bonding apparatus 15 bonds the release film H12 (refer FIG. 5A, 5B) to the 1st optical member F11 via the 1st adhesive layer F14 after a 1st fault test process. In order to maintain flatness, it is preferable to perform the bonding so that bubbles such as bubbles do not occur. The detail of the 1st release film bonding apparatus 15 is mentioned later. In this embodiment, since the 1st sheet product F1 is conveyed in a vertical state, it is the structure which performs a release film bonding process in the state according to it.

  (6) First cutting step (FIG. 2, S26). Next, after the release film bonding step, the first cutting device 16 leaves the release film H12, and the surface protective film F13, the pressure-sensitive adhesive layer F15, the first optical member F11, and the first pressure-sensitive adhesive layer F14 have a predetermined size. Disconnect. In the present embodiment, since the first sheet material F1 is conveyed in a vertical state, the cutting process is configured to cut in a state corresponding to the cutting process. Examples of the cutting means include a laser device, a cutter, and other known cutting means.

  (7) The 1st optical member bonding process (Drawing 2, S27). Next, after the first cutting step, the first peeling device 17 peels the release film H12. The 1st bonding apparatus 18 bonds the 1st optical member F11 from which the release film H12 was peeled to the board | substrate W through the 1st adhesive layer F14. At the time of bonding, as will be described later, the first optical member F11 and the substrate W are sandwiched between rolls (181, 182) and are bonded by pressure.

  In the present embodiment, since the substrate W and the first sheet product F1 are conveyed in a vertical state, the bonding process is also performed in a vertical state in a state corresponding to the substrate (see the side view of the production line in FIG. 6A). . As a result, no foreign matter is dropped on the bonding surface of the substrate W, and no foreign matter is dropped on the first optical member F11 side of the bonding surface. In addition, since there is nothing that blocks the flow of clean air, an airflow acts on the substrate W and the first optical member F11, and foreign matter does not accumulate, so that the bonding process can be executed in a high cleanliness environment.

  (8) Substrate cleaning process (FIG. 2, S6). The same process as described above.

  (9) 2nd roll original fabric preparation process (FIG. 2, S11). A long second sheet product F2 is prepared as a second roll material. The laminated structure of the second sheet product F2 has the configuration shown in FIG.

  (10) Transporting process (FIG. 2, S12). The second sheet material F2 is fed out from the prepared and installed second roll, and is conveyed downstream. In the configuration of the present embodiment, the second sheet product F2 is configured to be conveyed in a vertical state.

  (11) Release film removing step (FIG. 2, S33). The second pre-inspection peeling device 23 peels the release film F22 (H21 in FIG. 7) from the second sheet product F2 being conveyed. Details of the peeling mechanism will be described later. In the present embodiment, since the second sheet product F2 is conveyed in a vertical state, the release film removing process is also performed in accordance with the second film product F2.

  (12) Second defect inspection step (FIG. 2, S34). The second defect inspection device 24 inspects the defect of the second sheet product F2 after the release film removing step. In the present embodiment, since the second sheet product F2 is conveyed in a vertical state, the defect inspection is also performed in accordance with the second sheet product F2. It is not necessary to consider the phase difference inherent in the release film F22, foreign matter attached to the release film F22, etc., and the defect inspection of the second optical member F21 can be performed. The method of defect inspection is as described above. The second sheet product F2 including the defect is excluded by a second rejection device 29 described later, and is configured not to be attached to the substrate.

  (13) Release film bonding process (FIG. 2, S35). The 2nd release film bonding apparatus 25 bonds the release film H22 (refer FIG. 7) to the 2nd optical member F21 via the 2nd adhesive layer F24 after a 2nd fault test process. In order to maintain flatness, it is preferable to perform the bonding so that bubbles such as bubbles do not occur. The detail of the 2nd release film bonding apparatus 25 is mentioned later. In this embodiment, since the 2nd sheet material F2 is conveyed in a vertical state, it is the structure which performs a release film bonding process in the state according to it.

  (14) Second cutting step (FIG. 2, S36). Next, after the release film bonding step, the second cutting device 26 leaves the release film H22, and the surface protective film F23, the adhesive layer F25, the second optical member F21, and the second adhesive layer F24 have a predetermined size. Disconnect. In the present embodiment, since the second sheet product F2 is conveyed in a vertical state, the cutting process is configured to be cut in a state corresponding to that. Examples of the cutting means include a laser device, a cutter, and other known cutting means.

  (15) A bonding step of the second optical member (FIG. 2, S37). Next, after the second cutting step, the second peeling device 27 peels the release film H22. The 2nd bonding apparatus 28 differs from the surface where the 1st optical member F11 of the board | substrate W1 is bonded through the 2nd adhesive layer F24 for the 2nd optical member F21 from which the release film H22 was peeled. Paste to. Before the second optical member F21 is bonded to the substrate W1, the substrate W1 is rotated 90 degrees so that the polarizer of the first optical member F11 and the polarizer of the second optical member F21 have a crossed Nicols relationship. . At the time of bonding, as will be described later, the second optical member F21 and the substrate W1 are sandwiched by a roll and are bonded. As described above, it is possible to manufacture the optical display unit W12 in which the first optical member F11 is bonded to one surface of the substrate W, the second optical member F21 is bonded to the other surface, and the optical members are provided on both surfaces.

