JP2015049349A - Method for manufacturing optical member laminate - Google Patents

Method for manufacturing optical member laminate Download PDF

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Publication number
JP2015049349A
JP2015049349A JP2013180590A JP2013180590A JP2015049349A JP 2015049349 A JP2015049349 A JP 2015049349A JP 2013180590 A JP2013180590 A JP 2013180590A JP 2013180590 A JP2013180590 A JP 2013180590A JP 2015049349 A JP2015049349 A JP 2015049349A
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Japan
Prior art keywords
optical member
bonding
process
liquid crystal
sheet
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Pending
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JP2013180590A
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Japanese (ja)
Inventor
力也 松本
Rikiya Matsumoto
力也 松本
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住友化学株式会社
Sumitomo Chemical Co Ltd
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Priority to JP2013180590A priority Critical patent/JP2015049349A/en
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    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00Investigating or analysing materials by the use of optical means, i.e. using infra-red, visible or ultra-violet light
    • G01N21/84Systems specially adapted for particular applications
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29DPRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00Producing optical elements, e.g. lenses or prisms
    • B29D11/0073Optical laminates
    • GPHYSICS
    • G02OPTICS
    • G02FDEVICES OR ARRANGEMENTS, THE OPTICAL OPERATION OF WHICH IS MODIFIED BY CHANGING THE OPTICAL PROPERTIES OF THE MEDIUM OF THE DEVICES OR ARRANGEMENTS FOR THE CONTROL OF THE INTENSITY, COLOUR, PHASE, POLARISATION OR DIRECTION OF LIGHT, e.g. SWITCHING, GATING, MODULATING OR DEMODULATING; TECHNIQUES OR PROCEDURES FOR THE OPERATION THEREOF; FREQUENCY-CHANGING; NON-LINEAR OPTICS; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating, or modulating; Non-linear optics
    • G02F1/01Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating, or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating, or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/1303Apparatus specially adapted to the manufacture of LCDs
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00Investigating or analysing materials by the use of optical means, i.e. using infra-red, visible or ultra-violet light
    • G01N21/84Systems specially adapted for particular applications
    • G01N2021/8477Investigating crystals, e.g. liquid crystals
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00Investigating or analysing materials by the use of optical means, i.e. using infra-red, visible or ultra-violet light
    • G01N21/84Systems specially adapted for particular applications
    • G01N21/88Investigating the presence of flaws or contamination
    • G01N21/95Investigating the presence of flaws or contamination characterised by the material or shape of the object to be examined
    • G01N2021/9513Liquid crystal panels
    • GPHYSICS
    • G02OPTICS
    • G02FDEVICES OR ARRANGEMENTS, THE OPTICAL OPERATION OF WHICH IS MODIFIED BY CHANGING THE OPTICAL PROPERTIES OF THE MEDIUM OF THE DEVICES OR ARRANGEMENTS FOR THE CONTROL OF THE INTENSITY, COLOUR, PHASE, POLARISATION OR DIRECTION OF LIGHT, e.g. SWITCHING, GATING, MODULATING OR DEMODULATING; TECHNIQUES OR PROCEDURES FOR THE OPERATION THEREOF; FREQUENCY-CHANGING; NON-LINEAR OPTICS; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating, or modulating; Non-linear optics
    • G02F1/01Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating, or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating, or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/1306Details
    • G02F1/1309Repairing; Testing

Abstract

The present invention provides a method for producing an optical member bonded body capable of detecting the occurrence of defective products in a production line within a short time after the occurrence of defective products. A method for manufacturing an optical member bonded body in which an optical member is bonded to an optical display component, wherein a plurality of optical member sheets obtained by unwinding a belt-shaped optical member sheet from a raw roll and cutting the optical member sheet 1st autoclave process which heat-presses the optical member bonding body formation process S13 which bonds the optical member of this to several optical display components, and forms several optical member bonding body, and several optical member bonding body. After step S14 and the first autoclave treatment step, inspection step S15 for optically inspecting defects for each of the plurality of optical member bonded bodies subjected to the heat and pressure treatment, and an optical member bonded body forming step, The manufacturing method of the optical member bonding body which performs a 1st autoclave process process and an inspection process in the continuous manufacturing line. [Selection] Figure 6

Description

  The present invention relates to a method for producing an optical member bonded body.

