JP2010217878A - System and method for manufacturing optical display unit, and rolled sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a system and method for manufacturing an optical display unit, which allows satisfactory conveyance and the reduction in manufacturing cost of the optical display unit, and to provide a rolled sheet. <P>SOLUTION: Band-shaped polarizing sheets 30 and 40 are conveyed while adhesive layers of the band-shaped polarizing sheets 30 and 40 are transferred to an outer surface of a belt 51 having releasability, and polarizing sheet pieces F1 and F2 obtained by cutting the band-shaped polarizing sheets 30 and 40 at prescribed intervals are stuck to a display substrate W, thereby an optical display unit is manufactured. The band-shaped polarizing sheets 30 and 40 are conveyed while their adhesive layers are transferred to the belt 51, satisfactory conveyance is achievable and the manufacturing cost of the optical display unit can be reduced because they can be conveyed with a simple configuration using the belt 51. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a manufacturing system and a manufacturing method of an optical display unit in which a polarizing sheet piece is bonded to a display substrate, and a roll material.

  FIG. 7 is a flowchart showing an example of a conventional manufacturing method of an optical display unit mounted on an optical display device. First, in an optical film manufacturer, a long (band-like) sheet member having an optical film is manufactured as a roll original by being wound into a roll (# 1). The sheet member is formed by bonding a release film to a strip-shaped polarizing sheet having an optical film. Since the specific manufacturing process of a roll raw material is well-known, description is abbreviate | omitted.

  Next, the roll material is slit to a predetermined width (a width corresponding to the shape of the display substrate) (# 2). Then, the sheet member fed out from the slit roll raw material is cut in a fixed size in accordance with the shape of the display substrate to be bonded (# 3). Thereby, the sheet member of the sheet | seat with which the release film was bonded together to the polarizing sheet piece cut out from the strip | belt-shaped polarizing sheet is obtained. Appearance inspection is performed on the sheet member that has been cut into regular lengths (# 4). Examples of the inspection method include visual defect inspection and inspection using a known defect inspection apparatus. Next, a finished product inspection is performed (# 5). The finished product inspection is an inspection based on criteria that are stricter than the appearance inspection. Thereafter, each end surface of the sheet member of the single wafer is subjected to end surface processing (# 6). This end face processing is performed in order to prevent the adhesive from protruding from the end face during transportation. Next, in a clean room environment, a single sheet member is packed (# 7) and packed for transportation (# 8). As described above, a sheet member is manufactured and transported to a panel processing manufacturer.

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

  Next, the optical display unit is formed by attaching the sheet member to the display substrate (# 14). At this time, the polarizing sheet piece obtained by peeling the release film while leaving the pressure-sensitive adhesive layer from the sheet member is bonded to one surface of the display substrate using the pressure-sensitive adhesive layer as a bonding surface. Furthermore, a polarizing sheet piece can be similarly bonded to the other surface of the display substrate. When the polarizing sheet pieces are bonded to both surfaces of the display substrate, the polarizing sheet pieces having the same configuration may be bonded to both surfaces of the display substrate, or polarizing sheet pieces having different configurations may be bonded to both surfaces of the display substrate. The structure which can be match | combined may be sufficient. Thereafter, the bonded state and defects of the optical display unit formed by bonding the polarizing sheet piece to the display substrate are inspected (# 15). The optical display unit determined to be non-defective in this inspection is transported to the mounting process and mounted on the optical display device (# 16). On the other hand, the optical display unit determined to be defective is subjected to a rework process (# 17). In the rework process, the polarizing sheet piece is peeled from the display substrate, and a new polarizing sheet piece is bonded to the display substrate (# 14).

  In the above manufacturing process, in particular, end face processing, packaging of sheet members of sheets, packing and unpacking are necessary steps because the optical film manufacturer and the panel processing manufacturer exist in different places. ing. However, the multi-step manufacturing process as described above has a problem that the manufacturing cost increases, and the sheet member of the manufactured sheet is likely to be scratched or soiled.

  As a method for solving this problem, in the invention disclosed in Japanese Patent Application Laid-Open No. 2007-140046 (Patent Document 1), a sheet member is pulled out from a roll and cut, and the cut sheet member is used as a display substrate. The process of bonding is performed on a continuous production line. Thereby, the productivity of the optical display unit can be improved as compared with the conventional method of packing and delivering single sheet members one by one.

Japanese Patent Laid-Open No. 2007-140046

  However, in the invention disclosed in Patent Document 1, the cut sheet member is adsorbed and conveyed to the next process such as bonding, so that an optical display is accompanied by the use of a complicated conveying device. The manufacturing cost of the unit increases. Further, when the sheet member of a single sheet is greatly curled, there is a problem that the sheet member cannot be conveyed satisfactorily.

  The present invention has been made in view of the above circumstances, and can manufacture an optical display unit that can be favorably transported to the next process such as bonding, and can reduce the manufacturing cost of the optical display unit. It is an object of the present invention to provide a system, a manufacturing method, and a roll material.

  An optical display unit manufacturing system according to the present invention is an optical display unit manufacturing system in which a polarizing sheet piece is bonded to a display substrate, which has a polarizer and has a pressure-sensitive adhesive layer on one surface. A transport device that feeds and transports the belt-shaped polarizing sheet from a roll original formed by releasably winding the sheet without the release film being bonded to the pressure-sensitive adhesive layer, and the belt-shaped polarized light A support that includes a cutting device that generates the polarizing sheet piece by cutting the sheet at a predetermined interval, and a bonding device that bonds the polarizing sheet piece to the display substrate, and the transport device has release properties. The band-shaped polarizing sheet is conveyed in a state where the pressure-sensitive adhesive layer of the band-shaped polarizing sheet is transferred onto the band-shaped polarizing sheet.