  In the present embodiment, since the substrate W1 and the second sheet product F2 are conveyed in a vertical state, the bonding process is configured to be bonded in a vertical state corresponding to the bonding process. As a result, no foreign matter is dropped on the bonding surface of the substrate W1, and no foreign matter is dropped on the second optical member side of the bonding surface. In addition, since there is nothing that blocks the flow of clean air, an air flow acts on the substrate W1 and the second optical member, and foreign matter does not accumulate, so that the bonding process can be executed in a high cleanliness environment.

  (16) Inspection step of the optical display unit (FIG. 2, S16). This step is the same as described above. In this inspection step, the optical display unit W12 may be inspected in a vertical state, or may be inspected in a state where it is laid sideways (see FIG. 11). When the inspection is performed in the state of being laid sideways, the transport mechanism R includes a mechanism that causes the optical display unit W12 to be laid down from the vertical state to the side after the bonding process.

  (17) The non-defective product of the optical display unit W12 is determined based on the defect information obtained by the inspection apparatus 30. The optical display unit W12 determined to be non-defective is conveyed to the next mounting process. If a defective product is determined, a rework process is performed, a new optical film is applied, and then inspected.If a good product is determined, the process proceeds to a mounting process. Discarded.

  In the above series of manufacturing steps, the optical display unit can be suitably manufactured by executing the bonding step of the first optical member F11 and the second optical member F21 bonding step in a continuous production line. In particular, the above steps are performed inside the isolation structure isolated from the factory, and the optical member can be bonded to the substrate in a high cleanliness environment by performing the bonding process between the substrate and the optical member in a vertical state. And a high quality optical display unit can be manufactured.

(Suitable manufacturing system for realizing the manufacturing method of the first and second embodiments)
Below, an example of the suitable manufacturing system which implement | achieves the manufacturing method of Embodiment 2 is demonstrated. 5A and 5B are views showing the first transport device 12, the first pre-inspection peeling device 13, the first defect inspection device 14, the first release film sticking device 15, and the first cutting device 16. FIG. FIG. 5A is a schematic side view of these production lines viewed from the side, and FIG. 5B is a schematic plan view viewed from the ceiling side in the floor direction.

  6A and 6B are views showing the first peeling device 17, the first sticking device 18, and the first excluding device 19. FIG. FIG. 6A is a schematic side view of these production lines viewed from the side, and FIG. 6B is a schematic plan view viewed from the ceiling side in the floor direction.

  FIG. 7 shows the manufacturing apparatus of the second transport device 22, the second pre-inspection peeling device 23, the second defect inspection device 24, the second release film sticking device 25, and the second cutting device 26 from the ceiling side to the floor surface direction. It is the plane schematic diagram visually recognized. The isolation structure 50 includes a blower (not shown) and an air discharge opening (not shown). FIG. 8 is a schematic plan view of the second peeling device 27, the second sticking device 28, and the second excluding device 29 viewed from the ceiling side in the floor direction. This isolation structure 50 is provided with a blower (not shown) and an airflow discharge hole (not shown).

  9A and 9B are views showing the polishing cleaning apparatus 10. FIG. 9A is a schematic side view of the apparatus viewed from the side, and FIG. 9B is a schematic plan view of the apparatus viewed from the ceiling side in the floor direction. 10A and 10B are views showing the water cleaning device 11. FIG. 10A is a schematic side view of the apparatus viewed from the side, and FIG. 10B is a schematic plan view of the apparatus viewed from the ceiling side in the floor direction. FIG. 11 is a view showing the inspection apparatus 30. FIG. 11 is a schematic side view of the apparatus viewed from the side.

  The various devices described above are isolated from the outside by the isolation structure 50. The inside surrounded by the isolation structure 50 is kept clean compared to the outside. The isolation structure 50 is composed of a transparent material wall and a frame structure. The blower 40 is installed on the ceiling of the isolation structure 50. The blower device 40 includes a HEPA filter and blows air with high cleanness into the partition wall structure 50. An air discharge opening 50a for discharging the internal air to the outside is provided at the bottom of the wall surface of the partition wall structure 50. In addition, a filter can be provided on the opening surface to prevent intruders from the outside. By this partition structure 50 and the air blower 40, the whole manufacturing system can be maintained in a clean environment, and foreign matter mixing from the outside can be suitably prevented. Further, since only the manufacturing system is isolated from the outside by the partition wall structure 50, the entire factory does not need to be a so-called clean room.

  First, the polishing cleaning apparatus 10 shown in FIGS. 9A and 9B will be described. The substrate W is taken out from the storage box and set in the transport mechanism R. The substrate W is set in a vertical state. The transport mechanism R places the substrate W between the lower side and the upper side of both sides of the substrate W and a roller or belt that is placed on the bottom surface of the substrate W and can be rotated in the transport direction of the substrate W, and sends the substrate W in the transport direction. The apparatus includes a rotatable roller, a rotational drive motor that rotates the roller in the transport direction, reversely rotates and stops the transport direction, and a control device that controls the operation of the motor. Further, the transport mechanism R has a linkage mechanism for interlocking with each device. Further, the transport mechanism R has a state changing mechanism that changes the state of the substrate W from vertical to horizontal.

  When the substrate W reaches the cleaning position, the conveyance is stopped, and the end portion of the substrate W is held by holding means (not shown). The polishing means 101 is brought into contact with one surface of the substrate W, and the polishing means 102 is brought into contact with the other surface. The respective polishing means 101 and 102 are rotated on both surfaces of the substrate W. As a result, the adhered foreign matter on both surfaces of the substrate W is removed. Examples of the adhering foreign matter include glass fine pieces, fiber pieces, and the like.

