JP2012068641A - Optical display device manufacturing system and optical display device manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an optical display device manufacturing system and an optical display device manufacturing method which can excellently stick optical films onto both surfaces of a liquid crystal cell with a simpler configuration.SOLUTION: A first optical film F11 is sent out in a direction orthogonal to a width direction from a first roll raw fabric R1 on which the first optical film F11 is wound so that an absorption axis B1 is extended in the direction orthogonal to the width direction. The first optical film is then cut and stuck on one surface of a liquid crystal cell W. A second optical film F21 is sent out in a direction orthogonal to a width direction from a second roll raw fabric R2 on which the second optical film F21 is wound so that an absorption axis B2 is extended in the width direction. The second optical film is then cut and stuck on the other surface of the liquid crystal cell W. This structure can allow the first optical film F11 and the second optical film F21 to be stuck together in a crossed Nicol relationship without providing any mechanisms to rotate the liquid crystal cell W or the like.

Description

  The present invention relates to an optical display device manufacturing system and an optical display device for manufacturing an optical display device by feeding the optical film from a raw roll formed by winding the optical film and bonding the optical film to a liquid crystal cell. It relates to a manufacturing method.

  FIG. 6 conceptually shows a method of manufacturing an optical display device mounted on a conventional liquid crystal display device. First, an optical film manufacturer manufactures a long (band-like) optical film as a roll original (# 1). This specific manufacturing process is a known manufacturing process and will not be described. Examples of the roll original of the long (strip-shaped) optical film include, for example, a polarizing plate original used for a liquid crystal display device, a retardation plate original, a laminated film original of a polarizing plate and a retardation plate, and the like. Next, the raw roll is slit into a predetermined size (size according to the size of the liquid crystal cell) (# 2). Next, the slit raw material is cut to a fixed length in accordance with the size of the liquid crystal cell to be bonded (# 3). Next, an appearance inspection is performed on the optical film that has been cut into pieces (# 4). Examples of the inspection method include visual defect inspection and inspection using a known defect inspection apparatus. The defect means, for example, a surface or internal stain, scratch, a special defect such as a dent in which a foreign object is bitten (sometimes referred to as a knick), a bubble, a foreign object, or the like. Next, the finished product is inspected (# 5). The finished product inspection is an inspection that complies with quality standards that are more stringent than the appearance inspection. Next, end surfaces of the four end surfaces of the single-wafer optical film 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-wafer optical film is clean-wrapped (# 7). Next, packaging for transportation (transport packaging) (# 8). As described above, a single-wafer optical film is manufactured and transported to a panel processing manufacturer.

  The panel processing manufacturer packs and disassembles the single-sheet optical film 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 wafer optical film determined to be non-defective in the inspection is conveyed to the next process. Note that this appearance inspection may be omitted. The liquid crystal cell to which the single-wafer optical film is bonded is manufactured in advance, and the liquid crystal cell is washed before the bonding step (# 13).

  The sheet optical film and the liquid crystal cell are bonded together (# 14). The release film is peeled off from the sheet optical film leaving the pressure-sensitive adhesive layer, and is bonded to one surface of the liquid crystal cell using the pressure-sensitive adhesive layer as a bonding surface. Further, it can be similarly bonded to the other surface of the liquid crystal cell. When bonding to both surfaces, the optical film of the same structure may be bonded to each surface of a liquid crystal cell, and the optical film of a different structure may be bonded. Next, inspection and defect inspection of the optical display device with the optical film bonded are performed (# 15). The optical display device 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, a rework process is performed on the optical display device determined to be defective (# 17). The optical film is peeled from the liquid crystal cell by the rework process. An optical film is newly bonded to the reworked liquid crystal cell (# 14).

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

  As a method for solving this, Japanese Patent Laid-Open No. 2007-140046 (Patent Document 1) has been proposed. According to this method, a supply unit that draws and supplies an optical film from a roll raw material on which a belt-shaped optical film that is a member of an optical display device is wound, and a defect in the optical film drawn by the supply unit are detected. The optical film is cut based on the detection means, the detection result of the detection means, and processed into individual optical films, and the optical film cut by the cutting means is transferred for bonding. It comprises a transfer means, and an optical film transferred by the transfer means and a bonding processing means for bonding a liquid crystal cell which is a member of an optical display device, and these means are arranged on a continuous production line process. And In said structure, it cuts directly into a desired size from a strip | belt-shaped optical film, and this cut | disconnected optical film can be bonded together to a liquid crystal cell. Therefore, in the past, the strip-shaped optical film was punched out, the punched optical film was strictly packed, and the product was delivered to the panel processing manufacturer. Can be delivered.

  Japanese Patent Application Laid-Open No. 2005-37416 (Patent Document 2) discloses an example of a technique for cutting a band-shaped optical film (band-shaped film) as described above and bonding it to a liquid crystal cell (substrate). In this technique, a polarizing plate having a transmission axis oriented parallel to the film longitudinal direction and a polarizing plate having a transmission axis oriented perpendicular to the film longitudinal direction are used.

  In JP 2005-37417 A (Patent Document 3), when a strip-shaped optical film (band-shaped film) is cut and bonded to both surfaces of a liquid crystal cell (substrate), it is bonded to one surface of the liquid crystal cell. A configuration is disclosed in which the transmission axis direction of the film piece and the transmission axis direction of the film piece bonded to the other surface are oriented at right angles.

Japanese Patent Laid-Open No. 2007-140046 JP 2005-37416 A JP 2005-37417 A

  FIG. 5 is a schematic view showing an example of a possible mode of bonding the optical films F11 and F21 to the liquid crystal cell W. In this example, the first optical film F11 is bonded to one surface of the liquid crystal cell W, and the second optical film F21 is bonded to the other surface, so that the optical films F11 and F21 are formed on both surfaces of the liquid crystal cell W. Can be pasted together.

  The first optical film F11 is orthogonal to the width direction of the first optical film F11 from a first roll R1 formed by winding the first optical film F11 around the core A1. Sent out in the direction. Similarly, the second optical film F21 extends from the second roll original fabric R2 formed by winding the second optical film F21 around the core A2 in the width direction of the second optical film F21. On the other hand, it is sent out in the orthogonal direction. The first optical film F11 and the second optical film F21 have absorption axes B1 and B2 extending in a direction orthogonal to the width direction, that is, in the transport direction of the optical films F11 and F21, respectively. Only light that vibrates along B2 can be absorbed.

  First, the first optical film F11 is bonded to one surface of the liquid crystal cell W. The width along the core A1 of the first optical film F11 corresponds to the short side of the liquid crystal cell W, and the first optical film F11 is cut in the width direction at intervals corresponding to the long side of the liquid crystal cell W. As a result, the first optical film F11 having a shape corresponding to the liquid crystal cell W is formed. Then, after the cut first optical film F11 is bonded to one surface of the liquid crystal cell W, the liquid crystal cell W is rotated 90 ° in the horizontal direction by the panel rotation mechanism, and the second optical film is formed on the other surface. F21 is pasted.

  The width along the core A2 of the second optical film F21 corresponds to the long side of the liquid crystal cell W, and the second optical film F21 is cut in the width direction at intervals corresponding to the short side of the liquid crystal cell W. As a result, the second optical film F21 having a shape corresponding to the liquid crystal cell W is formed. The second optical film F21 cut in this way is bonded to the other surface of the liquid crystal cell W, whereby the liquid crystal cell W in which the optical films F11 and F21 are bonded to both surfaces is obtained.

  As described above, after the first optical film F11 is bonded to one surface of the liquid crystal cell W, the liquid crystal cell W is rotated 90 ° in the horizontal direction by the panel rotation mechanism, and the second optical film F21 is formed on the other surface. By adhering to each other, the absorption axes of the optical films F11 and F21 respectively bonded to both surfaces of the liquid crystal cell W can be made orthogonal to each other to have a crossed Nicols relationship.