  According to such a structure, the polarizing sheet produced | generated by conveying with the adhesive layer of a strip | belt-shaped polarizing sheet having been transferred to the support body which has mold release property, and cut | disconnecting the said strip | belt-shaped polarizing sheet at a predetermined space | interval An optical display unit can be manufactured by bonding the pieces to the display substrate. As described above, by transporting the band-shaped polarizing sheet with the pressure-sensitive adhesive layer transferred to the support, the belt-shaped polarizing sheet being transported can be prevented from meandering, and can be transported satisfactorily. Can prevent misalignment. Moreover, since it can convey with a simple structure using a support body, the manufacturing cost of an optical display unit can be reduced.

  Moreover, a mold release film can be abbreviate | omitted by using the roll raw material formed by winding so that peeling film is not bonded to an adhesive layer but being peelable. Thereby, the manufacturing cost of a roll original fabric can be reduced, and the manufacturing cost of an optical display unit can be reduced by extension. In addition, by omitting a relatively rigid release film, it is easy to roll a strip-shaped polarizing sheet to produce a roll, and the number of turns of the strip-shaped polarizing sheet is reduced by the amount of the omitted release film. Can be increased.

  In the optical display unit manufacturing system according to the present invention, the support having releasability includes at least one of a belt, a roller, a film, and a drum.

  According to such a configuration, the belt-shaped polarizing sheet can be transported with a simple configuration including at least one of a belt, a roller, a film, and a drum, so that the manufacturing cost of the optical display unit can be effectively reduced. it can.

  The belt, roller, film and drum are preferably made of resin, rubber, metal or the like. Although the contact surface of the support with the pressure-sensitive adhesive layer of the band-shaped polarizing sheet in the above support has releasability, a release treatment for improving the surface releasability such as silicone treatment or long-chain alkyl treatment is performed. Alternatively, a lubricant such as water or oil may be dropped on the contact surface so as to have releasability.

  The optical display unit manufacturing system according to the present invention is characterized in that the cutting device cuts the strip-shaped polarizing sheet on the support having the releasability.

  According to such a structure, a strip | belt-shaped polarizing sheet can be cut | disconnected reliably on a support body. In other words, the band-shaped polarizing sheet can be stably cut in a state of being transferred onto the support, and even if there is a variation in cutting accuracy, the band-shaped polarizing sheet can be formed by slightly setting the cutting depth. It is possible to prevent a state where the polarizing sheet cannot be completely cut (half cut state). In this case, it is preferable that the support is made of a hard-to-cut material.

  The optical display unit manufacturing system according to the present invention is characterized in that the width of the support having releasability is larger than the width of the strip-shaped polarizing sheet.

  According to such a configuration, the strip-shaped polarizing sheet can be stably cut over the entire width direction in a state where the strip-shaped polarizing sheet is transferred onto the support having a width larger than that of the strip-shaped polarizing sheet. The width of the strip-shaped polarizing sheet may be substantially the same as the width of the display substrate.

  The optical display unit manufacturing system according to the present invention is characterized in that the cutting device cuts the strip-shaped polarizing sheet on the roll material.

  According to such a structure, a strip | belt-shaped polarizing sheet can be cut | disconnected stably on a roll original fabric. That is, since it is not necessary to separately provide an apparatus for stably cutting the strip-shaped polarizing sheet in a state where the belt-like polarizing sheet is transferred, the manufacturing system can be simplified and the manufacturing cost of the optical display unit can be further reduced. it can.

  The optical display unit manufacturing system according to the present invention is characterized in that the cutting device cuts the band-shaped polarizing sheet at a predetermined interval based on a defect included in the band-shaped polarizing sheet detected in advance.

  According to such a configuration, by cutting the strip-shaped polarizing sheet at a predetermined interval based on the defects detected in advance, it is possible to efficiently generate a non-defective polarizing sheet piece that does not include the defects and to bond it to the display substrate. Therefore, the yield of the optical display unit can be improved.

  A defect inspection apparatus for inspecting defects included in the band-shaped polarizing sheet conveyed by the conveying apparatus is provided, and the cutting device cuts the band-shaped polarizing sheet at predetermined intervals based on a result of defect inspection by the defect inspection apparatus. Such a configuration may be adopted. Further, the transport device feeds and transports the belt-shaped polarizing sheet from a roll raw material whose defects have been inspected in advance, and the cutting device removes the belt-shaped polarizing sheet at predetermined intervals based on the results of the inspection performed in advance. The structure which cut | disconnects may be sufficient.

  The optical display unit manufacturing system according to the present invention is characterized in that a surface of the strip-shaped polarizing sheet opposite to the pressure-sensitive adhesive layer has releasability.

  According to such a configuration, when the belt-shaped polarizing sheet is unwound and conveyed from the roll raw material formed by winding the belt-shaped polarizing sheet without the release film being bonded to the pressure-sensitive adhesive layer, The pressure-sensitive adhesive layer is easily peeled off from the surface of the strip-shaped polarizing sheet. Therefore, it is possible to satisfactorily feed and convey the belt-shaped polarizing sheet from the roll raw fabric.

  A release treatment for improving release properties such as silicone treatment and long-chain alkyl treatment may be applied to the surface of the strip-shaped polarizing sheet opposite to the pressure-sensitive adhesive layer.

  The method for manufacturing an optical display unit according to the present invention is a method for manufacturing an optical display unit in which a polarizing sheet piece is bonded to a display substrate, which has a polarizer and has a pressure-sensitive adhesive layer on one surface. A conveying step of unwinding and conveying the band-shaped polarizing sheet from a roll raw material formed by winding the sheet releasably without the release film being bonded to the pressure-sensitive adhesive layer; and the band-shaped polarized light A support step having a releasability in the transporting step, comprising: a cutting step for generating the polarizing sheet piece by cutting the sheet at a predetermined interval; and a bonding step for bonding the polarizing sheet piece to the display substrate. The strip-shaped polarizing sheet is conveyed in a state where the pressure-sensitive adhesive layer of the strip-shaped polarizing sheet is transferred onto the strip.