  Next, the water cleaning apparatus 11 shown in FIGS. 10A and 10B will be described. The substrate W that has been polished and cleaned is transferred to the water bath 111 by the transfer mechanism R, where it is cleaned with water. Pure water wt flows inside the water bath 111. Both surfaces of the substrate W transferred from the water bath 111 are cleaned by pure water wt flowing out from the flowing water pipe 112. Next, the substrate W is drained by the blowing of clean air by the drying device 113. Next, the substrate W is transported to the first bonding apparatus 18. As another embodiment, it is possible to perform cleaning using an ethanol aqueous solution instead of pure water wt. In another embodiment, the water bath 111 can be omitted.

  The polishing cleaning device 10 and the water cleaning device 11 can be configured to clean the substrate W while lying down sideways. The transport mechanism R in this case is a mechanism for transporting the substrate W in a state in which it is laid down accordingly, and a mechanism for changing the substrate W from the horizontal state to the vertical state before transporting it to the first bonding apparatus 18. Is provided.

  Next, FIGS. 5A to 8 will be described in order. The first roll of the long first sheet product F1 is installed on a roller gantry that is linked to a motor or the like so as to rotate freely or at a constant rotational speed. The rotation speed is set by the control device 1 and the drive is controlled. The first roll is set in a vertical state as shown in FIG. 5A.

  The first conveying device 12 is a conveying mechanism that conveys the first sheet product F1 to the downstream side. The first transport device 12 is controlled by the control device 1. The 1st conveying apparatus 12 and the 2nd conveying apparatus 22 mentioned later are the structures which convey a sheet | seat product to a vertical state, as shown to FIG. 5A and 6A.

  The first pre-inspection peeling device 13 has a configuration in which the release film H11 is peeled from the conveyed first sheet product F1 and wound on a roll 132. The winding speed around the roll 132 is controlled by the control device 1. The peeling mechanism 131 has a knife edge portion with a sharp tip. The release film H11 is wound around the knife edge portion and reversely transferred, whereby the release film H11 is peeled off and the release film H11 is removed. It is comprised so that the 1st sheet material F1 after peeling may be conveyed in a conveyance direction.

  The first defect inspection device 14 performs defect inspection after the release film H11 is peeled off. The first defect inspection device 14 detects the defect by analyzing the image data captured by the CCD camera, and further calculates its position coordinates. The position coordinates of this defect are provided for the skip cut by the first cutting device 16 described later.

  The 1st release film bonding apparatus 15 bonds the release film H12 to the 1st optical member F11 via the 1st adhesive layer F14 after a 1st fault test | inspection. As shown in FIGS. 5A and 5B, the release film H12 is unwound from the roll 151 of the release film H12, and the release film H12 and the first optical part F11 are sandwiched by one or a plurality of roller pairs 152, Bonding is performed by applying a predetermined pressure with the roller pair 152. The rotation speed, pressure control, and conveyance control of the roller pair 152 are controlled by the control device 1.

  After the release film H12 is bonded to the first cutting device 16, the first optical member F11, the surface protection film 15, the first pressure-sensitive adhesive layer F14, and the pressure-sensitive adhesive layer F15 are predetermined while leaving the release film H12. Cut to size. The first cutting device 16 is, for example, a laser device. Based on the position coordinates of the defect detected in the first defect inspection process, the first cutting device 16 cuts to a predetermined size so as to avoid the defect portion. That is, the cut product including the defective portion is rejected as a defective product by the first rejecting device 19 in a subsequent process. Alternatively, the first cutting device 16 may continuously cut into a predetermined size while ignoring the existence of the defect. In this case, it can be configured such that the portion is removed without being bonded in the bonding process described later. Control in this case also depends on the function of the control device 1.

  Moreover, the 1st cutting device 16 arrange | positions the holding table which adsorbs-holds the release film surface of the 1st sheet product F1, and equips the surface protection film side of the 1st sheet product F1 with the laser apparatus. The first sheet material F1 is moved in parallel so that the laser is scanned in the width direction, and the first optical member F11, the first pressure-sensitive adhesive layer F14, the surface protective film F13, the pressure-sensitive adhesive layer, leaving the lowermost release film H12. F15 is cut at a predetermined pitch in the conveying direction (hereinafter referred to as “half cut” as appropriate). In addition, this laser device collects gas (smoke) generated from the air nozzle that blows warm air toward the cutting site and the cutting site conveyed by the hot air so as to be sandwiched from the width direction of the first sheet product F1. It is preferable that the smoke collecting duct that smokes is configured integrally. When the first sheet product F1 is sucked by the holding table, the accumulation device A of the transport mechanism is vertically vertical in plan view so as not to stop the continuous transport of the first sheet product F1 on the downstream side and the upstream side. Configured to move to. This operation is also controlled by the control device 1.

  The 1st bonding apparatus 18 is 1st optical member F11 surface of the 1st sheet product F1 from which the release film H12 was peeled by the 1st peeling apparatus 17 after the said cutting process via the 1st adhesive layer F14. Affix to the substrate W. The first sheet product F1 and the substrate W are both configured to be conveyed in parallel in a vertical state and bonded together by the first bonding apparatus 18. As shown to FIG. 6A, the flow of the clean air from the air blower 40 is not obstruct | occluded by the 1st sheet product F1, the board | substrate W, the release film after peeling, etc., and an air flow does not weaken partially. Therefore, no stagnation of air occurs, so that foreign matter mixing during the bonding process is suppressed.