  However, in the above aspect, since the panel rotation mechanism must be provided, there is a problem that the system becomes complicated. Further, since the optical films F11 and F21 cannot be bonded to both surfaces of the liquid crystal cell W at the same time, there is a problem that efficiency is poor. In particular, in the case of cutting at intervals corresponding to the long sides of the liquid crystal cell W like the first optical film F11 in the above example, the first roll original is used to obtain one cut first optical film F11. Since the time for sending the first optical film F11 from the anti-R1 becomes longer than the case of cutting at intervals corresponding to the short sides of the liquid crystal cell W, the efficiency is further worse.

  Patent Document 2 describes the orientation direction of the absorption axis in the polarizing plate to be bonded to one surface of the liquid crystal cell, but there is no description regarding the case in which the polarizing plate is bonded to both surfaces of the liquid crystal cell. The relationship between the absorption axes of the polarizing plates to be bonded to each other is not considered. Therefore, in the case where the polarizing plates are bonded to both surfaces of the liquid crystal cell, even if the technique as described in Patent Document 2 is used, it is not always possible to bond the film in a favorable manner with respect to the alignment direction of the absorption axis.

  Patent Document 3 discloses a configuration in which the absorption axis direction of a film piece bonded to one surface of a liquid crystal cell and the absorption axis direction of a film piece bonded to the other surface are oriented at right angles. However, the absorption axis direction in each film piece intersects the width direction of the optical film and the direction orthogonal to the width direction (see FIG. 3). Thus, when stretching (oblique stretching) so that the absorption axis intersects the width direction of the optical film and the direction perpendicular to the width direction, the speed ratio and magnification of the left and right tenters are precisely controlled. It is necessary to do this, and it is difficult to obtain the shaft accuracy. For this reason, when a polarizing plate with low axial accuracy is bonded so as to be aligned with the short side or the long side of the liquid crystal cell, the possibility of being bonded with the absorption axis shifted is very high. Contrast abnormality of the optical display device due to the shift is likely to occur.

  The present invention has been made in view of the above circumstances, and provides an optical display device manufacturing system and an optical display device manufacturing method capable of satisfactorily laminating an optical film on both surfaces of a liquid crystal cell with a simpler configuration. The purpose is to do. Another object of the present invention is to provide an optical display device manufacturing system and an optical display device manufacturing method capable of efficiently laminating an optical film on both surfaces of a liquid crystal cell.

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

  In the optical display device manufacturing system according to the first aspect of the present invention, the optical film is fed from a roll original formed by winding an optical film including a polarizer, and the optical film is cut in the width direction. Is an optical display device manufacturing system for manufacturing an optical display device by cutting into a predetermined size and bonding to a liquid crystal cell, the first optical film having a width corresponding to the long side or the short side of the liquid crystal cell A first conveying device that feeds the first optical film in the orthogonal direction from a first roll material formed by winding the film so that the absorption axis extends in a direction orthogonal to the width direction; An absorption axis extends in the width direction of a second optical film that is arranged so that the width direction is parallel to one roll original fabric and has the same width as the first optical film. A second transport device that feeds the second optical film in a direction orthogonal to the width direction from a second roll of the second roll formed by winding the first roll, and a first optical film fed by the first transport device A first cutting device that cuts the liquid crystal cell at an interval corresponding to a short side or a long side of the liquid crystal cell having the predetermined size, and a second optical film fed out by the second transport device at the same interval as the first optical film A second cutting device for cutting the first optical film, the first bonding device for bonding the cut first optical film to one surface of the liquid crystal cell, and the cut second optical film for the liquid crystal cell. It has the 2nd bonding apparatus bonded to the other surface, It is characterized by the above-mentioned.

  According to this configuration, the absorption axis of the first optical film sent from the first roll original fabric and cut and the second optical film sent from the second roll original fabric and cut are orthogonal to each other. In this way, it is bonded to both sides of the liquid crystal cell. Thereby, since the 1st optical film and 2nd optical film which are respectively bonded together on both surfaces of a liquid crystal cell can be made into a cross Nicol relation, without providing the mechanism for rotating a liquid crystal cell, etc., it is simpler. The optical film can be satisfactorily bonded to both surfaces of the liquid crystal cell with the configuration.

  In particular, the first optical film is wound so that the absorption axis extends in a direction orthogonal to the width direction, and the second optical film is wound so that the absorption axis extends in the width direction. It is easy to align the absorption axis and the long side or short side of the liquid crystal cell. For this reason, the possibility that the absorption axis is shifted when the optical film is bonded to the liquid crystal cell is low, and the contrast abnormality of the optical display device due to the shift of the absorption axis hardly occurs. Can be better bonded.

  In the optical display device manufacturing system according to the second aspect of the present invention, the first bonding device is a period in which the first optical film is bonded to the one surface of the liquid crystal cell, and the second bonding device is the liquid crystal. The period of pasting the second optical film on the other surface of the cell is at least partially overlapped.

  According to this configuration, the first optical film and the second optical film can be bonded to both surfaces of the liquid crystal cell in parallel for at least a predetermined period. Thereby, since the first optical film and the second optical film can be bonded simultaneously or continuously in a state where the alignment of the liquid crystal cell is performed, the first optical film and the second optical film are separately provided. Unlike the case of bonding, it is not necessary to align the liquid crystal cells at the time of bonding. Therefore, the number of alignment devices can be reduced, and the optical film can be satisfactorily bonded to both surfaces of the liquid crystal cell with a simpler configuration.

  In the optical display device manufacturing system according to the third aspect of the present invention, the width of the first optical film and the width of the second optical film are lengths corresponding to the long sides of the liquid crystal cell, respectively. And

  According to this configuration, the first optical film and the second optical film are cut at intervals corresponding to the short sides of the liquid crystal cell, and the cut optical films are bonded to both surfaces of the liquid crystal cell. The optical film and the second optical film can be in a crossed Nicols relationship. Thereby, in order to obtain one cut | disconnected 1st optical film, the time which sends out a 1st optical film from a 1st roll original fabric, and the 2nd roll original fabric in order to obtain the cut | disconnected 2nd optical film Since the time for feeding out the second optical film can be made shorter than in the case of cutting at intervals corresponding to the long sides of the liquid crystal cell, the optical film can be efficiently bonded to both surfaces of the liquid crystal cell.

  In this case, it is preferable that the interval at which the first cutting device cuts the first optical film is equal to the interval at which the second cutting device cuts the second optical film, and the interval is shorter than the width. .

  In the optical display device manufacturing system according to the fourth aspect of the present invention, the width of the first optical film and the width of the second optical film are respectively lengths corresponding to the short sides of the liquid crystal cell. And

  According to this configuration, the first optical film and the second optical film are cut at intervals corresponding to the long sides of the liquid crystal cell, and the cut optical films are bonded to both surfaces of the liquid crystal cell. The optical film and the second optical film can be in a crossed Nicols relationship. As described above, the widths of the first optical film and the second optical film may be the length corresponding to the long side of the liquid crystal cell or the length corresponding to the short side as long as they are the same. May be.

  In the optical display device manufacturing system according to a fifth aspect of the present invention, the first optical film is bonded to the front surface of the liquid crystal cell when the optical display device is viewed, and the second optical The film is bonded to a surface which becomes a back side when the optical display device is visually recognized.

  According to this configuration, the contrast of the optical display device can be effectively improved.

  An optical display device manufacturing system according to a sixth aspect of the present invention includes a film alignment device that performs relative alignment between the first optical film and the second optical film.

  According to this configuration, the first optical film and the second optical film can be relatively aligned, and they can be bonded to the liquid crystal cell with a crossed Nicol relationship with higher accuracy. Therefore, the optical film can be better bonded to both surfaces of the liquid crystal cell.