  According to such a configuration, it is possible to provide a method for manufacturing an optical display unit that has the same effect as the above-described optical display unit manufacturing system according to the present invention.

  The roll raw fabric according to the present invention has a polarizer, and from the roll raw fabric formed by winding a strip-shaped polarizing sheet having a pressure-sensitive adhesive layer on one side, the strip-shaped polarizing sheet is drawn out, A polarizing sheet piece obtained by transferring the adhesive layer of the strip-shaped polarizing sheet to a support having releasability in a state of being transferred and cutting the strip-shaped polarizing sheet at predetermined intervals is attached to a display substrate. It is a roll raw material for bonding, and the band-shaped polarizing sheet is formed by being peelably wound without a release film being bonded to the pressure-sensitive adhesive layer.

  According to such a configuration, the belt-shaped polarizing sheet is transported in a state where the pressure-sensitive adhesive layer is transferred to the support, thereby preventing meandering of the belt-shaped polarizing sheet being transported and being able to be transported satisfactorily. In addition, it is possible to provide a roll material that can prevent misalignment to the display substrate.

  Moreover, a release film can be abbreviate | omitted in the roll original fabric formed by winding so that peeling film may not be bonded to an adhesive layer so that peeling is possible. Thereby, the manufacturing cost of a roll original fabric can be reduced. In addition, by omitting a relatively rigid release film, it is easy to roll a strip-shaped polarizing sheet to produce a roll, and the number of turns of the strip-shaped polarizing sheet is reduced by the amount of the omitted release film. Can be increased.

It is the schematic sectional drawing which showed the aspect at the time of bonding a polarizing sheet piece to a display substrate, and manufacturing an optical display unit. It is the schematic plan view which showed an example of the manufacturing system of the optical display unit which concerns on 1st Embodiment of this invention. It is the flowchart which showed an example of the manufacturing method of the optical display unit which concerns on 1st Embodiment of this invention. It is the schematic side view which showed partially the structure of the manufacturing system of the optical display unit which concerns on 1st Embodiment of this invention. It is the schematic side view which showed partially the structure of the manufacturing system of the optical display unit which concerns on 2nd Embodiment of this invention. It is the schematic side view which showed partially the structure of the manufacturing system of the optical display unit which concerns on 3rd Embodiment of this invention. It is the flowchart which showed an example of the conventional manufacturing method of the optical display unit mounted in an optical display apparatus.

(First embodiment)
FIG. 1 shows a mode in which an optical display unit U is manufactured by bonding polarizing sheet pieces F1 and F2 to a display substrate W.

  In the present embodiment, the first polarizing sheet piece F1 generated by unwinding and cutting the first strip-shaped polarizing sheet from the first roll raw fabric is bonded to one surface (first surface) of the display substrate W. The second polarizing sheet piece F2 generated by feeding and cutting the second strip-shaped polarizing sheet from the second roll original is bonded to the other surface (second surface) of the display substrate W, so that the optical The display unit U is manufactured. However, the configuration is not limited to such a configuration, and a configuration in which the polarizing sheet piece is bonded to only one surface of the display substrate W may be used.

(Display board)
Examples of the display substrate W include a glass substrate unit of a liquid crystal cell, an organic EL light emitting unit, and the like. The display substrate W is formed in a rectangular shape, for example.

(Polarized sheet piece)
As polarizing sheet piece F1, F2, it can comprise from the polarizing film or the laminated film which combined the retardation film and the brightness enhancement film with the polarizing film. The polarizing sheet pieces F1 and F2 have pressure-sensitive adhesive layers F14 and F24 that form a bonding surface with the display substrate W on one surface, and the pressure-sensitive adhesive layers F14 and F24 have a release film. Are not pasted together.

  That is, the first roll original is wound so that the first strip-shaped polarizing sheet having the first pressure-sensitive adhesive layer F14 on one surface can be peeled off without the release film being bonded to the first pressure-sensitive adhesive layer F14. Is formed. The 1st polarizing sheet piece F1 is produced | generated by cut | disconnecting the 1st strip | belt-shaped polarizing sheet extended | stretched from the said 1st roll original fabric. Similarly, the second roll original roll is wound so that the second belt-shaped polarizing sheet having the second pressure-sensitive adhesive layer F24 on one surface can be peeled off without the release film being bonded to the second pressure-sensitive adhesive layer F24. It is formed by turning. The second polarizing sheet piece F2 is generated by cutting the second strip-shaped polarizing sheet fed from the second roll raw fabric.

  In this example, the first strip-shaped polarizing sheet and the first polarizing sheet piece F1 include a first optical film F11 and a surface protective film F13. The first optical film F11 includes, for example, a first polarizer F11a, a first film F11b bonded to one surface thereof, and a second film F11c bonded to the other surface.

  The 1st film F11b and the 2nd film F11c consist of polarizer protective films (a triacetyl cellulose film, a polyethylene terephthalate film, etc.), for example. The second film F11c is bonded to the display substrate W via the first pressure-sensitive adhesive layer F14. The pressure-sensitive adhesive layer F14 can be formed on the first optical film F11 (second film F11c) by, for example, a method in which a solventless pressure-sensitive adhesive is directly applied to the first optical film F11 and cured by light irradiation. . The first film F11b can be subjected to a surface treatment such as an antireflection treatment. The surface protective film F13 is bonded to the first film F11b through the adhesive layer F15. The surface of the surface protective film F13 opposite to the pressure-sensitive adhesive layer F15 is subjected to release treatment for improving release properties such as silicone treatment and long-chain alkyl treatment.