  As shown in FIGS. 6A, 6B, and 12 (detailed drawings), when bonding, the first optical member F11 of the first sheet product F1 is bonded to the surface of the substrate W while being pressed by the pressing roller 181 and the guide roller 182. . The control device 1 controls the pressing pressure and driving operation of the pressing roller 181 and the guide roller 182.

  The peeling mechanism 171 of the first peeling device 17 has a knife edge portion N1 having a sharp tip, and the release film H12 is peeled off by wrapping the release film H12 around the knife edge portion N1 and reversely transferring it. In addition, the first sheet product F1 after the release film H12 is peeled off is configured to be sent out to the substrate W surface. At this time, a state in which a tension of 150 N / m or more and 1000 N / m or less is applied to the release film H12 and / or a time until the first optical member is pressed against the substrate W surface after the release film H12 is peeled off. By performing within 3 seconds, the bonding accuracy of the first optical member can be improved. If the tension is less than 150 N / m, the delivery position of the first optical member is not stable. If the tension is greater than 1000 N / m, the release film H12 may be stretched and broken, and the time until press contact is longer than 3 seconds. And there exists a possibility that the 1st optical member edge part peeled from the release film H12 may curve, and a crease | fold and a bubble may generate | occur | produce. The peeled release film H12 is wound around a roll 172. The winding control of the roll 172 is controlled by the control device 1.

  The laminating mechanism is composed of a pressing roller 181 and a guide roller 182 disposed opposite thereto. The guide roller 182 is composed of a rubber roller that is rotationally driven by a motor, and is arranged to be movable. On the opposite side, a pressing roller 181 made of a metal roller that is rotationally driven by a motor is movably provided. When the substrate W is fed to the bonding position, the pressing roller 181 is moved to a position away from the bonding position so as to open a roller interval. Note that both the guide roller 182 and the pressing roller 181 may be rubber rollers or metal rollers. As described above, the substrate W is cleaned by various cleaning apparatuses and is transported by the transport mechanism R. The transport control of the transport mechanism R is also controlled by the control device 1.

(Exclusion device)
The first rejection apparatus 19 that excludes the first sheet product F1 including the defect will be described. When the first sheet material F1 including the defect is conveyed to the bonding position, the guide roller 182 moves away from the bonding position. Next, the roller 192 around which the adhesive tape 191 is stretched moves to a bonding position that is a fixed position of the guide roller 182. The pressing roller 181 is moved to the bonding position, the first sheet product F1 including the defect is pressed against the adhesive tape 191, and the first sheet product F1 is applied to the adhesive tape 191. The sheet product F1 is wound around the roller 193.

  The board | substrate W1 manufactured above is conveyed downstream, and the 2nd optical member F21 is bonded together. In the following, the description of the same device configuration will be briefly described.

  When the polarizer of the second optical member F21 is bonded to the polarizer of the first optical member F11 in a 90 ° relationship (crossed Nicols relationship), the substrate W1 is rotated by 90 ° by the transfer direction switching mechanism of the transfer mechanism R. Then, the second optical member F21 is bonded. In the bonding method of the second sheet product F2 described below, the second sheet product F2 is configured to be conveyed in a vertical state.

  As shown in FIG. 7, the second roll of the long second sheet product F2 is installed on a roller mount device that is linked to a motor or the like so as to freely rotate or rotate at a constant rotational speed. The rotation speed is set by the control device 1 and the drive is controlled.

  The second conveying device 22 is a conveying mechanism that conveys the second sheet product F2 to the downstream side. The second transport device 22 is controlled by the control device 1.

  The second pre-inspection peeling device 23 is configured to peel the release film H <b> 21 from the conveyed second sheet product F <b> 2 and wind it on a roll 232. The winding speed around the roll 232 is controlled by the control device 1. The peeling mechanism 231 has a knife edge portion N1 with a sharp tip, and the release film H21 is wound around the knife edge portion N1 and reversely transferred to peel the release film H21 and release film. It is comprised so that the 2nd sheet material F2 after peeling H21 may be conveyed in a conveyance direction.

  The second defect inspection device 24 performs defect inspection after the release film H21 is peeled off. The second defect inspection device 24 analyzes the image data picked up by the CCD camera, detects the defect, and calculates its position coordinates. The position coordinates of this defect are provided for the skip cut by the second cutting device 26 described later.

  The 2nd release film bonding apparatus 25 bonds the release film H22 to the 2nd optical member F21 via the 2nd adhesive layer F24 after a 2nd fault test | inspection. As shown in FIG. 7, the release film H22 is fed out from the roll 251 of the release film H22, and the release film H22 and the second optical member F21 are sandwiched by one or a plurality of roller pairs 252, and the pair of rollers At 252, a predetermined pressure is applied to perform bonding. The rotation speed, pressure control, and conveyance control of the roller pair 252 are controlled by the control device 1.