  In the optical display device manufacturing method according to the seventh aspect of the present invention, the optical film is fed out from a roll raw material formed by winding an optical film including a polarizer, and the optical film is cut in the width direction. An optical display device manufacturing method for manufacturing an optical display device by cutting into a predetermined size and bonding to a liquid crystal cell, wherein the first optical film has a width corresponding to the long side or the short side of the liquid crystal cell A first conveying step of feeding the first optical film in the orthogonal direction from a first roll raw material formed by winding the film so that an absorption axis extends in a direction orthogonal to the width direction; The second optical film having the same width as that of the first optical film is arranged so that the absorption axis extends in the width direction with respect to the original roll. A second transport step for feeding out the second optical film in a direction orthogonal to its width direction from the second roll original formed by winding, and a first optical film sent out by the first transport step A first cutting step for cutting at a distance corresponding to a short side or a long side of the liquid crystal cell having the predetermined size, and a second optical film sent out by the second conveying step at the same interval as the first optical film. A second cutting step for cutting, a first bonding step for bonding the cut first optical film to one surface of the liquid crystal cell; and the other of the liquid crystal cell for cutting the second optical film. And a second bonding step for bonding to the surface.

  According to this configuration, it is possible to provide an optical display device manufacturing method that exhibits the same effect as the optical display device manufacturing system according to the first aspect of the present invention.

  In the optical display device manufacturing method according to the eighth aspect of the present invention, in the first bonding step, the first optical film is bonded to the one surface of the liquid crystal cell, and the liquid crystal is used in the second bonding step. The period of pasting the second optical film on the other surface of the cell is at least partially overlapped.

  According to this configuration, it is possible to provide an optical display device manufacturing method that exhibits the same effect as the optical display device manufacturing system according to the second aspect of the present invention.

  In the optical display device manufacturing method according to the ninth aspect of the present invention, the width of the first optical film and the width of the second optical film are lengths corresponding to the long sides of the liquid crystal cell, respectively. And

  According to this configuration, it is possible to provide an optical display device manufacturing method that exhibits the same effects as those of the optical display device manufacturing system according to the third aspect of the present invention.

  In the optical display device manufacturing method according to the tenth aspect of the present invention, the width of the first optical film and the width of the second optical film are lengths corresponding to the short sides of the liquid crystal cell, respectively. And

  According to this configuration, it is possible to provide an optical display device manufacturing method that exhibits the same effect as the optical display device manufacturing system according to the fourth aspect of the present invention.

  In the optical display device manufacturing method according to an eleventh aspect of the present invention, the first optical film is bonded to a surface on the front side when the optical display device is viewed with respect to the liquid crystal cell. The film is bonded to a surface which becomes a back side when the optical display device is visually recognized.

  According to this configuration, it is possible to provide an optical display device manufacturing method that exhibits the same effect as the optical display device manufacturing system according to the fifth aspect of the present invention.

  An optical display device manufacturing method according to a twelfth aspect of the present invention includes a film alignment step of performing relative alignment between the first optical film and the second optical film.

  According to this configuration, it is possible to provide an optical display device manufacturing method that exhibits the same effect as the optical display device manufacturing system according to the sixth aspect of the present invention.

Flowchart of manufacturing method of optical display device of embodiment 1 The figure for demonstrating an example of the laminated structure of a 1st, 2nd optical film Schematic showing one configuration example for bonding an optical film to a liquid crystal cell Schematic diagram for explaining the bonding mode of the optical film to the liquid crystal cell The schematic diagram which showed an example of the aspect considered as a bonding aspect of the optical film with respect to a liquid crystal cell A flowchart of a conventional method for manufacturing an optical display device

(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 device according to the first embodiment. As another embodiment of the manufacturing system of the first embodiment, a configuration that does not include the first and second defect inspection apparatuses can be exemplified.

(Liquid crystal cell)
First, examples of the liquid crystal cell used in the present invention include a glass substrate unit, an organic EL light emitting unit and the like. The liquid crystal cell is formed in a rectangular shape, for example.

(Optical film)
The optical film to be bonded to the liquid crystal cell may be a laminated film in which other films such as a retardation film and a brightness enhancement film are combined as long as it includes a polarizer (polarizer film). A protective transparent film may be laminated on the surface of the optical film. Moreover, an adhesive layer is formed on one surface of the optical film so as to be attached to the liquid crystal cell, and a release film for protecting the adhesive layer is provided. Moreover, a surface protective film is provided on the other surface of the optical film via an adhesive layer. Specific configurations of these films will be described later. Hereinafter, an optical film in which a surface protective film and a release film are laminated via an adhesive layer may be referred to as a sheet product.

(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 of a liquid crystal cell. As shown in FIG. 2, the laminated structure of the first sheet product F1 includes a first optical film F11, a first release film F12, and a surface protective film F13. The first optical film 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 liquid crystal cell surface side via the first pressure-sensitive adhesive layer 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. Below, the laminated structure of a polarizer and a polarizer protective film may be called a polarizing plate.

  The width of the first roll original fabric or the width of the second roll original fabric described later “depends on the bonding size of the liquid crystal cell” means the size of either the long side or the short side of the liquid crystal cell Means to match. “Adjust to the size of either the long side or the short side of the liquid crystal cell” means that the length of the optical film bonded to the length of the long side or the short side of the liquid crystal cell (the length excluding the exposed part) The length of the long side or the short side of the liquid crystal cell and the width of the first roll original fabric or the second roll original fabric need not be the same.

  Each of the following processes is performed in an isolation structure isolated in the factory, and the cleanliness is maintained. In particular, it is preferable that the cleanliness is maintained in the bonding step of bonding the optical film to the liquid crystal cell.

  (2) Transport process (FIG. 1, S2: first transport step). The first sheet material F1 is fed out from the first roll stock prepared and installed, and is conveyed downstream.

  (3) First inspection step (FIG. 1, S3). The first sheet product F1 is inspected for defects using the first defect inspection apparatus. The defect inspection method here includes a method of photographing and processing images with transmitted light and reflected light on both sides of the first sheet product F1, and an inspection polarizing film between the CCD camera and the inspection object. A method of taking an image and processing an image by arranging it so that it is in crossed Nicols with the absorption axis of the target polarizing plate (sometimes referred to as 0 degree cross), and a polarizing film for inspection between the CCD camera and the inspection object In addition, an image is photographed and image-processed by being arranged (sometimes referred to as an x-degree cross) so as to be at a predetermined angle (for example, a range greater than 0 degree and within 10 degrees) with the absorption axis of the polarizing plate to be inspected. A method is mentioned. 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 is linked with the position information (for example, position coordinates), transmitted to the control apparatus, and can contribute to the cutting method by the first cutting apparatus described later. .

  (4) First cutting step (FIG. 1, S4: first cutting step). The first cutting device cuts the surface protective film F13, the pressure-sensitive adhesive layer F15, the first optical film F11, and the first pressure-sensitive adhesive layer F14 into a predetermined size without cutting the first release film F12. 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, it is configured to cut away from the defect so that the defect is not included in the region bonded to the liquid crystal cell W. Thereby, the yield of the first sheet product F1 is greatly improved. As described above, a method of cutting while avoiding the defect so as not to include the defect in the region bonded to the liquid crystal cell W is called a skip cut. However, defect information at the time of cutting is obtained by an inline defect inspection apparatus. Or may have been previously applied to the roll. The first sheet product F <b> 1 including the defect is excluded by a first rejection device described later, and is not attached to the liquid crystal cell W.

  It is preferable that each process of these 1st roll original fabric preparation processes, a 1st inspection process, and a 1st cutting process is made into the continuous production line. In the series of manufacturing steps described above, the cut first optical film F11 for bonding to one surface of the liquid crystal cell W is formed. Below, the process of forming the cut | disconnected 2nd optical film F21 for bonding to the other surface of the liquid crystal cell W is demonstrated. In addition, the process of forming these cut | disconnected 1st optical film F11 and 2nd optical film F21, respectively is performed in parallel.

  (5) 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. 2, the laminated structure of the second sheet product F2 has the same configuration as that of the first sheet product, but is not limited thereto. The second sheet product F2 includes a second optical film F21, a second release film F22, and a surface protection film F23. The second optical film 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 liquid crystal cell 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.

  (6) Transport process (FIG. 1, S12: second transport step). The second sheet material F2 is fed out from the prepared and installed second roll, and is conveyed downstream.

  (7) Second inspection step (FIG. 1, S13). A defect of the second sheet product F2 is inspected using a second defect inspection apparatus. The defect inspection method here is the same as the method using the first defect inspection apparatus described above.