  Thus, the first strip-shaped polarizing sheet and the first polarizing sheet piece F1 have the first pressure-sensitive adhesive layer F14 on one surface (inner surface), and the surface opposite to the first pressure-sensitive adhesive layer F14 (outer surface). Surface) has releasability. For example, the configuration may be such that, for example, the surface protective film F13 and the pressure-sensitive adhesive layer F15 are omitted, and the outer surface of the first optical film F11 has releasability. One of the first film F11b and the second film F11c can be omitted. When the 1st strip | belt-shaped polarizing sheet has the surface protective film F13 like this embodiment, the surface protective film F13 and the 1st adhesive layer which mutually overlap in the state which wound the said 1st strip | belt-shaped polarizing sheet are wound. The surface protective film F13 is opposite to the pressure-sensitive adhesive layer F15 so that the pressure-sensitive adhesive force with the F14 is smaller than the pressure-sensitive adhesive force between the pressure-sensitive adhesive layer F15 and one surface (first film F11b) of the first optical film F11. A release treatment is applied to the surface of

  Similarly, the second strip-shaped polarizing sheet and the second polarizing sheet piece F2 include a second optical film F21 and a surface protective film F23. The second optical film F21 includes, for example, a second polarizer F21a, a third film F21b bonded to one surface thereof, and a fourth film F21c bonded to the other surface.

  The 3rd film F21b and the 4th film F21c consist of a polarizer protective film similar to the 1st film F11b and the 2nd film F11c, for example. The fourth film F21c is bonded to the display substrate W via the second pressure-sensitive adhesive layer F24. Formation of the adhesive layer F24 with respect to the 2nd optical film F21 (4th film F21c) can be performed by the method similar to the adhesive layer F14. The third film F21b can be subjected to a surface treatment such as an antireflection treatment. The surface protective film F23 is bonded to the third film F21b through the adhesive layer F25. The surface of the surface protective film F23 opposite to the pressure-sensitive adhesive layer F25 is subjected to the same release treatment as described above.

  As described above, the second strip-shaped polarizing sheet and the second polarizing sheet piece F2 have the second pressure-sensitive adhesive layer F24 on one surface (inner surface) and the surface opposite to the second pressure-sensitive adhesive layer F24 (outside). Surface) has releasability. For example, the surface protective film F23 and the pressure-sensitive adhesive layer F25 may be omitted, and the outer surface of the second optical film F21 may have a releasability. It is. When the second belt-shaped polarizing sheet has the surface protective film F23 as in the present embodiment, the surface protective film F23 and the second pressure-sensitive adhesive layer that overlap each other in a state where the second belt-shaped polarizing sheet is wound. The surface protective film F23 is opposite to the pressure-sensitive adhesive layer F25 so that the pressure-sensitive adhesive force with the F24 is smaller than the pressure-sensitive adhesive force between the pressure-sensitive adhesive layer F25 and one surface (third film F21b) of the second optical film F21. A release treatment is applied to the surface of

  Since the surface opposite to the pressure-sensitive adhesive layers F14 and F24 has releasability (light release), the first belt-shaped polarizing sheet and the second belt-shaped polarizing sheet are separated from the pressure-sensitive adhesive layers F14 and F24, respectively. When the strip-shaped polarizing sheet is unwound and conveyed from the roll raw material formed by winding the strip-shaped polarizing sheet without the mold film being bonded, the pressure-sensitive adhesive layers F14 and F24 from the surface of the strip-shaped polarizing sheet. Is easy to peel. Therefore, it is possible to satisfactorily feed and convey the belt-shaped polarizing sheet from the roll raw fabric.

(Optical display unit manufacturing system and manufacturing method)
FIG. 2 shows an example of a system for manufacturing the optical display unit U according to the first embodiment of the present invention. FIG. 3 is a flowchart showing an example of a method for manufacturing the optical display unit U according to the first embodiment of the present invention. Hereinafter, a manufacturing system and a manufacturing method of the optical display unit U will be described with reference to FIGS.

  (1) 1st roll original fabric R1 is a roll-shaped winding body of the 1st strip | belt-shaped polarizing sheet 30 by which the slit process was given by the width | variety corresponding to the short side of the display substrate W (1st roll original fabric preparation process) : S1).

  (2) The prepared first roll original fabric R1 is set so as to be rotatable about its axis, and the first belt-shaped polarizing sheet 30 is fed out from the first roll original fabric R1 by the first conveying device 12. It is conveyed (first conveying step: S2). The 1st strip | belt-shaped polarizing sheet 30 drawn | fed out from 1st roll original fabric R1 is conveyed toward the bonding position with the display substrate W. The first transport device 12 includes a plurality of transport rollers (not shown) for transporting the first strip-shaped polarizing sheet 30 and is provided from the first roll original R1 to the first bonding device 18 described later. .

  (3) The defect inspection is performed by the first defect inspection device 14 on the first strip-shaped polarizing sheet 30 drawn out from the first roll raw fabric R1 (first inspection step: S3). Examples of the defect inspection method include a method of photographing and processing an image by irradiating both surfaces of the first strip-shaped polarizing sheet 30 with light. A known technique can be applied to the image processing algorithm. For example, a defect can be detected by density determination by binarization processing. Information on the defect detected by the first defect inspection device 14 is stored in association with the position information (for example, position coordinates), and is used for processing of the first cutting device 16 described later.

  (4) The 1st strip | belt-shaped polarizing sheet 30 conveyed by the 1st conveying apparatus 12 is cut | disconnected by the 1st cutting device 16 at predetermined intervals, and the 1st polarizing sheet piece F1 is produced | generated (1st cutting process: S4). . The 1st cutting device 16 is a structure containing a laser apparatus or a cutter, for example, and cut | disconnects the 1st strip | belt-shaped polarizing sheet 30 along the width direction. At this time, the first polarizing sheet piece F1 having a shape corresponding to the display substrate W can be continuously generated by cutting the first strip-shaped polarizing sheet 30 at a constant interval corresponding to the long side of the display substrate W. However, in the present embodiment, based on the defects included in the first band-shaped polarizing sheet 30 detected in advance by the first defect inspection apparatus 14, the first band-shaped polarizing sheet 30 is cut at a predetermined interval avoiding the defects. It is like that.