  As a method of bonding a polarizing plate (optical member) to a liquid crystal panel (optical display component), a bonding method called an RTP (Roll to Panel) method is known (for example, see Patent Document 1). In this bonding method, a long polarizing plate unwound from a raw roll is cut into a predetermined size and directly bonded to a liquid crystal panel conveyed on the line.

  When sticking a polarizing plate to a liquid crystal panel, there is a defect such as dust generated from operating equipment or dust generated due to workers entering the liquid crystal panel and the polarizing plate as a sticking foreign matter. May occur. Such a defective product can be detected by inspecting the product carried out of the production line. However, in this method, the inspection position of the defective product is separated from the production line, and the occurrence of the defective product is A time lag occurs between detection of a defective product. As a result, after the occurrence of defective products, measures such as line stoppage and cause removal are delayed.As a result, defective products will continue to be generated until defective products are detected, and a considerable number of defective products will be generated, increasing the production line yield. There is a problem of lowering.

  Therefore, in the production system of Patent Document 1, an automatic optical inspection device (Automatic Optical Inspection) is installed on the production line, and defects of the bonded body conveyed on the line are sequentially automatically inspected. Various defect inspection apparatuses such as a transmission type and a reflection type are known as such defect inspection apparatuses, and these defect inspection apparatuses are appropriately selected and used according to the type of defect. In the production system of Patent Document 1, since the defect inspection apparatus is installed on the production line, the time lag as described above does not occur, and the production yield is improved.

Japanese Patent No. 46669070

  In the automatic inspection using the currently available defect inspection apparatus, compared with the visual inspection, “missing” for determining a defective product as a non-defective product is likely to occur. Usually, in the defect inspection apparatus, the pass / fail judgment threshold is strictly set to suppress the occurrence of oversight. However, even in the automatic inspection using the defect inspection apparatus, there are cases where oversight may occur. Therefore, drastic improvement measures for increasing the accuracy of defect detection are required.

  The present invention has been made in view of such circumstances, and it is possible to detect defects with accuracy without excess or deficiency in actual use, and to attach an optical member that can be stably manufactured without impairing the manufacturing yield. It aims at providing the manufacturing method of unification.

  In order to solve the above-described problem, one aspect of the present invention is a method for manufacturing an optical member bonded body in which an optical member is bonded to an optical display component, and a belt-shaped optical member sheet is unwound from a raw roll. The plurality of optical members obtained by cutting the optical member sheet are bonded to the plurality of optical display components, and the plurality of optical member bonding bodies are formed into an optical member bonding body forming step and the plurality of the optical members. A first autoclave treatment step for heating and pressurizing the member bonded body, and an inspection step for optically inspecting each of the plurality of optical member bonded bodies subjected to the heat and pressure processing after the first autoclave processing step. And providing the manufacturing method of the optical member bonding body which performs the said optical member bonding body formation process, a said 1st autoclave process process, and the said test | inspection process in the continuous manufacturing line.

  Moreover, one aspect of the present invention is a method for producing an optical member bonded body obtained by bonding an optical member to an optical display component, the belt-shaped optical member sheet being unwound from a raw roll, and the optical member sheet being A plurality of sheet pieces obtained by cutting are bonded to a plurality of the optical display components to form a plurality of bonded bodies, and in the bonded body, the sheet pieces and the optical display components In the detection step of detecting the outer peripheral edge of the bonding surface, and in the bonding body, an excess portion disposed outside the portion corresponding to the bonding surface from the sheet piece bonded to the optical display component, The optical member bonding body formation process which forms the said optical member bonding body which cut | disconnects along the said outer periphery, and contains the said optical member of the magnitude | size corresponding to the said bonding surface, and heat-pressurizes a plurality of said optical member bonding bodies. First autoclave processing A process and an inspection process for optically inspecting each of the plurality of optical member bonded bodies subjected to the heat and pressure treatment after the first autoclave treatment process, and the bonded body forming process and the The manufacturing method of the optical member bonding body which performs a detection process, an optical member bonding body formation process, a said 1st autoclave process process, and the said test | inspection process in the continuous manufacturing line is provided.