  (8) Second cutting step (FIG. 1, S14: second cutting step). The second cutting device cuts the surface protective film F23, the pressure-sensitive adhesive layer F25, the second optical film F21, and the second pressure-sensitive adhesive layer F24 into a predetermined size without cutting the second release film F22. Examples of the cutting means include a laser device, a cutter, and other known cutting means. Based on the defect information obtained by the second defect inspection apparatus, it is configured so as to avoid the defect and cut the defect so that the defect is not included in the region bonded to the liquid crystal cell W. Thereby, the yield of the second sheet product F2 is greatly improved. The second sheet product F <b> 2 including the defect is excluded by a second rejection device described later, and is not attached to the liquid crystal cell W.

  The process of conveying the liquid crystal cell W is performed in parallel with the process of forming the cut first optical film F11 and the second optical film F21 as described above. The liquid crystal cell W is subjected to the following processing during its conveyance.

  (9) Cleaning step (FIG. 1, S6). The surface of the liquid crystal cell W is cleaned by polishing cleaning, water cleaning, or the like.

  (10) Liquid crystal cell alignment step (FIG. 1, S5). The liquid crystal cell W is aligned by a panel alignment device so as to be conveyed at a predetermined position.

  In this embodiment, the cut | disconnected 1st optical film F11 and 2nd optical film F21 are bonded in the following aspects on both surfaces of the liquid crystal cell W conveyed as mentioned above, respectively. ing.

  (11) Optical film alignment step (FIG. 1, S15: film alignment step). The first optical film F11 is aligned by a first film alignment device, and the second optical film F21 is aligned by a second film alignment device so as to be conveyed at predetermined positions. By this step, relative alignment between the first optical film F11 and the second optical film F21 is realized. The optical film alignment process is not limited to the configuration performed after the first cutting process and the second cutting process, but is performed before or in parallel with the first cutting process and the second cutting process. Such a configuration may be adopted.

  (12) Optical film bonding process (FIG. 1, S16: 1st bonding step, 2nd bonding step). After the first release film F12 is removed by the first peeling device, the cut first optical film F11 is applied to one surface of the liquid crystal cell W via the first adhesive layer F14 by the first bonding device. Bonding is performed (first bonding step). In addition, after the second release film F22 is removed by the second peeling device, the second optical film F21 that has been cut is removed from the other liquid crystal cell W by the second bonding device via the second adhesive layer F24. It is bonded to the surface (second bonding step). In other words, the bonding step including the first bonding step and the second bonding step is performed by the bonding device including the first bonding device and the second bonding device. Thereby, the optical films F11 and F21 are bonded to both surfaces of the liquid crystal cell W.

  (13) Inspection step of the optical display device (FIG. 1, S17). The inspection device inspects an optical display device in which an optical film is attached to both surfaces of the liquid crystal cell W. Examples of the inspection method include a method of taking an image and processing an image using reflected light on both sides of the optical display device. 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.

  (14) A non-defective product of the optical display device is determined based on the defect information obtained by the inspection device. The optical display device 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 device can be suitably manufactured by making the bonding step of the first optical film F11 and the bonding step of the second optical film F21 into a continuous production line.

(Another embodiment of skip cut)
Further, another embodiment of the first cutting step and the second cutting step will be described below. 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 products is coded in a predetermined pitch unit (for example, 1000 mm). It may be attached as information (for example, QR code, barcode). In such a case, before the cutting, the code information is read and analyzed, and cut into a predetermined size in the first and second cutting steps so as to avoid the defective portion. Then, the part including the defect is removed or bonded to a member that is not a liquid crystal cell, and a non-defective sheet product cut to a predetermined size is bonded to the liquid crystal cell. Thereby, the yield of optical film F11, F21 is improved significantly.

(Suitable manufacturing system for realizing the manufacturing method of Embodiment 1)
Below, an example of the suitable manufacturing system which implement | achieves the manufacturing method of Embodiment 1 is demonstrated.

  Various devices that realize the manufacturing method of Embodiment 1 are isolated from the outside by an isolation structure. The inside surrounded by the isolation structure is kept clean compared to the outside. The isolation structure is composed of a transparent material wall and a framework structure. A blower is installed on the ceiling of the isolation structure. The blower device includes a HEPA filter and blows air with high cleanness into the partition wall structure. An air discharge opening for discharging the internal air to the outside is provided at the bottom of the wall surface of the partition wall structure. In addition, a filter can be provided on the opening surface to prevent intruders from the outside. With this partition wall structure and blower, the entire manufacturing system can be maintained in a clean environment, and foreign matters can be suitably prevented from entering. Further, since only the manufacturing system is isolated from the outside by the partition wall structure, the entire factory does not need to be a so-called clean room.

  First, the polishing cleaning apparatus will be described. The liquid crystal cell W is taken out from the storage box and placed on the transport mechanism. When the liquid crystal cell W reaches the cleaning position, the conveyance is stopped and the end of the liquid crystal cell W is held by the holding means. The polishing means is brought into contact with the upper surface of the liquid crystal cell W from above and the other polishing means is brought into contact with the lower surface of the liquid crystal cell from below. The respective polishing means are rotated on both surfaces of the liquid crystal cell W. As a result, the adhered foreign matter on both surfaces of the liquid crystal cell W is removed. Examples of the adhering foreign matter include glass fine pieces, fiber pieces, and the like.

  Next, the water cleaning device will be described. The liquid crystal cell W that has been polished and cleaned is transferred to a water bath by a transfer mechanism, where it is cleaned with water. Pure water flows inside the bath. Both surfaces of the liquid crystal cell W conveyed from the water bath are washed with pure water flowing out from the flowing water pipe. Next, the liquid crystal cell W is drained by blowing clean air from a drying device. As another embodiment, it is possible to wash with an aqueous ethanol solution instead of pure water. In another embodiment, the water bath can be omitted.

  FIG. 3 is a schematic diagram showing a configuration example for bonding the optical films F11 and F21 to the liquid crystal cell W. Hereinafter, various devices will be described in order with reference to FIG.

  The liquid crystal cell W cleaned as described above is aligned by the panel alignment apparatus 10 in the process of being transported, and then the optical films F11 and F21 are bonded to both surfaces thereof. The panel alignment apparatus 10 includes, for example, one or a plurality of rollers for transporting the liquid crystal cell W and an edge detection unit for detecting the edge of the liquid crystal cell W. The panel alignment apparatus 10 causes the liquid crystal cell W to meander by tilting the roller based on the detection result of the edge of the liquid crystal cell W by the edge detection unit, and sets the liquid crystal cell W to a predetermined position. Align so that it is transported.

  The first roll raw material R1 of the long first sheet product F1 is installed on a roller mount device that is linked to a motor or the like so as to rotate freely or at a constant rotational speed. The rotational speed is set by the control device, and the drive is controlled.

  The first conveying device 12 is a conveying mechanism that conveys the first sheet product F1 to the downstream side. The first conveying device 12 includes a number of conveying rollers, and the first sheet product F1 is conveyed along a conveying path formed by these conveying rollers. The said conveyance path is extended from the 1st roll original fabric R1 to the 1st bonding apparatus 18. FIG. The first transport device 12 is controlled by a control device.

  The first defect inspection device 14 performs defect inspection after the first release film F12 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 cutting device 16 cut | disconnects the 1st optical film F11 sent out by the 1st conveying apparatus 12, and in this example, without cut | disconnecting the 1st release film F12, 1st optical film F11, surface The protective film F13, the first pressure-sensitive adhesive layer F14, and the pressure-sensitive adhesive layer F15 are cut into a predetermined 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 while avoiding the defect portion so as not to include the defect in the region bonded to the liquid crystal cell W. To do. That is, the cut product including the defective portion is rejected as a defective product by the first rejecting device 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. The control in this case also depends on the function of the control device.

  The first film alignment device 19 aligns the first optical film F11. The first film alignment device 19 includes, for example, one or a plurality of rollers for conveying the first optical film F11, and an edge detection unit for detecting the edge of the cut first optical film F11. ing. The first film alignment device 19 causes the first optical film F11 to meander by tilting the roller based on the detection result of the edge of the first optical film F11 by the edge detection unit, and the first optical film. F11 is aligned so that a predetermined position is conveyed.