  Specifically, when it is assumed that the first strip-shaped polarizing sheet 30 is cut at the above-mentioned regular intervals, if the first polarizing sheet piece F1 to be generated includes a defect, the defect is avoided. The cutting position is shifted. As a result, the first polarizing sheet piece F1 cut at intervals corresponding to the long sides of the display substrate W does not include a defect, and only a good first polarizing sheet piece F1 that does not include the defect is attached to the display substrate W. Can be combined. Therefore, by cutting the first strip-shaped polarizing sheet 30 at intervals based on the defects detected in advance as described above, the first polarizing sheet piece F1 that does not include the defects is efficiently generated and bonded to the display substrate W. Therefore, the yield of the optical display unit U can be improved.

  The first defect inspection apparatus 14 can be omitted. In this case, defect inspection is performed in advance at the stage of manufacturing the first roll raw fabric R1, and the first strip-shaped polarizing sheet 30 is cut at a predetermined interval avoiding the defect based on the result of the defect inspection. It may be a configuration. The position information of the defect detected in advance may be attached to the first roll original fabric R1 as code information (for example, QR code, barcode, etc.) and supplied to the manufacturing system. What is the first roll original fabric R1? You may make it take in another information medium and be supplied to this manufacturing system.

  (5) The 1st polarizing sheet piece F1 produced | generated by cut | disconnecting the 1st strip | belt-shaped polarizing sheet 30 is bonded together by the 1st bonding apparatus 18 on the 1st surface of the display substrate W (1st bonding process: S5). In this bonding, the first polarizing sheet piece F1 and the display substrate W are paired with the first pressure-sensitive adhesive layer F14 of the first polarizing sheet piece F1 facing the first surface of the display substrate W (see FIG. (Not shown). Note that before the first polarizing sheet piece F1 is bonded, the surface of the display substrate W is cleaned by polishing cleaning, water cleaning, or the like (display substrate cleaning step: S6).

  The above-mentioned 1st conveyance process, the 1st inspection process, the 1st cutting process, and the 1st pasting process are performed in the continuous production line. On the display substrate W to which the first polarizing sheet piece F1 is bonded by this series of processes, the second polarizing sheet piece F2 cut from the second roll raw fabric R2 is bonded by the process described below.

  (6) 2nd roll original fabric R2 is a roll-shaped winding body of the 2nd strip | belt-shaped polarizing sheet 40 by which the slit process was given by the width | variety corresponding to the long side of the display substrate W (2nd roll original fabric preparation process) : S11). When the display substrate W is formed in a rectangular shape as in the present embodiment, the second roll original fabric R2 is slit with a width different from that of the first roll original fabric R1.

  (7) The prepared second roll original fabric R2 is set so as to be rotatable about its axis, and the second belt-shaped polarizing sheet 40 is fed out from the second roll original fabric R2 by the second transport device 22. It is transported (second transport process: S12). The 2nd strip | belt-shaped polarizing sheet 40 drawn | fed out from 2nd roll original fabric R2 is conveyed toward the bonding position with the display substrate W. The 2nd conveying apparatus 22 is provided with the some conveyance roller (not shown) for conveying the 2nd strip | belt-shaped polarizing sheet 40, and is provided over the 2nd bonding apparatus 28 mentioned later from 2nd roll original fabric R2. .

  (8) The defect inspection is performed by the second defect inspection device 24 on the second strip-shaped polarizing sheet 40 fed out from the second roll raw fabric R2 (second inspection step: S13). Since this defect inspection mode is the same as that of the first defect inspection apparatus 14, a detailed description thereof will be omitted.

  (9) The 2nd strip | belt-shaped polarizing sheet 40 conveyed by the 2nd conveying apparatus 22 is cut | disconnected by the 2nd cutting device 26 at predetermined intervals, and the 2nd polarizing sheet piece F2 is produced | generated (2nd cutting process: S14). . The second cutting device 26 is configured to cut the second strip-shaped polarizing sheet 40 at a predetermined interval based on the defects included in the second strip-shaped polarizing sheet 40 detected in advance by the second defect inspection device 24. The same as the first cutting device 16. In addition, it is also possible to adopt a configuration in which a defect inspection is performed in advance at the stage of manufacturing the second roll raw fabric R2, and the second strip-shaped polarizing sheet 40 is cut at predetermined intervals based on the result of the defect inspection. This is the same as in the case of the single cutting device 16.

  (10) The second polarizing sheet piece F2 generated by cutting the second strip-shaped polarizing sheet 40 is bonded to the second surface of the display substrate W by the second bonding device 28 (second bonding step: S15). The mode of bonding by the second bonding apparatus 28 is the same as that of the first bonding apparatus 18. Prior to the bonding of the second polarizing sheet piece F2, the display substrate W having the first polarizing sheet piece F1 bonded to the first surface is rotated by 90 ° in the horizontal direction by the rotating device 20. . Thus, the polarization axes of the first polarizing sheet piece F1 and the second polarizing sheet piece F2 bonded to the display substrate W are in a state of being orthogonal to each other (so-called crossed Nicols relationship). However, the display substrate W is not limited to the configuration in which the display substrate W is rotated by 90 °, and the display substrate may be configured so that the first strip-shaped polarizing sheet 30 and the second strip-shaped polarizing sheet 40 are transported in directions orthogonal to each other. The first polarizing sheet piece F1 and the second polarizing sheet piece F2 bonded to W can be in a crossed Nicols relationship.