  In 1 aspect of this invention, it is good also as a manufacturing method which detects the outer periphery of the bonding surface of the said sheet piece and the said optical display component for every said some optical display component in the said detection process.

  In one aspect of the present invention, the inspection step is an automatic inspection step for optically automatically inspecting the defect using an automatic inspection device arranged in the production line, and is detected in the automatic inspection step. About a defective product, it is good also as a manufacturing method which further has the 1st visual inspection process which isolate | separates from the said manufacturing line and visually inspects a defect.

  In one mode of the present invention, the inspection process may be a manufacturing method which is a first visual inspection process for visually inspecting defects.

  In one mode of the present invention, about the 1st visual inspection defective article detected at the 1st visual inspection process, according to the state of the defect which the 1st visual inspection defective article has, the 1st visual inspection defective article is given. A second autoclave treatment for heating and pressurizing treatment, or the optical member is peeled off from the first visual inspection defective product to expose the optical display component, and a new prepared in advance on the exposed surface of the optical display component A reprocessing process for selecting and implementing any one of the rework processes for bonding the optical member and forming a new optical member bonded body, and the regenerating process, It is good also as a manufacturing method performed separately from a manufacturing line.

  In 1 aspect of this invention, it has the 2nd visual inspection process which carries out the visual inspection of a defect about each of the said some optical member bonding body which passed through the said reproduction | regeneration processing process, The said 2nd visual inspection process is the said production line. It is good also as a manufacturing method performed separately.

  In one aspect of the present invention, the second visual inspection defective product detected in the second visual inspection step may be a manufacturing method in which the regeneration process is performed again.

  In one aspect of the present invention, in the first autoclave treatment step, the plurality of optical member bonding bodies sequentially conveyed through the optical member bonding body forming step are distributed to a plurality of processing lines, and each processing line is provided. It is good also as a manufacturing method which heat-presses.

  In one aspect of the present invention, in the inspection step, a plurality of the optical member bonding bodies that are sequentially heated and pressurized in a plurality of the processing lines and sequentially conveyed are introduced into one inspection line, and the inspection line It is good also as a manufacturing method which optically inspects the defect.

  ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of the optical member bonding body which can detect a defect with the accuracy without excess and deficiency in actual use, and can be manufactured stably without impairing a manufacturing yield can be provided.

It is a schematic block diagram about a film bonding system. It is explanatory drawing about the 1st inversion apparatus which a film bonding system has. It is a top view of a liquid crystal panel. It is IV-IV sectional drawing in FIG. It is a fragmentary sectional view of an optical member sheet. It is explanatory drawing about the manufacturing method of the optical member bonding body in 1st Embodiment. It is a schematic block diagram about the film bonding system of 2nd Embodiment. It is a schematic diagram of the 1st detection apparatus which detects the outer periphery of the bonding surface. It is a schematic diagram which shows the modification of a 1st detection apparatus. It is a top view which shows the position which detects the outer periphery of the bonding surface. It is a schematic diagram of the 2nd detection apparatus which detects the outer periphery of the bonding surface.

  Hereinafter, the manufacturing method of the optical member bonding body which concerns on embodiment of this invention is demonstrated. 1 and 2 are explanatory views showing an optical member bonded body production system used for carrying out the method for manufacturing an optical member bonded body according to the present embodiment. Drawing 1 is a schematic structure figure about film pasting system 1 which constitutes a part of production system of an optical member pasting object. In FIG. 1, for convenience of illustration, the film bonding system 1 is illustrated in two upper and lower stages. FIG. 2 is an explanatory diagram of the first reversing device 15 included in the film bonding system 1.