  In order to satisfactorily align the first optical film F11, the edge detector preferably detects the edge of the tip of the first optical film F11, and the roller is the tip of the first optical film F11. It is preferable to meander the first optical film F11 to some extent on the front side. Therefore, it is preferable that the edge detection unit is provided after the first cutting device 16 and the roller is provided before the first cutting device 16.

  The 1st bonding apparatus 18 is cut | disconnected by the 1st cutting device 16, and the 1st adhesion of the 1st sheet product F1 (1st optical film F11) from which the 1st release film F12 was peeled by the 1st peeling apparatus 17 is 1st adhesion. It is bonded to one surface (in this example, the upper surface) of the liquid crystal cell W via the agent layer F14. In the case of bonding, the first optical film F11 is bonded to the liquid crystal cell W surface while being pressed by a pressing roller and a guide roller. The pressing pressure and driving operation of the pressing roller and guide roller are controlled by a control device.

  As a peeling mechanism of the first peeling device 17, the first sheet product after peeling the first release film F12 and peeling the first release film F12 by reversing and transferring the first release film F12. It is configured to send F1 (first optical film F11) to the liquid crystal cell 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 first release film F12 and / or the liquid crystal cell W surface after the first release film F12 is peeled off from the first optical film F11. By performing the time until the pressure contact is made within 3 seconds, the bonding accuracy of the first optical film F11 can be improved. If the tension is less than 150 N / m, the delivery position of the first optical film F11 is not stable, and if it is more than 1000 N / m, the first release film F12 may be stretched and broken, and the time until press contact is 3 seconds. If it is longer, the end portion of the first optical film F11 peeled from the first release film F12 may be bent and folds or bubbles may be generated. The peeled first release film F12 is wound up on a roll. Roll winding control is controlled by a control device.

  The laminating mechanism is composed of a pressing roller and a guide roller arranged to face the pressing roller. The guide roller is composed of a rubber roller that is rotationally driven by a motor, and is arranged to be movable up and down. In addition, a pressing roller made of a metal roller that is rotationally driven by a motor is disposed directly above it. When the liquid crystal cell W is sent to the bonding position, the pressing roller is raised to a position higher than the upper surface so as to open a roller interval. Note that the guide roller and the pressing roller may both be rubber rollers or metal rollers. As described above, the liquid crystal cell W is cleaned by various cleaning devices and is transported by the transport mechanism. The transport control of the transport mechanism is also controlled by the control device.

  Although not shown in FIG. 3, a first rejection apparatus that eliminates the first sheet product F <b> 1 including a defect will be described. When the first sheet product F1 including the defect is conveyed to the bonding position, the guide roller moves vertically downward. Next, the roller around which the removal film is stretched moves to a fixed position of the guide roller. The first sheet product F1 including the defect is adhered to the removal film by moving the pressing roller vertically downward to press the first sheet product F1 including the defect against the removal film. Wind F1 on a roller. The removal film can stick the first sheet product F1 including the defects by using the adhesive force of the first adhesive layer F14 of the first sheet product F1, but an adhesive tape is used as the removal film. It is also possible to do.

  The second optical film F21 (second sheet product F2) is bonded in the same manner to the other surface of the liquid crystal cell W in which the first optical film F11 is bonded to one surface as described above. In the following, the description of the same device configuration will be briefly described.

  The second roll material R2 of the long second sheet product F2 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 rotational speed is set by the control device, 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 conveying device 22 includes a large number of conveying rollers, and the second sheet product F2 is conveyed along a conveying path formed by these conveying rollers. The said conveyance path is extended from the 2nd roll original fabric R2 to the 2nd bonding apparatus 28. FIG. The second transport device 22 is controlled by the control device, and the transport speed is set to be the same as the transport speed of the first transport device 12.

  The second defect inspection device 24 performs defect inspection after the second release film F22 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 cutting device 26 cut | disconnects the 2nd optical film F21 sent out by the 2nd conveying apparatus 22, and in this example, without cut | disconnecting the 2nd release film F22, 2nd optical film F21, surface The protective film F23, the second pressure-sensitive adhesive layer F24, and the pressure-sensitive adhesive layer F25 are cut into a predetermined 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 while avoiding the defect portion so as not to include the defect in the region bonded to the liquid crystal cell W. To do. That is, the cut product including the defective portion is rejected by the second rejecting device as a defective product in a subsequent 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. The control in this case also depends on the function of the control device.

  The second film alignment device 29 aligns the second optical film F21. The second film alignment device 29 includes, for example, one or a plurality of rollers for conveying the second optical film F21, and an edge detection unit for detecting the edge of the cut second optical film F21. ing. The second film alignment device 29 causes the second optical film F21 to meander by tilting the roller based on the detection result of the edge of the second optical film F21 by the edge detection unit, and the second optical film. F21 is aligned so that a predetermined position is conveyed.

  In order to satisfactorily align the second optical film F21, the edge detector preferably detects the edge of the tip of the second optical film F21, and the roller is the tip of the second optical film F21. It is preferable that the second optical film F21 meanders to some extent on the near side. Therefore, it is preferable that the edge detection unit is provided after the second cutting device 26 and the roller is provided before the second cutting device 26.

  The 2nd bonding apparatus 28 is cut | disconnected by the 2nd cutting apparatus 26, and the 2nd adhesion | attachment was made into the 2nd adhesion of the 2nd sheet product F2 (2nd optical film F21) from which the 2nd release film F22 was peeled off. It is bonded to the other surface (the lower surface in this example) of the liquid crystal cell W via the agent layer F24. In the case of bonding, the second optical film F21 is bonded to the liquid crystal cell W surface while being pressed by a pressing roller and a guide roller. The pressing pressure and driving operation of the pressing roller and guide roller are controlled by a control device.

  As the peeling mechanism of the second peeling device 27, the second release film F22 is reversed and transferred to peel the second release film F22 and the second sheet product after the second release film F22 is peeled off. It is configured to send F2 (second optical film F21) to the liquid crystal cell W surface. At this time, the state in which a tension of 150 N / m or more and 1000 N / m or less is applied to the second release film F22 and / or the liquid crystal cell W surface after the second release film F22 is peeled off the second optical film F21. By performing the time until the pressure contact is made within 3 seconds, the bonding accuracy of the second optical film F21 can be improved. If the tension is less than 150 N / m, the delivery position of the second optical film F21 is not stable, and if it is more than 1000 N / m, the second release film F22 may be stretched and broken, and the time until press contact is 3 seconds. If it is longer, the end portion of the first optical film F21 peeled from the second release film F22 may be bent and folds or bubbles may be generated. The peeled second release film F22 is wound up on a roll. Roll winding control is controlled by a control device.

  The laminating mechanism is composed of a pressing roller and a guide roller disposed opposite to the pressing roller. The guide roller is composed of a rubber roller that is rotationally driven by a motor, and is arranged to be movable up and down. In addition, a pressing roller made of a metal roller that is rotationally driven by a motor is disposed directly below it. When the liquid crystal cell W is sent to the bonding position, the pressing roller is moved to a lower position so as to open a roller interval. Note that the guide roller and the pressing roller may both be rubber rollers or metal rollers.

  Although not shown in FIG. 3, a second rejection apparatus that eliminates the second sheet product F <b> 2 including the defect will be described. When the second sheet material F2 including the defect is conveyed to the bonding position, the guide roller moves vertically upward. Next, the roller around which the removal film is stretched moves to a fixed position of the guide roller. By moving the pressing roller vertically upward, the second sheet product F2 including the defect is pressed against the removal film, the second sheet product F2 is attached to the removal film, and the second sheet product including the defect together with the removal film. Wind F2 around the roller.