  After the release film H22 is bonded, the second cutting device 26 leaves the release film H22, and determines the second optical member F21, the surface protective film 25, the second pressure-sensitive adhesive layer F24, and the pressure-sensitive adhesive layer F25. Cut to size. The second cutting device 26 is, for example, a laser device. Based on the position coordinates of the defect detected in the second defect inspection process, the second cutting device 26 cuts to a predetermined size so as to avoid the defect portion. That is, the cut product including the defective portion is rejected as a defective product by the second rejection device 29 in a later process. Or the 2nd cutting device 26 may ignore the presence of a fault, and may cut continuously to a predetermined size. In this case, it can be configured such that the portion is removed without being bonded in the bonding process described later. Control in this case also depends on the function of the control device 1.

  Moreover, the 2nd cutting device 26 arrange | positions the holding table which adsorbs and holds the release film surface of the 2nd sheet product F2, and equips the surface protection film side of the 2nd sheet product F2 with the laser apparatus. The second sheet material F2 is moved in parallel so as to scan the laser in the width direction, the second optical member F21, the second pressure-sensitive adhesive layer F24, the surface protective film F23, the pressure-sensitive adhesive layer leaving the lowermost release film H22. F25 is cut at a predetermined pitch in the conveying direction. When the second sheet product F2 is adsorbed by the holding table, the accumulation device A of the transport mechanism is vertically vertical in plan view so as not to stop the continuous transport of the downstream and upstream second sheet products F2. Configured to move to. This operation is also controlled by the control device 1.

  The 2nd bonding apparatus 28 is a board | substrate through the 2nd adhesive layer F24 on the 2nd optical member F21 surface of the 2nd sheet product F2 from which the release film H22 was peeled by the 2nd peeling apparatus 27 after a cutting process. Affix to W1. The second sheet product F <b> 2 and the substrate W <b> 1 are both conveyed in parallel in a vertical state and are bonded by the second bonding device 28. As shown in FIG. 8, the flow of clean air from the blower 40 is not blocked by the second sheet product F2, the substrate W1, the release film after peeling, and the airflow is not partially weakened. Therefore, no stagnation of air occurs, so that foreign matter mixing during the bonding process is suppressed. As shown in FIG. 8, when bonding, the second optical member F21 is bonded to the surface of the substrate W1 by the pressing roller 281 and the guide roller 282. The control device 1 controls the pressing pressure and driving operation of the pressing roller 281 and the guide roller 282.

  The peeling mechanism 271 of the second peeling device 27 has a knife edge portion N1 with a sharp tip, and the release film H22 is peeled off by winding the release film H22 around the knife edge portion N1 and transferring it in reverse. At the same time, the second sheet product F2 after the release film H22 is peeled off is sent to the surface of the substrate W1. At this time, a state in which a tension of 150 N / m or more and 1000 N / m or less is applied to the release film H22 and / or a time until the second optical member is pressed against the surface of the substrate W1 after the release film H22 is peeled off. By performing within 3 seconds, the bonding accuracy of the second optical member can be improved. If the tension is less than 150 N / m, the delivery position of the second optical member is not stable, and if it is greater than 1000 N / m, the release film H22 may stretch and break, and the time until press contact is longer than 3 seconds. And there exists a possibility that the 2nd optical member edge part peeled from the release film H22 may curve, and a crease | fold and a bubble may generate | occur | produce. The peeled release mold H22 is wound around a roll 272. The winding control of the roll 272 is controlled by the control device 1.

  The laminating mechanism is composed of a pressing roller 281 and a guide roller 282 arranged to face it. The guide roller 282 is composed of a rubber roller that is rotationally driven by a motor, and is arranged so as to be movable. On the opposite side, a pressing roller 281 made of a metal roller that is driven to rotate by a motor is movably disposed. When the substrate W1 is sent to the bonding position, the pressing roller 281 is moved to a position away from the bonding position so as to open a roller interval. Note that both the guide roller 282 and the pressing roller 281 may be rubber rollers or metal rollers.

  The 2nd rejection apparatus 29 which excludes the 2nd sheet material F2 containing a fault is demonstrated. When the second sheet product F2 including the defect is conveyed to the bonding position, the guide roller 282 moves to a position away from the bonding position. Next, the roller 292 around which the adhesive tape 291 is stretched moves to a fixed bonding position of the guide roller 282. By moving the pressing roller 281 to the bonding position, the second sheet product F2 including the defect is pressed against the adhesive tape 291 and the second sheet product F2 is applied to the adhesive tape 291. The sheet product F2 is wound around the roller 293.

  The optical display unit W12 to which the first and second optical members are bonded is conveyed to the inspection apparatus 30 shown in FIG. The transport mechanism R includes a mechanism (not shown) that changes the optical display unit W12 from a vertical state to a horizontal state. The inspection device 30 performs an inspection on both sides of the optical display unit W12 that has been conveyed. The light source 301 vertically irradiates the upper surface of the optical display unit W12 with a half mirror, and captures the reflected light image as image data with the CCD camera 302. The light source 305 and the CCD camera 306 perform inspection of the opposite surfaces. The light source 303 irradiates the surface of the optical display unit W12 at a predetermined angle, and the reflected light image is captured as image data by the CCD camera 304. The light source 307 and the CCD camera 308 perform inspection of the opposite surfaces. Defects are subjected to image processing analysis from these image data, and non-defective products are determined. In addition, the inspection apparatus 30 can be configured such that a CCD camera, a light source, and the like are arranged beside both surfaces of the optical display unit W12 so as to inspect the optical display unit W12 in the vertical state.