  (11) The optical display unit U manufactured by bonding the first polarizing sheet piece F1 and the second polarizing sheet piece F2 is inspected by an inspection device (not shown) (optical display unit inspection step: S16). ). Examples of the inspection method include a method of photographing and processing an image by irradiating both surfaces of the optical display unit U with light. A known technique can be applied to the image processing algorithm. For example, a defect can be detected by density determination by binarization processing.

  (12) The non-defective product of the optical display unit U is determined based on the defect information obtained by the inspection apparatus. The optical display unit U determined to be non-defective is conveyed to the next mounting process. On the other hand, when it is determined that the product is defective, the first polarizing sheet piece F1 and the second polarizing sheet piece F2 are bonded again in the above-described manner, and the rework processing is performed until it is determined to be a non-defective product. Is repeated.

  FIG. 4 shows a configuration of a manufacturing system of the optical display unit U according to the first embodiment of the present invention. In this embodiment, the conveyors 12 and 22 are provided with a belt 51 as a support, and the strip-shaped polarizing sheets 30 and 40 fed out from the rolls R1 and R2 are transferred to the outer surface of the belt 51. It can be transported by.

  The belt 51 is made of, for example, a rubber annular belt, and is wound around a plurality of rollers 52. The plurality of rollers 52 are provided side by side in the transport direction of the strip-shaped polarizing sheets 30 and 40, and are arranged in parallel to each other so as to extend in a direction orthogonal to the transport direction. A part of the outer surface of the belt 51 wound around the plurality of rollers 52 arranged in this way constitutes a conveyance path for the strip-shaped polarizing sheets 30 and 40.

  The strip-shaped polarizing sheets 30 and 40 fed out from the rolls R1 and R2 and conveyed are conveyed with the adhesive layers F14 and F24 facing the belt 51 side. Therefore, the pressure-sensitive adhesive layers F14 and F24 of the strip-shaped polarizing sheets 30 and 40 come into contact with the outer surface of the belt 51 and are transferred onto the belt-shaped polarizing sheets 30 and 40. Here, “transfer” is temporarily attached to the support (belt 51) and then peeled off from the support, and the adhesive layers F14 and F24 are not peeled off from the optical films F11 and F21. It means that it is conveyed in the state of.

  The outer surface of the belt 51 as the support has light release properties by being subjected to a mold release process. Accordingly, the pressure-sensitive adhesive layers F14 and F24 of the strip-shaped polarizing sheets 30 and 40 transferred to the outer surface of the belt 51 are easily peeled from the outer surface appropriately, and the strip-shaped polarizing sheets 30 and 40 are transported satisfactorily. Can do. As the mold release treatment, a mold release for improving the mold release properties such as silicone treatment and long chain alkyl treatment on the contact surface of the belt-like polarizing sheets 30 and 40 with the adhesive layers F14 and F24 on the outer surface of the belt 51. Processing can be performed.

  The belt 51 may be configured to rotate when at least one roller 52 is driven, or accompanying the conveyance of the strip-shaped polarizing sheets 30 and 40 transferred via the adhesive layers F14 and F24. May be configured to rotate. The support for transferring the adhesive layers F14 and F24 of the strip-shaped polarizing sheets 30 and 40 is not limited to a belt, and supports of various shapes such as a roller, a film, or a drum can be used. Even with such a configuration, the strip-shaped polarizing sheets 30 and 40 can be transported with a relatively simple configuration, so that the manufacturing cost of the optical display unit U can be effectively reduced. Such a support is preferably made of resin, rubber, metal, or the like, from the viewpoint of ease of mold release treatment or difficulty of cutting at the time of cutting described later.

  The roller as an example of the support is a rotatable support formed in a cylindrical shape, for example, and the adhesive layers F14 and F24 of the strip-shaped polarizing sheets 30 and 40 are transferred onto the outer surface thereof. The adhesive layers F14 and F24 are peeled off from the outer peripheral surface in a short time, so that the conveying direction of the strip-shaped polarizing sheets 30 and 40 is not changed. The drum which is an example of the support is, for example, a rotatable support formed in a cylindrical shape, and the adhesive layers F14 and F24 of the strip-shaped polarizing sheets 30 and 40 are transferred onto the outer surface of the drum. Although common to the rollers, the conveying direction of the strip-shaped polarizing sheets 30 and 40 changes (curves) when the adhesive layers F14 and F24 are transferred to the outer surface for a longer time than the rollers. ). The film as an example of the support is a support having a thickness smaller than that of the belt 51 and having flexibility.

  In the present embodiment, the cutting devices 16 and 26 cut the strip-shaped polarizing sheets 30 and 40 on the outer surface of the belt 51. This cutting is based on a mode (full cut) in which all the layers constituting the belt-like polarizing sheets 30 and 40 are cut, and the surface protective films F13 and F23, the adhesive layers F15 and F25, and the optical film F11. , F21 and the adhesive layers F14, F24 are completely cut. The defect inspection of the strip-shaped polarizing sheets 30 and 40 by the defect inspection devices 14 and 24 is performed before the transfer to the belt 51. The polarizing sheet pieces F1 and F2 generated by cutting the strip-shaped polarizing sheets 30 and 40 are bonded to the display substrate W by the bonding devices 18 and 28.

  As described above, in this embodiment, the belt-shaped polarizing sheets 30 and 40 are transported to the outer surface of the belt 51 having releasability by the adhesive layers F14 and F24, and the belt-shaped polarizing sheets 30 and 40 are transported. The optical display unit U can be manufactured by bonding the polarizing sheet pieces F1 and F2 generated by cutting at a predetermined interval to the display substrate W. As described above, the belt-shaped polarizing sheets 30 and 40 are transported in a state where the adhesive layers F14 and F24 are transferred to the belt 51, thereby preventing the belt-shaped polarizing sheets 30 and 40 being meandering from being conveyed, and the strip-shaped polarizing sheet 30. , 40 can be transported satisfactorily, and misalignment to the display substrate W can be prevented. Moreover, since it can convey with the simple structure using the belt 51, the manufacturing cost of the optical display unit U can be reduced.