  The optical display device formed by bonding the first and second sheet products to the liquid crystal cell W is transported to the inspection device. The inspection device performs an inspection on both sides of the optical display device that has been conveyed. The light source irradiates the upper surface of the optical display device vertically by the half mirror, and the reflected light image is captured as image data by the CCD camera. Another light source irradiates the surface of the optical display device at a predetermined angle, and a reflected light image is captured as image data by a CCD camera. Inspection of the opposite surface of the optical display device is similarly performed using a light source and a CCD camera. Defects are subjected to image processing analysis from these image data, and non-defective products are determined.

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

  In the present embodiment, the first film alignment device 19 and the second film alignment device 29 constitute a film alignment device that performs relative alignment between the first optical film F11 and the second optical film F21. Yes. In this example, the first optical film F11 and the second optical film F21 that have been cut are aligned so that the tips of the first optical film F11 and the second optical film F21 are simultaneously guided to the same position in plan view, whereby the first optical film is aligned with the liquid crystal cell W. The film F11 and the second optical film F21 are bonded together at the same time.

  However, the period during which the first bonding device 18 bonds the first optical film F11 to one surface of the liquid crystal cell W, and the second bonding device 28 bonds the second optical film F21 to the other surface of the liquid crystal cell W. As long as at least a part of the period to be combined overlaps, it is not necessary to have a configuration in which they are bonded together as described above. According to the configuration in which the above periods partially overlap, the first optical film F11 and the second optical film F21 can be bonded to both surfaces of the liquid crystal cell W in parallel for at least a predetermined period. Accordingly, the first optical film F11 and the second optical film F21 can be bonded simultaneously or continuously in a state where the alignment of the liquid crystal cell W is performed. Therefore, the first optical film F11 and the second optical film Unlike the case where the films F21 are bonded separately, it is not necessary to align the liquid crystal cell W in each bonding. Therefore, the number of alignment devices can be reduced, and the optical films F11 and F21 can be satisfactorily bonded to both surfaces of the liquid crystal cell W with a simpler configuration. It should be noted that the present invention is not limited to a configuration in which the respective periods partially overlap, and a configuration in which the respective periods do not overlap may be employed.

(Another embodiment of the manufacturing system)
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 product. The automatic inspection apparatus emits light, and the reflected light image and the transmitted light image are image sensors such as a line sensor and 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 absorption axis of the inspection polarizing filter is arranged so as to be in a state (crossed Nicols) orthogonal to the 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.

  In the above-described cutting step, a method (half-cut method) for cutting other members of the sheet product without cutting the release film has been described. According to such a configuration, the optical film and the pressure-sensitive adhesive layer are cut without cutting the release film bonded to the optical film via the pressure-sensitive adhesive layer, and before the bonding process to the liquid crystal cell. The release film can be peeled from the optical film. That is, since the pressure-sensitive adhesive layer that is the bonding surface of the optical film can be configured not to be exposed until just before the bonding, it is possible to prevent foreign matters from being mixed into the bonding surface of the optical film.

  In particular, by cutting the optical film and the pressure-sensitive adhesive layer without cutting the release film, the cut optical film and the pressure-sensitive adhesive layer can be transported using the release film as a carrier. Therefore, since the optical film transport device can be made simpler, the manufacturing cost of the optical display device can be further reduced.

  FIG. 4 is a schematic diagram for explaining a bonding mode of the optical films F11 and F21 to the liquid crystal cell W. The 1st optical film F11 and the 2nd optical film F21 consist of a stretched film stretched | stretched so that only the light which vibrates along absorption axis B1, B2 can each be allowed to pass through.

  The first roll original fabric R1 is formed by winding the first optical film F11 (first sheet product F1) so that the absorption axis B1 extends in a direction orthogonal to the width direction along the core A1. Yes. The width of the first optical film F11 along the core A1 of the first roll original fabric R1 is a length corresponding to the long side of the liquid crystal cell W. The 1st conveyance apparatus 12 sends out the 1st optical film F11 from this 1st roll original fabric R1 in the orthogonal direction with respect to the width direction. Then, the fed first optical film F11 is cut in the width direction at intervals corresponding to the short sides of the liquid crystal cell W, so that the first optical film F11 cut into a rectangular shape corresponding to the liquid crystal cell W is obtained. Is formed.

  On the other hand, the 2nd roll original fabric R2 is the 2nd optical so that absorption axis B2 may extend in the direction parallel to the width direction along core A2, ie, the direction orthogonal to absorption axis B1 of the 1st optical film F11. It is formed by winding a film F21 (second sheet product F2). The width of the second optical film F21 along the core A2 of the second roll original fabric R2 is the same as the width of the first optical film F11 and corresponds to the long side of the liquid crystal cell W. The 1st roll original fabric R1 and the 2nd roll original fabric R2 are arrange | positioned so that each core A1 and A2 may become mutually parallel. The 2nd conveyance apparatus 22 sends out the 2nd optical film F21 from this 2nd roll original fabric R2 to the orthogonal direction with respect to the width direction. And the sent 2nd optical film F21 is cut | disconnected by the width direction by the space | interval corresponding to the short side of the liquid crystal cell W, The 2nd optical film F21 cut | disconnected by the rectangular shape corresponding to the liquid crystal cell W Is formed.

  The first optical film F11 and the second optical film F21 cut as described above have long and short sides corresponding to the long and short sides of the liquid crystal cell W, respectively. Can be attached to both sides. Thereby, the 1st optical film F11 and the 2nd optical film F21 are bonded together on both surfaces of the liquid crystal cell W so that each absorption axis B1, B2 may mutually orthogonally cross. Therefore, without providing a mechanism for rotating the liquid crystal cell W, the first optical film F11 and the second optical film F21 bonded to both surfaces of the liquid crystal cell W can be in a crossed Nicols relationship, The optical films F11 and F21 can be satisfactorily bonded to both surfaces of the liquid crystal cell W with a simpler configuration.

  In particular, the first optical film F11 is wound so that the absorption axis B1 extends in a direction orthogonal to the width direction, and the second optical film F21 is wound so that the absorption axis B2 extends in the width direction. It is easy to align the absorption axes B1 and B2 of the optical films F11 and F21 and the long side or the short side of the liquid crystal cell W. For this reason, when the optical films F11 and F21 are bonded to the liquid crystal cell W, the possibility that the absorption axes B1 and B2 are shifted becomes low, and the contrast abnormality of the optical display device due to the deviation of the absorption axes B1 and B2 occurs. Therefore, the optical films F11 and F21 can be better bonded to both surfaces of the liquid crystal cell W.

  In the present embodiment, the first optical film F11 and the second optical film F21 are cut at intervals corresponding to the short sides of the liquid crystal cell W, and the cut optical films F11 and F21 are both surfaces of the liquid crystal cell W. The first optical film F11 and the second optical film F21 can be brought into a crossed Nicol relationship by being bonded to each other. Thereby, in order to obtain one piece of the cut first optical film F11, the time for feeding the first optical film F11 from the first roll R1 and the first piece of the cut second optical film F21 are obtained. Since the time for feeding the second optical film F21 from the two-roll original fabric R2 can be made shorter than when cutting at intervals corresponding to the long sides of the liquid crystal cell W, the optical films F11 and F21 are formed on both sides of the liquid crystal cell W. Can be efficiently bonded.

  The optical display device manufactured in the manner as in the present embodiment is mounted on an image display device such as a liquid crystal display device and is visually recognized from one of the front and back surfaces. The 1st optical film F11 is bonded to the surface which becomes the front side (viewing side) when visually recognizing the optical display device, and the 2nd optical film F21 becomes the back side (backlight side) when visually recognizing the optical display device. It is preferable to be bonded to the surface. Below, the reference example is demonstrated.

