JP2013113897A - Operational method for production system of optical display device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an operational method for a production system of an optical display device obtained by performing predetermined processing on an optical display component, capable of suppressing generation of defective products and preventing the yield of the production system from deteriorating.SOLUTION: The operational method for a production system of an optical display device comprises: an initial production step (step S3) of making a predetermined amount of optical display components pass through a main line of the production system and performing predetermined processing on the optical display components; an initial product checking step (step S4) of checking, after the initial production step, defects of products obtained by the initial production step; and a main production transition determination step (step S5) of determining whether or not transition to a main production step is made, according to the number of the defective products detected by the initial product checking step.

Description

  The present invention relates to a method for operating a production system of an optical display device such as a liquid crystal display.

  Conventionally, in a production system of an optical display device such as a liquid crystal display, there is one in which a polarizing film having an adhesive layer on one side is bonded to a liquid crystal panel (see, for example, Patent Documents 1 and 2).

Japanese Patent No. 4079716 Japanese Patent No. 4307510

By the way, in the above-described conventional production system, when performing predetermined processing such as pasting a polarizing film on a large number of liquid crystal panels in actual production, due to an abnormality in the production system, a setting error, etc. Defective products such as stuck foreign material may occur. Such defective products are detected by an automatic inspection device or the like installed in the main part of the production system.For example, when the non-defective product rate is lower than a set value or a predetermined number of defective products are continuously generated, The production system is temporarily stopped, and after taking measures such as cleaning, the production system is restarted.
However, the above method has a problem that a considerable number of defective products are generated at the time when an abnormality is detected, and the yield of the production system is lowered.

  Therefore, an object of the present invention is to suppress the occurrence of defective products and prevent the yield of the production system from deteriorating in an operation method of an optical display device production system in which predetermined processing is performed on an optical display component.

  As a means for solving the above problems, the method of operating an optical display device production system according to the present invention corresponds to an optical display device obtained by subjecting an optical display component to predetermined processing. An initial production process in which a predetermined amount is distributed to the main line and the optical display component is subjected to the predetermined process; an initial product inspection process for inspecting a product defect obtained in the initial production process after the initial production process; And a main production transition determination step for determining whether or not to shift to the main production process according to the number of defective products detected in the product inspection step.

  The optical display device production system operating method according to the present invention may be configured such that before the optical display component is distributed to the main line, dust in the facility that performs the predetermined processing on the optical display component is discharged outside the facility. The structure containing the production preparation process to perform may be sufficient.

  In the configuration including the production preparation process, if the number of defective products is equal to or less than a first determination value in the initial product inspection process, the process proceeds to the production process, and the number of defective products is the first determination value. If it is greater than the second determination value, the process returns to the production preparation process. If the number of defective products is the third determination value between the first and second determination values, the process proceeds to an additional initial production process. It may be configured to.

  Further, at this time, in the additional initial production process, the optical display component is further distributed through the main line in a predetermined amount and subjected to the predetermined process, and then the process proceeds to an additional initial product inspection process. Inspect for defects in the product obtained in the initial production process, and if the number of defective products at this time is less than or equal to the fourth determination value, the process proceeds to the production process, and the number of defective products is greater than the fourth determination value. If it is more than the 5th big judgment value, the structure which returns to the said production preparation process may be sufficient.

In the configuration including the production preparation step, the production preparation step may include a step of distributing a dummy component corresponding to the optical display component to the main line.
Further, at this time, a configuration may be included that includes an operation suspension step of stopping the operation of the production system for a predetermined time after the production preparation step and before the initial production step.

  In addition, in the operation method of the production system of the optical display device of the present invention, the non-defective product rate is calculated every time the optical display component is circulated through the main line by a predetermined amount in the main production process, The production process may be continued if the value exceeds the value, and the initial production process may be returned if the yield rate is equal to or less than the predetermined value.

  According to the present invention, by performing an initial production process and an initial product inspection process with a limited number of productions, it is possible to detect abnormalities in the production system and setting errors that lead to the occurrence of defective products at an early stage, and then proceed to the main production process. Can be migrated. Thereby, generation | occurrence | production of inferior goods can be suppressed, generation | occurrence | production of inferior goods can be detected efficiently, and the yield deterioration of the said production system can be prevented.