  The operation timing of each device is calculated by, for example, a method in which a sensor is arranged at a predetermined position and detected, or calculated by detecting the rotation member of each transfer device or transfer mechanism R with a rotary encoder or the like. Is done. The control device 1 may be realized by a cooperative action between a software program and a hardware resource such as a CPU and a memory. In this case, a memory is stored in advance for the program software, processing procedure, various settings, and the like. Further, it can be configured by a dedicated circuit or firmware.

  In the above manufacturing system, the first sheet product F1 and the substrate W are placed in the vertical state, the first sheet product F1 is attached to the substrate W, and the second sheet product F2 is placed in the vertical state, whereby the vertical substrate is placed. It is the structure affixed on W1. Therefore, various apparatus members, the first sheet product F1, the substrate W, the adhesive tape 191, the release film, and the like do not interfere with the flow of clean air, and the bonding process can be performed in a high cleanliness environment.

(Manufacturing system of another embodiment)
A known defect inspection method can be applied to the defect inspection. The automatic inspection apparatus is an apparatus that automatically inspects defects (also referred to as defects) of a sheet-like product, and irradiates light, and the reflected light image and the transmitted light image are picked up by a line sensor or a two-dimensional TV camera. The defect detection is performed based on the acquired image data. Further, the image data is acquired in a state where the inspection polarizing filter is interposed in the optical path between the light source and the imaging unit. Usually, the polarization axis (for example, the polarization absorption axis) of the polarizing filter for inspection is arranged to be in a state (crossed Nicols) orthogonal to the polarization axis (for example, the polarization absorption axis) of the polarizing plate to be inspected. . By arranging in crossed Nicols, a black image is input from the imaging unit if there is no defect, but if there is a defect, that part will not be black (recognized as a bright spot). Therefore, a defect can be detected by setting an appropriate threshold value. In such bright spot detection, defects such as surface deposits and internal foreign matter are detected as bright spots. In addition to this bright spot detection, there is also a method of detecting a foreign object by CCD imaging a transmitted light image on an object and analyzing the image. There is also a method for detecting a surface-attached foreign substance by subjecting an object to a reflected light image by CCD imaging and analyzing the image.

(Example of configuration and manufacturing method of optical member)
First, a polarizing plate will be described as an example of an optical member. For the polarizing plate, for example, a TAC (triacetyl cellulose) film (polarizer protective film) is bonded to one side of a polyvinyl alcohol film (polarizer) manufactured in advance, and a PET (polyethylene terephthalate) film is bonded to the other side. It is obtained by combining.

  For example, the roll of the polarizing plate is manufactured by the following manufacturing process. As a previous step, (A) a step of obtaining a polarizer. Here, a polarizer is obtained by drying a polyvinyl alcohol (PVA) film subjected to dyeing / crosslinking and stretching treatment. (B) The process of manufacturing a polarizing plate. Here, a TAC film is bonded to one side of a polarizer via an adhesive, and a PET film is bonded to the other side and dried to produce a polarizing plate. Anti-glare treatment may be applied in advance to the PET film on the viewing side of the display device. (C) The process of bonding a release film (separator) and a protective film together. A separator is bonded to the TAC film surface of the polarizing plate via a strong adhesive, and a surface protective film is bonded to the PET film surface via a weak adhesive. Here, a strong adhesive is applied to the separator in advance, and a weak adhesive is applied to the surface protective film. The strong adhesive applied to the separator is transferred to the TAC film after peeling the separator. In addition, the weak adhesive applied to the surface protective film remains formed on the surface protective film even when the surface protective film is peeled off, and is not substantially transferred to the PET film. In the above pre-process, a long sheet-like product is manufactured, wound into a roll, and provided to the post-process.

  In this previous process (A, B, C), a predetermined inspection is performed by an inspector for each process. For example, in the case of the process (A), the inspector visually confirms defects (foreign matter, dirt, twist, etc.) during the conveyance of the PVA original fabric. Further, in the case of the step (B), when the obtained polarizing plate raw material is wound into a roll shape, the inspector visually observes a defect (foreign matter, dirt, nick, twist, Check for kinks. In addition, a defect inspection device (a well-known device that photographs foreign matter, dirt, etc. with a camera, and processes the image to determine the defect) automatically inspects the original polarizing plate after bonding and confirms the defect on the monitor. .

  Further, in the case of the step (C), when the obtained strip-shaped sheet-shaped product raw roll is wound up in a roll form, the inspector visually observes a defect (foreign matter, dirt, twist, etc.) at the timing of starting and ending the roll. ) And assessing this defect, the sheet-shaped product original is rated (good, defective, whether shipment is possible).

  Next, as a post-process, (D) a slit process of the raw roll. Since the roll material is wide, the roll material is slit to a predetermined size in accordance with the size of the optical display unit as the final product. Depending on the width of the roll, the slit process is omitted. Next, (E) a roll original fabric inspection process. Here, a visual inspection by a roll type automatic inspection apparatus and / or an inspector is performed as an appearance inspection of a long sheet-like product. The roll type automatic inspection device is a known device that takes a winding defect, an appearance defect, and the like with a camera, and performs image processing to determine a defect.

  In the above process, the manufactured roll material is packed and transported to the next process place. On the other hand, when the bonding process with the substrate is performed at the same place, it is transported to the next process in a simple packaging or as it is.

  In the above description, the first optical member, the polarizer forming the second optical member, and the film used on one side or both sides of the polarizer have been partially explained. Generally, the following materials are exemplified. it can.