  Further, the strip-shaped polarizing sheets 30 and 40 having the pressure-sensitive adhesive layers F14 and F24 on one surface were formed by being wound so as to be peeled without the release film being bonded to the pressure-sensitive adhesive layers F14 and F24. By using the rolls R1, R2, the release film can be omitted. Thereby, the manufacturing cost of roll original fabric R1, R2 can be reduced, and the manufacturing cost of the optical display unit U can be reduced by extension. Further, by omitting the release film having a relatively high rigidity, it is easy to manufacture the roll raw material by winding the belt-like polarizing sheets 30 and 40, and the belt-like polarizing sheet corresponding to the omitted release film. The number of turns of 30, 40 can be increased.

  Moreover, in this embodiment, since the strip | belt-shaped polarizing sheets 30 and 40 are cut | disconnected on the outer surface of the belt 51, the strip | belt-shaped polarizing sheets 30 and 40 can be cut | disconnected reliably. That is, the strip-shaped polarizing sheets 30 and 40 can be stably cut in a state where the belt-like polarizing sheets 30 and 40 are transferred onto the outer surface of the belt 51, and the cutting depth is slightly increased even when the cutting accuracy varies. By setting, it is possible to prevent a state where the strip-shaped polarizing sheets 30 and 40 cannot be completely cut (half cut state). The belt 51 is preferably formed of a difficult-to-cut flexible member.

  In the present embodiment, the width of the outer surface of the belt 51 is formed larger than the width of the band-shaped polarizing sheets 30 and 40. Thereby, in a state where the belt-like polarizing sheets 30 and 40 are transferred onto the outer surface of the belt 51 having a width larger than that of the belt-like polarizing sheets 30 and 40, the belt-like polarizing sheets 30 and 40 are stably spread over the entire width direction. Can be cut. However, the cutting devices 16 and 26 are not limited to the configuration that cuts the strip-shaped polarizing sheets 30 and 40 on the support such as the belt 51, but cuts the strip-shaped polarizing sheets 30 and 40 before or after the support. Such a configuration may be adopted.

(Second Embodiment)
FIG. 5 partially shows a configuration of a manufacturing system of the optical display unit U according to the second embodiment of the present invention. In this embodiment, the conveying devices 12 and 22 are provided with a plurality of belts as a support. In this example, two belts 61 and 62 are provided, and the strip-shaped polarizing sheets 30 and 40 fed out from the rolls R1 and R2 are sequentially transferred to the outer surfaces of the two belts 61 and 62 and conveyed. It has come to be.

  Each of the belts 61 and 62 is formed of, for example, a rubber annular belt, and is wound around a plurality of rollers 63. The plurality of rollers 63 are provided side by side in the conveyance direction of the strip-shaped polarizing sheets 30 and 40, and are arranged in parallel to each other so as to extend in a direction orthogonal to the conveyance direction. A part of the outer surface of each of the belts 61 and 62 wound around the plurality of rollers 63 arranged in this way constitutes a conveyance path for the belt-like polarizing sheets 30 and 40.

  The two belts 61 and 62 are arranged at intervals from each other along the conveying direction of the strip-shaped polarizing sheets 30 and 40. The strip-shaped polarizing sheets 30 and 40 fed out from the rolls R1 and R2 and conveyed are conveyed in a state where the adhesive layers F14 and F24 face the belts 61 and 62 side. Therefore, the pressure-sensitive adhesive layers F14 and F24 of the belt-like polarizing sheets 30 and 40 are sequentially brought into contact with the outer surfaces of the belts 61 and 62 during the transport process. The configurations of the belts 61 and 62 are the same as those of the belt 51 in the first embodiment, and a detailed description thereof will be omitted.

  In the present embodiment, the cutting devices 16 and 26 cut the strip-shaped polarizing sheets 30 and 40 between the two belts 61 and 62. This cutting is based on a mode (full cut) in which all the layers constituting the belt-like polarizing sheets 30 and 40 are cut, and the surface protective films F13 and F23, the adhesive layers F15 and F25, and the optical film F11. , F21 and the adhesive layers F14, F24 are completely cut. The defect inspection of the strip-shaped polarizing sheets 30 and 40 by the defect inspection devices 14 and 24 is performed before the belt 61. The polarizing sheet pieces F1 and F2 generated by cutting the strip-shaped polarizing sheets 30 and 40 are bonded to the display substrate W by the bonding devices 18 and 28.

  According to the configuration in which the strip-shaped polarizing sheets 30 and 40 are cut at a position different from the position where the belt-shaped polarizing sheets 30 and 40 are transferred onto the support such as a belt as in the present embodiment, the cutting device 16 and 26 supports the support. The band-shaped polarizing sheets 30 and 40 can be cut without being damaged. In addition, even if it is the structure which cut | disconnects the strip | belt-shaped polarizing sheets 30 and 40 on a support body like 1st Embodiment, when undulations, such as a groove | channel, are formed on a support body, it is strip | belt shape by the said undulation If the position where the polarizing sheets 30 and 40 are not transferred is the cutting position, the strip-shaped polarizing sheets 30 and 40 can be cut without damaging the support.

(Third embodiment)
FIG. 6 is a schematic side view partially showing the configuration of the manufacturing system of the optical display unit U according to the third embodiment of the present invention. In the present embodiment, the conveying devices 12 and 22 are provided with a roller 71 as a support. However, a distance L between the roller 71 and a position where the strip-shaped polarizing sheets 30 and 40 are peeled from the rolls R1 and R2. Is relatively short. Specifically, the distance L is set to be shorter than the length of the polarizing sheet pieces F1 and F2 to be generated by cutting the strip-shaped polarizing sheets 30 and 40 (length in the direction orthogonal to the width direction). Yes.