It is a schematic block diagram of the film bonding system of the optical display device in embodiment of this invention. It is A arrow directional view of FIG. It is a top view of the liquid crystal panel in embodiment of this invention. It is sectional drawing of the optical sheet in embodiment of this invention. It is a flowchart which shows the operating method of the film bonding system in embodiment of this invention. It is a flowchart of the main production process of FIG.

Embodiments of the present invention will be described below with reference to the drawings.
FIG. 1 shows a schematic configuration of a film bonding system 1 of the present embodiment. The film bonding system 1 is for bonding a film-shaped optical member such as a polarizing film, an antireflection film, or a light diffusion film to a panel-shaped optical display component such as a liquid crystal panel or an organic EL panel. And an optical display device including an optical member. In the film bonding system 1, the liquid crystal panel P is used as the optical display component.

  FIG. 3 is a plan view of the liquid crystal panel P as viewed from the thickness direction of the liquid crystal layer P3. The liquid crystal panel P includes a first substrate P1 that has a rectangular shape in plan view, a second substrate P2 that has a relatively small rectangular shape disposed to face the first substrate P1, a first substrate P1, and a second substrate. And a liquid crystal layer P3 sealed between the substrate P2. The liquid crystal panel P has a rectangular shape that conforms to the outer shape of the first substrate P1 in plan view, and a region that fits inside the outer periphery of the liquid crystal layer P3 in plan view is defined as a display region P4.

  FIG. 4 is a cross-sectional view of the optical sheet F including the optical member F1 bonded to the liquid crystal panel P. The optical sheet F is separated into one surface of the optical member F1 through the adhesive layer F2 provided on one surface (the upper surface in the drawing) of the optical member F1, the optical member F1, and the adhesive layer F2. It has separator F3 laminated | stacked possible and the surface protection film F4 laminated | stacked on the other surface (in the figure lower surface) of the optical member F1. The optical member F1 functions as a polarizing plate, and is bonded over the entire display area P4 of the liquid crystal panel P and its peripheral area. For convenience of illustration, hatching of each layer in FIG. 4 is omitted.

  The optical member F1 is bonded to the liquid crystal panel P via the adhesive layer F2 in a state where the separator F3 is separated while leaving the adhesive layer F2 on one surface thereof. Hereinafter, the part remove | excluding the separator F3 from the optical sheet F is called the bonding sheet | seat F5.

  The separator F3 protects the adhesive layer F2 and the optical member F1 until it is separated from the adhesive layer F2. The surface protective film F4 is bonded to the liquid crystal panel P together with the optical member F1. The surface protective film F4 is disposed on the side opposite to the liquid crystal panel P with respect to the optical member F1, protects the optical member F1, and is separated from the optical member F1 at a predetermined timing. In addition, the structure which the optical sheet F does not contain the surface protection film F4, or the structure where the surface protection film F4 is not isolate | separated from the optical member F1 may be sufficient.

  The optical member F1 includes a sheet-like polarizer F6, a first film F7 bonded to one surface of the polarizer F6 with an adhesive or the like, and a first film F7 bonded to the other surface of the polarizer F6 with an adhesive or the like. And two films F8. The first film F7 and the second film F8 are protective films that protect the polarizer F6, for example.

  Note that the optical member F1 may have a single-layer structure including a single optical layer or a stacked structure in which a plurality of optical layers are stacked on each other. In addition to the polarizer F6, the optical layer may be a retardation film, a brightness enhancement film, or the like. At least one of the first film F7 and the second film F8 may be subjected to a surface treatment that provides an effect such as anti-glare including hard coat treatment and anti-glare treatment for protecting the outermost surface of the liquid crystal display element. The optical member F1 may not include at least one of the first film F7 and the second film F8. For example, when the first film F7 is omitted, the separator F3 may be bonded to one surface of the optical member F1 via the adhesive layer F2.

  Hereinafter, the film bonding system 1 will be described with reference to FIGS. The right side in the figure shows the upstream side in the transport direction of the liquid crystal panel P (hereinafter referred to as the panel transport upstream side), and the left side in the figure shows the downstream side in the transport direction of the liquid crystal panel P (hereinafter referred to as the panel transport downstream side). And

  The film bonding system 1 sequentially performs a predetermined process on the liquid crystal panel P while transporting the liquid crystal panel P from the start position to the end position of the bonding process using, for example, a driving roller conveyor 5. The liquid crystal panel P is conveyed on the roller conveyor 5 with its front and back surfaces being horizontal.