(Reference Example 1)
Preparation of polarizing plate A: A polyvinyl alcohol film having a polymerization degree of 2700 and a thickness of 75 μm is drawn out from the raw material, stretched 1.2 times in the transport direction while being swollen in a 30 ° C. water bath for 1 minute, The film was stretched by a total of 3 times in the film conveying direction while being immersed and dyed in an aqueous solution having a potassium fluoride concentration of 0.03% and an iodine concentration of 0.3% for 60 seconds. Subsequently, the film was stretched 6 times in total while being immersed in an aqueous solution having a boric acid concentration of 4% and a potassium iodide concentration of 5% at 60 ° C. for 30 seconds. Finally, it was washed by dipping in an aqueous solution of potassium iodide concentration 2% at 30 ° C. for several seconds, and the obtained stretched film was dried at 70 ° C. for 2 minutes to obtain a polarizer. A polarizing plate A having an absorption axis perpendicular to the width direction is created by bonding “TD80UL manufactured by Fuji Film Co., Ltd.” as a polarizer protective film on both sides of the obtained polarizer through a PVA adhesive. did. When the optical properties of the obtained polarizing plate A were measured with “Spectrophotometer V7100 manufactured by JASCO Corporation”, the transmittance was 41.0% and the polarization degree was 99.997%.

  Preparation of polarizing plate B: A polyvinyl alcohol film having a degree of polymerization of 2400 and a thickness of 75 μm is fed out from the raw material, both ends in the width direction of the PVA film are held by holding means, and the PVA film is transferred at a speed of 1 m / min with a tenter stretching machine. Was conveyed in the longitudinal direction. Using a spraying device that reciprocates in the width direction of the PVA film at 30 m / min, water (swelling liquid) at 30 ° C. was applied for 30 seconds in the gas phase on both sides of the PVA film at a flow rate of 16 mL / min. Sprayed. Under the present circumstances, the said PVA film was extended | stretched in the width direction with the said holding | grip means so that it might become 2.2 times the length of an original fabric. Using the spraying device, a 30 ° C. aqueous solution (dye solution) containing 0.2 wt% iodine was sprayed on one side of the swollen PVA film in the gas phase for 25 seconds. At this time, the PVA film was stretched in the width direction by the gripping means so as to be 3.3 times as long as the original fabric. Using the spraying device, an aqueous solution (crosslinking solution) at 30 ° C. containing 3% by weight boric acid and 3% by weight potassium iodide in a gas phase on one side of the dyed PVA film. Sprayed for 10 seconds. At this time, the PVA film was stretched in the width direction by the gripping means so as to be 3.6 times as long as the original fabric. Using the spraying device, a 60 ° C. aqueous solution (stretching solution) containing 4% by weight boric acid and 5% by weight potassium iodide was sprayed on one side of the crosslinked PVA film for 60 seconds. At this time, the PVA film was stretched in the width direction by the holding means so as to be 5.9 times as long as the original fabric. Using the spraying device, a 30 ° C. aqueous solution (conditioning solution) containing 4% by weight of potassium iodide was sprayed on one side of the stretched PVA film for 10 seconds. The moisture content of the PVA film is decreased by releasing the PVA film from the gripping means and simultaneously performing a heat drying treatment in a 45 ° C. atmosphere for 1 minute while conveying the PVA film by a roll in the longitudinal direction. The length in the longitudinal direction of the PVA film was shrunk to 85% as compared to immediately after opening (shrinkage rate 15%). A total of four rolls were used, and the rotational speed of the rolls was sequentially decreased as going to the downstream side in the traveling direction of the PVA film. The rotation speed of each roll was 1.00 m / min, 0.9 m / min, 0.875 m / min, and 0.85 m / min, respectively, from the upstream side in the traveling direction of the PVA film. The PVA film after shrinkage was dried at 60 ° C. for 1 minute to obtain a polarizer. As a base film, “TD80UL manufactured by Fuji Film Co., Ltd.” is unwound from the original fabric and 2,2′-bis (3,4-dicarboxyphenyl) hexafluoropropane≈6FDA and 2,2′-bis (trifluoromethyl)- A solution prepared from 4,4′-diaminobiphenyl≈PFMB≈TFMB and prepared at 15 wt% using cyclohexanone as a solvent for a polyimide was applied to a thickness of 30 μm. Then, a substrate film with a thin film having a thin film with a thickness of about 4.5 μm was obtained by drying at 100 ° C. for 10 minutes. When the retardation of the obtained substrate film with thin film was measured using “KOBRA (registered trademark) 21ADH manufactured by Oji Scientific Instruments”, the front retardation was 1.5 nm and the thickness direction retardation was 242 nm. This base material film with a thin film was stretched 1.1 times in the conveying direction at 160 ° C. in a free end uniaxial orientation (stretching between rolls) to prepare a base film A with retardation. When the retardation of the obtained base material film A with retardation was measured using “KOBRA (registered trademark) 21ADH manufactured by Oji Scientific Instruments”, the front retardation was 54 nm and the thickness direction retardation was 272 nm. In addition, the slow axis of this base material film A with phase difference was a conveyance direction. On one side of the obtained polarizer, “TD80UL manufactured by Fuji Film Co., Ltd.” was bonded as a polarizer protective film via a PVA adhesive, and the other side was prepared as a polarizer protective film with a retardation layer on the other side. The base film A with a phase difference was bonded through a PVA adhesive to prepare a polarizing plate B having an absorption axis parallel to the width direction. The optical properties of the obtained polarizing plate B were measured by “Spectrophotometer V7100 manufactured by JASCO Corporation”. As a result, the transmittance was 42.6% and the polarization degree was 99.981%.

  Mounting evaluation: A liquid crystal cell was taken out from “32-inch liquid crystal television BRAVIA (registered trademark) KDL-32F1 manufactured by Sony Corporation” and the polarizing plates A and B were mounted. The polarizing plate A was bonded so that the absorption axis of the polarizer was in the horizontal direction on the viewing side of the cell. Further, the polarizing plate B was bonded to the backlight side of the cell so that the absorption axis was in the vertical direction. At this time, the polarizing plate B was bonded so that the surface of the base film A with retardation was on the cell side. The contrast of the obtained television was measured with a “Topcon luminance meter BM-5A”. The contrast was “2546”.

(Reference Example 2)
Preparation of polarizing plate C: “TD80UL manufactured by Fuji Film Co., Ltd.” is drawn out from the original as a base film, and 2,2′-bis (3,4-dicarboxyphenyl) hexafluoropropane≈6FDA and 2,2′-bis A solution prepared from (trifluoromethyl) -4,4′-diaminobiphenyl≈PFMB≈TFMB and prepared at 15 wt% using polyimide as a solvent and cyclohexanone was applied to a thickness of 20 μm. Then, a substrate film with a thin film having a thin film with a thickness of about 3 μm was obtained by drying at 100 ° C. for 10 minutes. When the retardation of the obtained substrate film with a thin film was measured using “KOBRA (registered trademark) 21ADH manufactured by Oji Scientific Instruments”, the front retardation was 1.2 nm and the thickness direction retardation was 188 nm. This substrate film with a thin film was stretched uniaxially (tenter stretching) at a fixed end of 1.19 times in the width direction at 160 ° C. to prepare a substrate film B with retardation. When the retardation of the obtained base material film B with retardation was measured using “KOBRA (registered trademark) 21ADH manufactured by Oji Scientific Instruments”, the front retardation was 56 nm and the thickness direction retardation was 270 nm. In addition, the slow axis of this base material film B with phase difference was the width direction. A polarizer protective film with a retardation layer is attached to one side of the polarizer prepared in the same manner as the polarizing plate A, using a PVA adhesive as a polarizer protective film and “TD80UL manufactured by Fuji Film Co., Ltd.”. As described above, the substrate film B with retardation prepared above was bonded through a PVA adhesive to prepare a polarizing plate C having an absorption axis perpendicular to the width direction. The optical properties of the obtained polarizing plate C were measured by “Spectrophotometer V7100 manufactured by JASCO Corporation”. As a result, the transmittance was 41.0% and the polarization degree was 99.995%.

  Preparation of polarizing plate D: “FD80UL manufactured by Fuji Film Co., Ltd.” as a polarizer protective film is bonded to both sides of a polarizer prepared in the same manner as polarizing plate B with a PVA adhesive, and the width direction is A polarizing plate D having a parallel absorption axis was prepared. When the optical properties of the obtained polarizing plate D were measured by “Spectrophotometer V7100 manufactured by JASCO Corporation”, the transmittance was 42.6% and the degree of polarization was 99.983%.