(Polarizer)
Each treatment of dyeing, crosslinking and stretching of the polyvinyl alcohol film need not be performed separately and may be performed simultaneously, and the order of the treatments may be arbitrary. In addition, you may use the polyvinyl alcohol-type film which gave the swelling process as a polyvinyl-alcohol-type film. Generally, a polyvinyl alcohol film is immersed in a solution containing iodine or a dichroic dye, dyed by adsorbing iodine or a dichroic dye, washed, and stretched in a solution containing boric acid or borax. After uniaxial stretching at a magnification of 3 to 7 times, it is dried. After stretching in a solution containing iodine or a dichroic dye, further stretching (two-stage stretching) in a solution containing boric acid or borax, and then drying, the orientation of iodine increases, and the degree of polarization This is particularly preferable because the characteristics are improved.

  Examples of the polyvinyl alcohol polymer include those obtained by polymerizing vinyl acetate and then saponifying vinyl acetate and a small amount of a copolymerizable monomer such as unsaturated carboxylic acid, unsaturated sulfonic acid, and cationic monomer. Polymerized products and the like can be mentioned. The average degree of polymerization of the polyvinyl alcohol polymer is not particularly limited, and any one can be used, but 1000 or more is preferable, and 2000-5000 is more preferable. Moreover, 85 mol% or more is preferable and, as for the saponification degree of a polyvinyl alcohol-type polymer, More preferably, it is 98-100 mol%.

  The thickness of the manufactured polarizer is generally 5 to 80 μm, but is not limited thereto, and the method for adjusting the thickness of the polarizer is not particularly limited. Ordinary methods such as roll stretching and rolling can be used.

  The adhesion treatment between the polarizer and the transparent polarizer protective film as the protective layer is not particularly limited, but for example, an adhesive made of a vinyl alcohol polymer, boric acid, borax, glutaraldehyde, It can be carried out via an adhesive comprising at least a water-soluble crosslinking agent of a vinyl alcohol polymer such as melamine or oxalic acid. Such an adhesive layer is formed as a coating / drying layer or the like of an aqueous solution. When preparing the aqueous solution, other additives and a catalyst such as an acid can be blended as necessary.

(Polarizer protective layer: Polarizer protective film)
An appropriate transparent film can be used for the polarizer protective layer provided on one side or both sides of the polarizer. For example, a thermoplastic resin excellent in transparency, mechanical strength, thermal stability, moisture barrier property, isotropy, etc. is used. Specific examples of such thermoplastic resins include cellulose resins such as triacetyl cellulose, polyester resins, polyethersulfone resins, polysulfone resins, polycarbonate resins, polyamide resins, polyimide resins, polyolefin resins, (meth) acrylic resins, cyclic Examples thereof include polyolefin resins (norbornene resins), polyarylate resins, polystyrene resins, polyvinyl alcohol resins, and mixtures thereof. A transparent protective film is bonded to one side of the polarizer by an adhesive layer. On the other side, as a transparent protective film, (meth) acrylic, urethane-based, acrylurethane-based, epoxy-based, silicone A thermosetting resin such as a system or an ultraviolet curable resin can be used. One or more kinds of arbitrary appropriate additives may be contained in the transparent protective film. Examples of the additive include an ultraviolet absorber, an antioxidant, a lubricant, a plasticizer, a release agent, a coloring inhibitor, a flame retardant, a nucleating agent, an antistatic agent, a pigment, and a coloring agent. The content of the thermoplastic resin in the transparent protective film is preferably 50 to 100% by weight, more preferably 50 to 99% by weight, still more preferably 60 to 98% by weight, and particularly preferably 70 to 97% by weight. . When content of the said thermoplastic resin in a transparent protective film is 50 weight% or less, there exists a possibility that the high transparency etc. which a thermoplastic resin originally has cannot fully be expressed. Moreover, an amorphous PO film, a cycloolefin polymer (COP) film, an Arton film (manufactured by JSR), a ZEONOR film (manufactured by Nippon Zeon) and the like can be mentioned.

  Further, the optical member may be formed by laminating a polarizing plate and two or more optical layers as in the above-described polarization separation type polarizing plate. Therefore, a reflective elliptical polarizing plate or a semi-transmissive elliptical polarizing plate in which the above-mentioned reflective polarizing plate or transflective polarizing plate and a retardation plate are combined may be used.

  The optical member in which the optical layer is laminated on the polarizing plate can be formed by a method of sequentially laminating separately in the manufacturing process of a liquid crystal display device or the like. There is an advantage that the manufacturing process of a liquid crystal display device or the like can be improved because of excellent stability and assembly work. For the lamination, an appropriate adhesive means such as a pressure-sensitive adhesive layer can be used. When adhering the polarizing plate and the other optical layer, their optical axes can be set at an appropriate arrangement angle in accordance with a target phase difference characteristic.

  In addition, in each layer such as the above-described polarizer, polarizer protective film, optical film, and pressure-sensitive adhesive layer, for example, salicylic acid ester compounds, benzophenol compounds, benzotriazole compounds, cyanoacrylate compounds, nickel complex salts It may be one having an ultraviolet absorbing ability by a method such as a method of treating with an ultraviolet absorber such as a compound.

  The optical member can be preferably used for forming an image display device such as a liquid crystal display device, an organic EL display device, or a PDP.

  The liquid crystal display device can be formed according to the conventional method. That is, a liquid crystal display device is generally formed by assembling components such as an optical display unit (having a liquid crystal cell substrate and an optical member) and an illumination system as necessary and incorporating a drive circuit. As the liquid crystal cell, any type such as a TN type, an STN type, or a π type can be used.