  The roller conveyor 5 is divided into an upstream conveyor 6 and a downstream conveyor 7 with a first reversing device 15 described in detail later as a boundary. For example, the liquid crystal panel P is transported in the direction in which the short side of the display area P4 is along the transport direction in the upstream conveyor 6 and in the direction in which the long side of the display area P4 is along the transport direction in the downstream conveyor 7. Be transported. The bonding sheet F5 cut out to a predetermined length from the belt-shaped optical sheet F is bonded to the front and back surfaces of the liquid crystal panel P. Each part of the film bonding system 1 is comprehensively controlled by the control part 20 as an electronic control apparatus.

  The film bonding system 1 includes a first adsorbing device 11 that adsorbs the liquid crystal panel P conveyed to the end position of the upstream process and conveys it to the initial position of the upstream conveyor 6 and aligns the liquid crystal panel P, and the initial position. The first dust collector 12 provided on the downstream side of the panel transport, the first bonding device 13 provided on the downstream side of the panel transport with respect to the first dust collector 12, and the panel transport with respect to the first paste device 13. The first deviation inspection device 14 provided on the downstream side, and the liquid crystal panel P provided on the downstream side of the panel conveyance from the first deviation inspection device 14 and reaching the end position of the upstream conveyor 6 are moved to the initial position of the downstream conveyor 7. And a first reversing device 15 that conveys the

  Moreover, the film bonding system 1 is provided with a second dust collector 16 provided on the downstream side of the panel transport from the initial position of the downstream conveyor 7 and a second dust collector provided on the downstream side of the panel transport with respect to the second dust collector 16. A bonding device 17, a second displacement inspection device 18 provided on the panel conveyance downstream side with respect to the second bonding device 17, and a second reversing device 19 provided on the panel conveyance downstream side with respect to the second displacement inspection device 18. And a defect inspection device 21 provided on the downstream side of the panel conveyance with respect to the second reversing device 19.

  The first suction device 11 holds the liquid crystal panel P and freely conveys it in the vertical and horizontal directions and aligns the liquid crystal panel P. For example, the first suction device 11 is provided in the panel holding portion 11a. And an alignment camera 11b for detecting the alignment reference.

  The panel holding part 11a holds the upper surface of the liquid crystal panel P transported to the end position of the upstream process by vacuum suction and keeps the liquid crystal panel P in a horizontal state at the starting position of the bonding process (upstream conveyor 6). Then, the suction is released at the position and the liquid crystal panel P is transferred to the upstream conveyor 6.

  For example, when the liquid crystal panel P held by the panel holding unit 11 a is placed on the upstream conveyor 6, the alignment camera 11 b images the alignment mark, the tip shape, and the like of the liquid crystal panel P. The imaging data of the alignment camera 11b is transmitted to the control unit 20, and the control unit 20 operates the panel holding unit 11a based on the imaging data. Thereby, alignment of liquid crystal panel P with respect to the upstream conveyor 6 is made. At this time, the liquid crystal panel P is positioned with respect to the upstream conveyor 6 in the horizontal direction (conveyor width direction) orthogonal to the transport direction and in the rotational direction around the vertical axis.

The 1st dust collector 12 is provided in the panel conveyance upstream in the vicinity of the bonding position of the 1st bonding apparatus 13, and the static electricity removal of the lower surface side of liquid crystal panel P just before being introduced into the bonding position And collect dust.
The 1st bonding apparatus 13 bonds the bonding sheet | seat F5 cut into predetermined size with respect to the lower surface of liquid crystal panel P introduced into the bonding position.

  The first laminating device 13 includes a transport device 22 that transports the optical sheet F along its longitudinal direction while unwinding the optical sheet F from the original roll R1 around which the optical sheet F is wound, and the transport device 22 is optical. A pressing roll 23 is provided that bonds the bonding sheet F5 having a predetermined length separated from the sheet F to the lower surface of the liquid crystal panel P conveyed by the upstream conveyor 6.