  Mounting evaluation: The liquid crystal cell was taken out from “32-inch liquid crystal television BRAVIA (registered trademark) KDL-32F1 manufactured by Sony Corporation” and the polarizing plates C and D were mounted. The polarizing plate D was bonded so that the absorption axis of the polarizer was in the horizontal direction on the viewing side of the cell. A polarizing plate C was bonded to the backlight side of the cell so that the absorption axis was in the vertical direction. At this time, the polarizing plate C was bonded so that the surface of the base film B with retardation was on the cell side. The contrast of the obtained television was measured with a “Topcon luminance meter BM-5A”. The contrast was “2173”. It can be seen that the contrast “2173” in the reference example 2 is inferior to the contrast “2546” in the reference example 1.

(Example of structure and manufacturing method of optical film)
First, a polarizing plate will be described as an example of an optical film. For the polarizing plate, for example, a TAC (triacetylcellulose) 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 pressure-sensitive adhesive layer, and a surface protective film is bonded to the PET film surface via a weak pressure-sensitive adhesive layer. Here, a strong pressure-sensitive adhesive layer is applied in advance to the separator, and a weak pressure-sensitive adhesive layer is applied to the surface protective film. The strong pressure-sensitive adhesive layer applied to the separator is transferred to the TAC film after peeling the separator. In addition, the weak pressure-sensitive adhesive layer 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 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. .

  Also, in the case of step (C), when winding the obtained strip-shaped sheet product in a roll, the inspector visually confirms defects (foreign matter, dirt, twist, etc.) at the start and end of winding of the roll. The sheet product is rated (good, defective, whether shipment is possible) by evaluating this defect.

  Next, as a post-process, (D) a slit process of the raw roll. Since the roll stock is wide, the roll stock is slit to a predetermined size in accordance with the size of the optical display device 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, as a visual inspection of a long sheet product, a roll type automatic inspection device and / or a visual inspection by an inspector is performed. 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 liquid crystal cell is performed at the same place, it is transported to the next process in simple packaging or as it is.

  The optical display device manufactured according to the present invention can be applied to 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 a liquid crystal cell, an optical film, and an illumination system as necessary, and incorporating a drive circuit. The present invention is effective when the liquid crystal cell is a VA mode or IPS mode liquid crystal cell, for example.

  An appropriate liquid crystal display device such as a liquid crystal display device in which an optical film is disposed on one side or both sides of a liquid crystal cell, or a backlight or a reflector used in an illumination system can be formed. In that case, the optical film can be installed on one side or both sides of the liquid crystal cell. When providing an optical film 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.

  The liquid crystal display device can be formed as a transmission type or reflection type in which an optical film is arranged on one side or both sides of a liquid crystal cell, or an appropriate structure according to the conventional type of transmission / reflection type. Accordingly, the liquid crystal cell forming the liquid crystal display device is arbitrary, and for example, a liquid crystal cell of an appropriate type such as an active matrix driving type typified by a thin film transistor type may be used.

  Moreover, when providing a polarizing plate and an optical member in the both sides of a liquid crystal cell, they may be the same thing and may differ. Furthermore, when forming the liquid crystal display device, for example, appropriate components such as a prism array sheet, a lens array sheet, a light diffusing plate, and a backlight can be arranged in one or more layers at appropriate positions.

12 1st conveying apparatus 16 1st cutting apparatus 18 1st bonding apparatus 19 1st film alignment apparatus 22 2nd conveyance apparatus 26 2nd cutting apparatus 28 2nd bonding apparatus 29 2nd film alignment apparatus F11 1st optical Film F21 2nd optical film R1 1st roll original fabric A1 Winding core B1 Absorption axis R2 2nd roll original fabric A2 Winding core B2 Absorption axis W Liquid crystal cell

Claims (12)

The optical film is fed from a roll original formed by winding an optical film containing a polarizer, and the optical film is cut in the width direction to be cut into a predetermined size and bonded to a liquid crystal cell. An optical display device manufacturing system for manufacturing an optical display device according to
From the first roll original fabric formed by winding the first optical film having a width corresponding to the long side or the short side of the liquid crystal cell so that the absorption axis extends in a direction perpendicular to the width direction, A first transport device for feeding the first optical film in an orthogonal direction;
Winding a second optical film, which is arranged so that the width direction is parallel to the first roll, and has the same width as the first optical film, so that the absorption axis extends in the width direction. A second transport device that sends out the second optical film in a direction orthogonal to the width direction from the second roll raw material formed by
A first cutting device for cutting the first optical film sent out by the first transport device at an interval corresponding to the short side or the long side of the liquid crystal cell having the predetermined size;
A second cutting device for cutting the second optical film delivered by the second transport device at the same interval as the first optical film;
A first laminating device for laminating the cut first optical film on one surface of the liquid crystal cell;
An optical display device manufacturing system, comprising: a second laminating device that bonds the cut second optical film to the other surface of the liquid crystal cell.   A period in which the first bonding device bonds the first optical film to the one surface of the liquid crystal cell, and the second bonding device bonds the second optical film to the other surface of the liquid crystal cell. The optical display device manufacturing system according to claim 1, wherein the period to be combined overlaps at least partially.   3. The optical display device manufacture according to claim 1, wherein a width of the first optical film and a width of the second optical film are lengths corresponding to long sides of the liquid crystal cell, respectively. system.   3. The optical display device manufacture according to claim 1, wherein a width of the first optical film and a width of the second optical film are lengths corresponding to short sides of the liquid crystal cell, respectively. system.   With respect to the liquid crystal cell, the first optical film is bonded to a surface that becomes the front side when viewing the optical display device, and the second optical film is attached to the back side when viewing the optical display device. The optical display device manufacturing system according to claim 1, wherein the optical display device manufacturing system is bonded to a surface to be formed.   The optical display device manufacturing system according to claim 1, further comprising a film alignment device that performs relative alignment between the first optical film and the second optical film. The optical film is fed from a roll original formed by winding an optical film containing a polarizer, and the optical film is cut in the width direction to be cut into a predetermined size and bonded to a liquid crystal cell. An optical display device manufacturing method for manufacturing an optical display device by:
From the first roll original fabric formed by winding the first optical film having a width corresponding to the long side or the short side of the liquid crystal cell so that the absorption axis extends in a direction perpendicular to the width direction, A first conveying step for feeding the first optical film in an orthogonal direction;
Winding a second optical film, which is arranged so that the width direction is parallel to the first roll, and has the same width as the first optical film, so that the absorption axis extends in the width direction. A second transporting step of feeding out the second optical film in a direction orthogonal to the width direction from the second roll raw material formed by
A first cutting step of cutting the first optical film sent out by the first transporting step at an interval corresponding to a short side or a long side of the liquid crystal cell having the predetermined size;
A second cutting step of cutting the second optical film sent out by the second transport step at the same interval as the first optical film;
A first bonding step of bonding the cut first optical film to one surface of the liquid crystal cell;
A method for manufacturing an optical display device, comprising: a second bonding step of bonding the cut second optical film to the other surface of the liquid crystal cell.   A period in which the first optical film is bonded to the one surface of the liquid crystal cell in the first bonding step, and a second optical film is bonded to the other surface of the liquid crystal cell in the second bonding step. 8. The method of manufacturing an optical display device according to claim 7, wherein the period to be combined overlaps at least partially.   9. The optical display device manufacture according to claim 7, wherein a width of the first optical film and a width of the second optical film are lengths corresponding to long sides of the liquid crystal cell, respectively. Method.   9. The optical display device manufacturing according to claim 7, wherein a width of the first optical film and a width of the second optical film are lengths corresponding to short sides of the liquid crystal cell, respectively. Method.   With respect to the liquid crystal cell, the first optical film is bonded to a surface that becomes the front side when viewing the optical display device, and the second optical film is attached to the back side when viewing the optical display device. The method for manufacturing an optical display device according to claim 7, wherein the optical display device is bonded to a surface.   The optical display device manufacturing method according to claim 7, further comprising a film alignment step of performing relative alignment between the first optical film and the second optical film.

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