  An appropriate liquid crystal display device such as a liquid crystal display device in which an optical member is disposed on one side or both sides of a liquid crystal cell, or a backlight system or a reflector plate used in an illumination system can be formed. In that case, the optical member by this invention can be installed in the one side or both sides of a liquid crystal cell. When optical members are provided on both sides, they may be the same or different. Further, when forming a liquid crystal display device, for example, a single layer or a suitable part such as a diffusing plate, an antiglare layer, an antireflection film, a protective plate, a prism array, a lens array sheet, a light diffusing plate, a backlight, etc. Two or more layers can be arranged.

Flowchart of manufacturing method of optical display unit of embodiment 1 Flowchart of manufacturing method of optical display unit of embodiment 2 The figure for demonstrating the manufacturing system of Embodiment 1. FIG. The figure for demonstrating the manufacturing system of Embodiment 2. FIG. The figure for demonstrating the apparatus structure of the manufacturing system of Embodiment 2. FIG. The figure for demonstrating the apparatus structure of the manufacturing system of Embodiment 2. FIG. The figure for demonstrating the apparatus structure of the manufacturing system of Embodiment 2. FIG. The figure for demonstrating the apparatus structure of the manufacturing system of Embodiment 2. FIG. The figure for demonstrating the apparatus structure of the manufacturing system of Embodiment 2. FIG. The figure for demonstrating the apparatus structure of the manufacturing system of Embodiment 2. FIG. The figure for demonstrating the apparatus structure of the manufacturing system of Embodiment 2. FIG. The figure for demonstrating the apparatus structure of the manufacturing system of Embodiment 2. FIG. The figure for demonstrating the apparatus structure of the manufacturing system of Embodiment 2. FIG. The figure for demonstrating the apparatus structure of the manufacturing system of Embodiment 2. FIG. The figure for demonstrating the apparatus structure of the manufacturing system of Embodiment 2. FIG. The figure for demonstrating the apparatus structure of the manufacturing system of Embodiment 2. FIG. The figure for demonstrating an example of the laminated structure of a 1st, 2nd optical member A flowchart of a conventional method for manufacturing an optical display unit

Explanation of symbols

F1 1st sheet product F2 2nd sheet product F11 1st optical film F11a 1st polarizer F11b 1st film F11c 2nd film F12 1st release film F13 Surface protection film F14 1st adhesive layer F21 2nd optical film F21a Second polarizer F21b Third film F21c Fourth film F22 Second release film F23 Surface protective film F24 Second adhesive layer W Substrate W12 Optical display unit 1 Control device 10 Polishing cleaning device 11 Water cleaning device 12 First transport device 13 First peeling device 14 before inspection 1st defect inspection device 15 1st release film bonding device 16 1st cutting device 17 1st peeling device 18 1st bonding device 19 1st exclusion device 22 2nd conveying device 23 1st 2 Pre-inspection peeling device 24 Second defect inspection device 25 Second release film laminating device 26 Second cutting device 27 2nd peeling apparatus 28 2nd bonding apparatus 29 2nd exclusion apparatus

Claims (7)

An optical display unit manufacturing method for manufacturing an optical display unit by bonding an optical member having a polarizer to a substrate via an adhesive,
A method for manufacturing an optical display unit, wherein a surface of the substrate is placed in a vertical state and an optical member is bonded to at least one surface. An optical display unit manufacturing system for manufacturing an optical display unit by bonding an optical member having a polarizer to a substrate via an adhesive,
An isolation structure that at least isolates the bonding process of the substrate and the optical member;
A blower that generates an air current acting on the optical member and the substrate;
A first laminating device that causes the surface of the substrate to be in a vertical state while causing the airflow to act on the optical member and the substrate, and bonds the first optical member to at least one surface;
An optical display unit manufacturing system comprising: A cutting device for cutting the first optical member and the first pressure-sensitive adhesive layer, leaving a release film formed on the first optical member via the first pressure-sensitive adhesive layer;
Before the treatment by the first laminating device, a peeling device for peeling the release film,
The system for manufacturing an optical display unit according to claim 2, further comprising: Before the cutting process by the cutting device, a peeling device for peeling the release film formed on the first optical member via the first pressure-sensitive adhesive layer;
An inspection device for inspecting defects of the first optical member after the release film is peeled;
After the defect inspection, a release film laminating apparatus for laminating a release film to the first optical member via a first adhesive layer;
The system for manufacturing an optical display unit according to claim 3, further comprising:   5. The optical display unit according to claim 2, further comprising: a second bonding device that bonds the second optical member to a surface opposite to the one surface where the first optical member of the substrate is bonded. Manufacturing system. A cutting device for cutting the second optical member and the second adhesive layer, leaving a release film formed on the second optical member via the second adhesive layer;
Before the treatment by the second laminating device, a peeling device for peeling the release film,
The system for manufacturing an optical display unit according to claim 5, further comprising: A peeling device for peeling a release film formed on the second optical member via a second pressure-sensitive adhesive layer before the cutting treatment by the cutting device;
An inspection device for inspecting defects of the second optical member after the release film is peeled;
After the defect inspection, a release film laminating apparatus for laminating a release film to the second optical member via a second pressure-sensitive adhesive layer;
The system for manufacturing an optical display unit according to claim 6, further comprising:

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