  The conveying device 22 conveys the bonding sheet F5 using the separator F3 as a carrier, and holds the raw roll R1 around which the belt-shaped optical sheet F is wound and roll holding the optical sheet F along its longitudinal direction. Half-cut the part 22a, the plurality of guide rollers 22b for winding the optical sheet F to guide the optical sheet F unwound from the original roll R1 along a predetermined transport path, and the optical sheet F on the transport path. A cutting device 22c to be applied, a knife edge 22d for supplying the bonding sheet F5 to the bonding position while separating the bonding sheet F5 from the separator F3 by winding the optical sheet F subjected to the half cut at an acute angle, and a knife edge And a winding portion 22e that holds a separator roll R2 that winds up the separator F3 that has become independent after 22d.

  The roll holding unit 22a positioned at the start point of the transport device 22 and the winding unit 22e positioned at the end point of the transport device 22 are driven in synchronization with each other, for example. Thereby, the winding unit 22e winds up the separator F3 that has passed through the knife edge 22d while the roll holding unit 22a feeds the optical sheet F in the transport direction. Hereinafter, the upstream side in the transport direction of the optical sheet F (separator F3) in the transport device 22 is referred to as a sheet transport upstream side, and the downstream side in the transport direction is referred to as a sheet transport downstream side.

  Each guide roller 22b changes the traveling direction of the optical sheet F being conveyed along the conveyance path, and at least a part of the plurality of guide rollers 22b is movable so as to adjust the tension of the optical sheet F being conveyed.

The cutting device 22c cuts a part in the thickness direction of the optical sheet F over the entire width in the width direction orthogonal to the longitudinal direction of the optical sheet F when the optical sheet F is fed out by a predetermined length (half cutting is performed). ).
The cutting device 22c adjusts the advancing / retreating position of the cutting blade so that the optical sheet F (separator F3) is not broken by the tension acting during the conveyance of the optical sheet F (so that a predetermined thickness remains in the separator F3). The half cut is performed up to the vicinity of the interface between the adhesive layer F2 and the separator F3. In addition, you may use the laser apparatus replaced with a cutting blade.

  In the optical sheet F after half-cutting, the optical member F1 and the surface protection film F4 are cut in the thickness direction, whereby a cut line extending over the entire width in the width direction of the optical sheet F is formed. A plurality of cutting lines are formed so as to be arranged in the longitudinal direction of the belt-shaped optical sheet F. For example, in the case of the bonding process which conveys liquid crystal panel P of the same size, a plurality of score lines are formed at equal intervals in the longitudinal direction of optical sheet F. The optical sheet F is divided into a plurality of sections in the longitudinal direction by the plurality of cut lines. Each section sandwiched between a pair of cut lines adjacent in the longitudinal direction in the optical sheet F is a sheet piece in the bonding sheet F5.

  The knife edge 22d is disposed below the upstream conveyor 6 and extends in the width direction of the optical sheet F at least over its entire width. The knife edge 22d is wound so as to come into sliding contact with the separator F3 side of the optical sheet F after half-cutting.

  The knife edge 22d is seen from the width direction of the optical sheet F above the first surface, and the first surface arranged in an inclined position when viewed from the width direction of the optical sheet F (the width direction of the upstream conveyor 6). It has the 2nd surface arrange | positioned at an acute angle with respect to a 1st surface, and the front-end | tip part where a 1st surface and a 2nd surface cross.

  The knife edge 22d winds the optical sheet F at an acute angle at its tip. The optical sheet F separates the sheet piece of the bonding sheet F5 from the separator F3 when turning back at an acute angle at the tip of the knife edge 22d. The tip end of the knife edge 22d is arranged close to the panel conveyance downstream side of the pinching roll 23. The bonding sheet F5 separated from the separator F3 by the knife edge 22d is introduced between the pair of bonding rollers 23a of the pinching roll 23 while overlapping with the lower surface of the liquid crystal panel P conveyed by the upstream conveyor 6.

  The pinching roll 23 has a pair of bonding rollers 23a that are arranged with their axial directions parallel to each other. A predetermined gap is formed between the pair of bonding rollers 23 a, and the inside of this gap is the bonding position of the first bonding device 13. The liquid crystal panel P and the bonding sheet F5 are overlapped and introduced into the gap. These liquid crystal panel P and the bonding sheet | seat F5 are sent out to a panel conveyance downstream, being pinched by each bonding roller 23a. Thereby, the bonding sheet | seat F5 is integrally bonded by the lower surface of liquid crystal panel P. FIG. Hereinafter, the panel after this bonding is called single-sided bonding panel P11.