  The roller 71 is made of resin, rubber or metal, and the strip-shaped polarizing sheets 30 and 40 fed out from the rolls R1 and R2 are transferred to the outer surface of the roller 71 and conveyed. . That is, the strip-shaped polarizing sheets 30 and 40 fed out from the rolls R1 and R2 and transported are transported with the adhesive layers F14 and F24 facing the roller 71 side, The pressure-sensitive adhesive layers F14 and F24 of the strip-shaped polarizing sheets 30 and 40 are brought into contact with the outer surface of the roller 71 in the process of being conveyed and transferred.

  In this embodiment, the cutting devices 16 and 26 cut | disconnect the strip | belt-shaped polarizing sheets 30 and 40 on roll original fabric R1, R2. More specifically, the strip-shaped polarizing sheets 30 and 40 are cut at positions where the strip-shaped polarizing sheets 30 and 40 are peeled from the rolls R1 and R2. This cutting is based on a mode (full cut) in which all the layers constituting the belt-like polarizing sheets 30 and 40 are cut, and the surface protective films F13 and F23, the adhesive layers F15 and F25, and the optical film F11. , F21 and the adhesive layers F14, F24 are completely cut. As described above, when the distance L is set to be shorter than the length of the polarizing sheet pieces F1 and F2 that are to be generated by cutting the strip-shaped polarizing sheets 30 and 40, the strip-shaped polarizing sheets 30 and 40 are completely cut. The polarizing sheet pieces F1 and F2 generated by this can be transported satisfactorily. The polarizing sheet pieces F1 and F2 generated by cutting the strip-shaped polarizing sheets 30 and 40 are bonded to the display substrate W by the bonding devices 18 and 28.

  In this embodiment, the strip | belt-shaped polarizing sheets 30 and 40 can be cut | disconnected stably on roll original fabric R1, R2. That is, since it is not necessary to separately provide an apparatus for stably cutting the strip-shaped polarizing sheets 30 and 40 in a state of being transferred, the manufacturing system can be simplified, and the manufacturing cost of the optical display unit U can be further increased. Can be reduced.

  The optical display unit U manufactured according to the above embodiment can be applied to an optical display device such as a liquid crystal display device, an organic EL display device, or a PDP.

12 1st conveyance apparatus 14 1st fault inspection apparatus 16 1st cutting device 18 1st bonding apparatus 22 2nd conveyance apparatus 24 2nd defect inspection apparatus 26 2nd cutting apparatus 28 2nd bonding apparatus 30 1st strip | belt-shaped polarizing sheet 40 Second belt-shaped polarizing sheet 51 Belt 52 Roller 61 Belt 62 Belt 63 Roller 71 Roller F1 First polarizing sheet piece F2 Second polarizing sheet piece F14 First adhesive layer F24 Second adhesive layer R1 First roll original R2 First 2 rolls

Claims (9)

An optical display unit manufacturing system in which a polarizing sheet piece is bonded to a display substrate,
From a roll raw material formed by winding a strip-shaped polarizing sheet having a polarizer and having an adhesive layer on one side so as to be peeled off without the release film being bonded to the adhesive layer. , A transport device that feeds and transports the band-shaped polarizing sheet;
A cutting device for generating the polarizing sheet piece by cutting the strip-shaped polarizing sheet at a predetermined interval;
A bonding apparatus for bonding the polarizing sheet piece to the display substrate;
An optical display unit manufacturing system, wherein the transport device transports the strip-shaped polarizing sheet in a state where the pressure-sensitive adhesive layer of the strip-shaped polarizing sheet is transferred onto a support having releasability. .   2. The optical display unit manufacturing system according to claim 1, wherein the support having releasability includes at least one of a belt, a roller, a film, and a drum.   3. The optical display unit manufacturing system according to claim 1, wherein the cutting device cuts the strip-shaped polarizing sheet on the support having the releasability.   4. The system for manufacturing an optical display unit according to claim 3, wherein a width of the support having releasability is larger than a width of the band-shaped polarizing sheet.   The optical display unit manufacturing system according to claim 1 or 2, wherein the cutting device cuts the band-shaped polarizing sheet on the raw roll.   6. The optical display according to claim 1, wherein the cutting device cuts the strip-shaped polarizing sheet at a predetermined interval based on a defect included in the strip-shaped polarizing sheet detected in advance. Unit manufacturing system.   The system for producing an optical display unit according to claim 1, wherein a surface of the strip-shaped polarizing sheet opposite to the pressure-sensitive adhesive layer has releasability. A method of manufacturing an optical display unit in which a polarizing sheet piece is bonded to a display substrate,
From a roll raw material formed by winding a strip-shaped polarizing sheet having a polarizer and having an adhesive layer on one side so as to be peeled off without the release film being bonded to the adhesive layer. , A transporting step for feeding and transporting the belt-shaped polarizing sheet;
A cutting step of generating the polarizing sheet piece by cutting the strip-shaped polarizing sheet at a predetermined interval;
A bonding step of bonding the polarizing sheet piece to the display substrate,
In the transporting step, the strip-shaped polarizing sheet is transported in a state where the pressure-sensitive adhesive layer of the strip-shaped polarizing sheet is transferred onto a support having releasability. A belt-shaped polarizing sheet having a polarizer and having a pressure-sensitive adhesive layer on one surface is rolled out from a roll raw material, and the belt-shaped polarizing sheet is fed out to a support having releasability. It is a raw roll for laminating the polarizing sheet piece obtained by transporting the adhesive layer of the band-shaped polarizing sheet in a state of being transferred and cutting the band-shaped polarizing sheet at a predetermined interval to a display substrate. ,
A roll original fabric, wherein the strip-shaped polarizing sheet is formed by being releasably wound without a release film being bonded to the pressure-sensitive adhesive layer.

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