  The first displacement inspection device 14 is whether or not the position of the bonding sheet F5 bonded by the first bonding device 13 in the single-sided bonding panel P11 with respect to the liquid crystal panel P is appropriate (whether the displacement is within the tolerance range). )). The first deviation inspection device 14 includes a pair of cameras 14a that image the edges of the bonding sheet F5 on the upstream side and the downstream side of the single-sided bonding panel P11, for example. Imaging data from each camera 14a is transmitted to the control unit 20, and it is determined based on this imaging data whether or not the relative positions of the bonding sheet F5 and the liquid crystal panel P are appropriate. The single-sided bonding panel P11 determined to have an inappropriate relative position is discharged out of the system by a not-shown payout means.

  The first reversing device 15 includes, for example, a rotation shaft 15a inclined at 45 ° in a plan view with respect to the transport direction of the liquid crystal panel P, the final position of the upstream conveyor 6 and the downstream conveyor 7 via the rotation shaft 15a. And a reversing arm 15b supported between the first starting positions. The reversing arm 15b holds the single-sided bonding panel P11 that has reached the terminal position of the upstream conveyor 6 through the first displacement inspection device 14 by suction or clamping, and the reversing arm 15b is rotated 180 ° around the rotation shaft 15a. By rotating, the front and back of the single-sided bonding panel P11 are reversed and, for example, the single-sided bonding panel P11 that has been transferred in parallel with the short side of the display area P4 is transferred in parallel with the long side of the display area P4. To change direction.

  The inversion is performed when the optical members F1 bonded to the front and back surfaces of the liquid crystal panel P are arranged so that the directions of the polarization axes are perpendicular to each other. The upstream conveyor 6 and the downstream conveyor 7 both have the direction from the right side to the left side of the drawing as the transport direction of the liquid crystal panel P, but the upstream conveyor 6 and the downstream conveyor pass through the first reversing device 15. 7 is offset by a predetermined amount in plan view.

  In the case of simply reversing the front and back of the liquid crystal panel P, for example, a reversing device having a reversing arm having a rotation axis parallel to the transport direction may be used. In this case, if the sheet conveying direction of the first laminating device 13 and the sheet conveying direction of the second laminating device 17 are arranged at right angles to each other in plan view, the polarization axis directions are perpendicular to the front and back surfaces of the liquid crystal panel P. The optical member F1 made can be pasted.

  The reversing arm 15b has an alignment function similar to that of the panel holding portion 11a of the first suction device 11. The first reversing device 15 is provided with an alignment camera 15c similar to the alignment camera 11b of the first suction device 11.

The second dust collecting device 16 is provided near the bonding position of the second bonding device 17 on the upstream side of the panel conveyance, and static electricity on the lower surface side of the single-sided bonding panel P11 immediately before being introduced into the bonding position. Remove dust and collect dust.
The 2nd bonding apparatus 17 bonds the bonding sheet | seat F5 cut into the predetermined size with respect to the lower surface of the single-sided bonding panel P11 introduced into the bonding position. The 2nd bonding apparatus 17 is provided with the conveying apparatus 22 and the pinching roll 23 similar to said 1st bonding apparatus 13. FIG.

  The single-sided bonding panel P11 and the bonding sheet F5 are introduced into the gap between the pair of bonding rollers 23a of the pinching roll 23 (the bonding position of the second bonding device 17), and single-sided bonding is performed. A bonding sheet F5 is integrally bonded to the lower surface of the combined panel P11. Hereinafter, the panel after this bonding is called double-sided bonding panel P12.

  Whether or not the position of the bonding sheet F5 bonded by the second bonding apparatus 17 in the double-sided bonding panel P12 with respect to the liquid crystal panel P is appropriate for the second shift inspection apparatus 18 (whether the position shift is within the tolerance range). )). The second misalignment inspection apparatus 18 includes a pair of cameras 18a that image the edge of the bonding sheet F5 on the upstream side and the downstream side of the double-sided bonding panel P12, for example. The imaging data by each camera 18a is transmitted to the control unit 20, and it is determined based on this imaging data whether the relative positions of the bonding sheet F5 and the liquid crystal panel P are appropriate. The double-sided bonded panel P12 determined to have an inappropriate relative position is discharged out of the system by a not-shown payout means.

The second reversing device 19 reverses the front and back of the liquid crystal panel P (double-sided bonding panel P12) with the backlight side facing upward through the first reversing device 15, and the liquid crystal is the same as when carrying into the film bonding system 1. The display surface side of the panel P is turned upward.
The defect inspection device 21 applies light from the lower surface side (backlight side) to the liquid crystal panel P (double-sided bonding panel P12) with the display surface side facing upward through the second reversing device 19, and the upper surface side (display surface). The image is taken by the camera 21a from the side), and the presence / absence of a defect (such as poor bonding) of the double-sided bonding panel P12 is inspected based on this imaging data.

Next, with reference to the flowcharts of FIGS. 5 and 6, the operation method of the production system of the optical display device of the present embodiment will be described focusing on the operation method of the film bonding system 1.
Referring to FIG. 5, when starting up the film bonding system 1, the equipment corresponding to all work items in the system is first cleaned, and then a dummy part corresponding to the liquid crystal panel P is supplied for one cassette as a production preparation process. Only (about 40 sheets per lot) is distributed to the main line (roller conveyor 5) of the film bonding system 1 (step S1). The dummy sheet is not bonded to the bonding sheet F5, but is conveyed on the roller conveyor 5 as a single product. Thereby, it is possible to make the dust etc. in the installation of the film bonding system 1 adhere to a dummy component, and to discharge outside the installation.

  After transporting the dummy parts for one cassette, as the operation stop process, the operation of the film bonding system 1 is stopped and left for a predetermined time (about 10 minutes) (step S2). Thereby, an atmosphere similar to that at the time of normal lot switching is reproduced.

  Next, as an initial production process, a predetermined amount (for example, 10) of liquid crystal panels P are circulated to actually produce the double-sided bonded panel P12 (step S3). By checking the bonding failure of the double-sided bonding panel P12 produced at this time (step S4, initial product inspection process), the situation such as whether the equipment in the film bonding system 1 is clean is confirmed. The step S4 may be performed automatically by the defect inspection apparatus 21 or may be performed visually by the operator.

  The control unit 20 detects the number n of defective bonding products from the inspection result in step S4, and determines whether or not to shift to the main production process described later based on the number n of defective bonding products (step). S5, main production transfer determination step). In step S5, if the number n of defective bonding is less than or equal to the first determination value f1 (for example, 1), the process proceeds to the main production process (step S6) in units of one cassette, and the number n of defective bonding is If it is greater than or equal to the second determination value f2 (for example, 3) that is larger than the first determination value f1, the process returns to the production preparation step (step S1). Thereby, generation | occurrence | production of the defective bonding by the production preparation shortage etc. in the initial stage of system operation is suppressed.

  On the other hand, when the number n of defective bonding is the third determination value f3 (for example, 2) between the first and second determination values f1 and f2, the process proceeds to the production process or returns to the production preparation process. In order to determine again, an additional initial production process (step S7) and an additional initial product inspection process (step S8) are performed. That is, a predetermined amount (for example, 6 sheets) of the liquid crystal panel P is further conveyed to form a double-sided bonding panel P12 (additional initial production process), and then the defective bonding of the double-sided bonding panel P12 by the defect inspection apparatus 21 or visually. Inspection (additional initial product inspection process). Thus, it is accurately determined whether the occurrence of defective bonding during initial production is temporary or should return to the production preparation process. Note that a plurality of third determination values f3 may be set to form a predetermined range.

  The control unit 20 detects the number n of defective bonding products from the inspection result in step S8, and determines again whether to shift to the production process based on the number n of defective bonding products (step S9). , Additional production transition judgment process). In step S9, if the number n of defective bonding products is equal to or less than the fourth determination value f4 (for example, 1), the process proceeds to the main production process (step S6) in units of one cassette, and the number n of defective bonding products is If it is greater than or equal to the fifth determination value f5 (for example, 2) that is larger than the fourth determination value f4, the process returns to the production preparation step (step S1). There is no numerical value corresponding to the number n of defective bonding between the fourth and fifth determination values f4 and f5, and in step S9, a two-choice determination without a gray zone is made.

  Next, referring to FIG. 6, in the production process, first, production is performed in which one cassette of liquid crystal panel P is used as double-sided bonding panel P12 (step S11). In the production process, the defect inspection apparatus 21 performs AOI inspection (Automatic Optical Inspection). The control unit 20 detects the non-defective product rate R obtained by removing the defective bonding product from the inspection result of the defect inspection device 21, and determines whether or not to continue the production process based on the non-defective product rate R (step S12). The production continuation determination process).

  When the non-defective product rate R ((total number−the number of non-defective products) / total number) per cassette is equal to or less than the sixth determination value f6 (for example, 70%) in step S12, the control unit 20 Then, “1” is added to the count C (step S13), and then it is determined whether or not the count C is equal to or greater than a seventh determination value f7 (eg, 3) (step S14).

  In step S14, if the count C is the seventh determination value f7, the state where the non-defective product rate R is equal to or less than the sixth determination value f6 continues for the seventh determination value f7 (for example, three times). In this case, the film bonding system 1 is stopped, and maintenance such as cleaning and checking of the entire system is performed (step S15).

  In step S14, if the count C is less than the seventh determination value f7, the process returns to step S3 (step S16), and the processes after the initial production process are repeated. Thereby, it is confirmed whether the clean state is maintained in the facility, and it is determined whether or not the fundamental improvement of the film bonding system 1 is required.

  In step S12, if the non-defective product rate R exceeds the sixth determination value f6, the count C is reset (step S17), and then the production process is continued (step S18). Thereby, it becomes possible to continue this production process of the film bonding system 1 while maintaining a state in which the non-defective product rate R is high.

  As described above, the operation method of the production system of the optical display device in the present embodiment corresponds to the optical display device that undergoes the bonding process of bonding the optical member F1 to the liquid crystal panel P. An initial production process (step S3) in which a predetermined amount is distributed to the main line (roller conveyor 5) of the production system (film bonding system 1) and the optical member F1 is bonded to the liquid crystal panel P, and the initial production process. An initial product inspection process (step S4) for inspecting defective bonding of products obtained in the initial production process later, and a main production process (step S6) according to the number n of defective bonding detected in the initial product inspection process. ) And a production shift determination step (step S5) for determining whether or not to shift to.

  According to this configuration, by performing the initial production process and the initial inspection process with a limited number of productions, the production system can detect the abnormality of the production system and the setting mistake leading to the occurrence of defective bonding products at an early stage. Can be transferred to. Thereby, while suppressing generation | occurrence | production of a bonding defect product, generation | occurrence | production of a bonding defect product can be detected efficiently and the yield deterioration of the said production system can be prevented.

  In addition, the operation method of the production system of the optical display device is a production preparation step (step S1) in which a dummy component corresponding to the liquid crystal panel P is distributed to the main line before the liquid crystal panel P is distributed to the main line. By including, the dust etc. of a main line can adhere to a dummy component before production of an optical display device, and can be discharged | emitted out of the equipment of the film bonding system 1. FIG.

  The optical display device production system operating method includes an operation stop step (step S2) for stopping the operation of the production system for a predetermined time after the production preparation step and before the initial production step. The production system can be shifted to the initial production process after being brought into a state similar to that at the time of lot switching in the main production process, and abnormalities in the production system, setting errors, etc. can be detected more reliably.

  Moreover, the operation method of the production system of the optical display device moves to the production process if the number n of defective bonding is equal to or less than the first determination value f1 in the initial product inspection process. If the number n of defective products is greater than or equal to the second determination value f2, which is greater than the first determination value f1, the process returns to the production preparation step, and the number n of bonding defects is the first and second determination values. If it is the third judgment value f3 between f1 and f2, the range of selection of the next process is widened by a plurality of judgment values regardless of a single judgment value by moving to an additional initial production process (step S7). The occurrence of defective bonding can be efficiently suppressed.

  In addition, in the operation method of the production system of the optical display device, in the additional initial production process, the liquid crystal panel P is further circulated through the main line by a predetermined amount and the optical member F1 is bonded. The process proceeds to the initial product inspection process (step S8), and the product obtained in the additional initial production process is inspected for defective bonding, and the number n of defective bonding products at this time is not more than the fourth determination value f4. If the number n of defective bonding products is greater than or equal to the fifth determination value f5, which is greater than the fourth determination value, the process returns to the production preparation step, so that the first and first The determination in the gray zone between the second determination values f1 and f2 can be left to the additional initial production process and the additional initial product inspection process, and the occurrence of defective bonding can be more efficiently suppressed.

  Further, according to the operation method of the production system of the optical display device, the non-defective product rate R is calculated every time a predetermined amount of the liquid crystal panel P is circulated through the main line in the main production process. If the determination value f6 is exceeded, the main production process is continued, and if the non-defective product rate R is equal to or less than the sixth determination value f6, the process returns to the initial production process, thereby periodically By monitoring the non-defective product rate, it is possible to suppress an increase in defective bonding due to an abnormality in the production system or a setting error.

  In addition, this invention is not limited to the said embodiment, For example, the backlight or the reflecting plate is arrange | positioned as an optical display device which bonded the optical member only to one of the front and back of an optical display component, or an illumination system. You may apply to the production system of various optical display devices. In forming the optical display device, it is possible to adopt a configuration in which one or two or more appropriate parts such as a diffusion plate, an antiglare layer, an antireflection film, a protective plate, a prism array, and a lens array sheet are arranged at appropriate positions.

In the present invention, the optical members to be bonded to both the front and back surfaces of the optical display component may have the same configuration or different configurations. The bonding process of each optical member may be performed simultaneously or substantially simultaneously, and when not performed simultaneously, either of the front and back sides may be performed first. The optical member may be completely cut for each liquid crystal panel to form individual sheet pieces, and the sheet pieces may be bonded to the liquid crystal panel.
And the structure in the said embodiment is an example of this invention, A various change is possible in the range which does not deviate from the summary of the said invention.

1 Film bonding system (Optical display device production system)
5 Roller conveyor (main line)
P Liquid crystal panel (optical display component)
n Number of defective bonding (number of defective products)
R Non-defective rate F1 Optical member S1 Production preparation process S2 Operation stop process S3 Initial production process S4 Initial product inspection process S5 Main production transition determination process S7 Additional initial production process S8 Additional initial product inspection process f1 First determination value f2 First Second judgment value f3 Third judgment value f4 Fourth judgment value f5 Fifth judgment value f6 Sixth judgment value (predetermined value)

Claims (7)

In an operation method of an optical display device production system obtained by performing predetermined processing on an optical display component,
An initial production step of distributing a predetermined amount of the optical display component to the main line of the production system and performing the predetermined processing on the optical display component;
An initial product inspection step for inspecting defects in the product obtained in the initial production step after the initial production step;
A method for operating a production system for an optical display device, comprising: a main production transition determination step for determining whether or not to shift to the main production step according to the number of defective products detected in the initial product inspection step.   2. The production preparation process according to claim 1, further comprising: a production preparation step for discharging dust in the facility that performs the predetermined processing on the optical display component before distributing the optical display component to the main line. Method of production system of optical display device in Japan.   In the initial product inspection process, if the number of defective products is equal to or less than the first determination value, the process proceeds to the production process, and the number of defective products is greater than or equal to the second determination value greater than the first determination value. If it is, it will return to the said production preparation process, and if the number of inferior goods is the 3rd determination value between said 1st and 2nd determination values, it will transfer to an additional initial production process. A method of operating a production system for an optical display device according to claim 1.   In the additional initial production process, the optical display component is further distributed through the main line in a predetermined amount and subjected to the predetermined process, and then the process proceeds to an additional initial product inspection process. If the number of defective products at this time is less than or equal to the fourth determination value, the process proceeds to the production process, and the number of defective products is greater than the fourth determination value. The method for operating the production system for an optical display device according to claim 3, wherein the process returns to the production preparation step if it is equal to or greater than the determination value.   5. The optical display device production system according to claim 2, wherein the production preparation step includes a step of distributing a dummy component corresponding to the optical display component to the main line. 6. how to drive.   The optical display device according to any one of claims 2 to 5, further comprising an operation stop step for stopping the operation of the production system for a predetermined time after the production preparation step and before the initial production step. How to operate the production system.   In the main production step, a non-defective product rate is calculated each time a predetermined amount of the optical display component is distributed to the main line. If the non-defective product rate exceeds a predetermined value, the main production process is continued, and the non-defective product rate is The method of operating an optical display device production system according to any one of claims 1 to 6, wherein if it is equal to or less than a predetermined value, the process returns to the initial production step.

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