  The film bonding system 1 manufactures an optical member bonding body by 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. Therefore, it is configured as a part of a production system for producing an optical display device including the optical display component and the optical member. In the film bonding system 1, the liquid crystal panel P is used as the optical display component.

  In the following description, first, after explaining liquid crystal panel P used in the film bonding system 1, the film bonding system 1 is demonstrated in detail.

(LCD panel)
FIG. 3 is a plan view of the liquid crystal panel P. FIG. 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 that is 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 follows the outer shape of the first substrate P1 in a plan view, and a region that fits inside the outer periphery of the liquid crystal layer P3 in a plan view is a display region P4.

  4 is a cross-sectional view taken along the line IV-IV in FIG. On the front and back surfaces of the liquid crystal panel P, the first optical member F11 and the second optical member F12 cut out from the long belt-like first optical member sheet F1 and second optical member sheet F2 (see FIG. 1) are appropriately bonded. The In the following description, the first optical member sheet F1 and the second optical member sheet F2 may be collectively referred to as “optical member sheet FX”. Further, the first optical member F11 and the second optical member F12 may be collectively referred to as “optical member F1X”.

  In the present embodiment, the first optical member F11 and the second optical member F12 as polarizing films are bonded to both the backlight side and the display surface side of the liquid crystal panel P, respectively. In addition, the 3rd optical member as a brightness improvement film may be further bonded on the surface by the side of the backlight of liquid crystal panel P so that it may overlap with the 1st optical member F11.

  FIG. 5 is a partial cross-sectional view of the optical member sheet FX. The optical member sheet FX includes a film-shaped optical member main body F1a, an adhesive layer F2a provided on one surface (the upper surface in FIG. 5) of the optical member main body F1a, and one of the optical member main bodies F1a via the adhesive layer F2a. The separator sheet F3a is detachably laminated on the other surface, and the surface protective film F4a is laminated on the other surface (lower surface in FIG. 5) of the optical member body F1a. Hereinafter, the part remove | excluding the separator sheet F3a from the optical member sheet | seat FX is called the bonding sheet | seat F5. For convenience of illustration, hatching of each layer in FIG. 5 is omitted.

  The optical member body F1a is bonded to the sheet-like polarizer F6, the first film F7 bonded to one surface of the polarizer F6 with an adhesive or the like, and the other surface of the polarizer F6 with an adhesive or the like. And a second film F8. The first film F7 and the second film F8 are protective films that protect the polarizer F6, for example.

  The optical member main body F1a may have a single-layer structure having 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 capable of obtaining an effect such as a hard coat treatment for protecting the outermost surface of the liquid crystal display element or an antiglare treatment. The optical member body F1a may not include at least one of the first film F7 and the second film F8. For example, when the 1st film F7 is abbreviate | omitted, it is good also as laminating | separating the separator sheet F3a on one surface of the polarizer F6 so that isolation | separation is possible via the adhesion layer F2a.

  After the optical member main body F1a is cut out to a predetermined length, the optical member main body F1a is bonded to the entire display area P4 of the liquid crystal panel P and its peripheral area. At that time, the sheet piece obtained by cutting the adhesive layer F2a into the same predetermined length is left in the sheet piece cut out from the optical member body F1a, and the sheet piece of the optical member body F1a is the sheet piece of the adhesive layer F2a. It is bonded to the liquid crystal panel P.

  The separator sheet F3a protects the adhesive layer F2a and the optical member body F1a before being separated from the adhesive layer F2a.

  The surface protective film F4a is cut out together with the optical member main body F1a and bonded to the liquid crystal panel P. The surface protective film F4a is disposed on the side opposite to the liquid crystal panel P with respect to the optical member body F1a to protect the optical member body F1a. The surface protective film F4a is separated from the optical member main body F1a at a predetermined timing. The optical member sheet FX may be configured not to include the surface protective film F4a, or the surface protective film F4a may be configured not to be separated from the optical member main body F1a.

  From such an optical member sheet | seat FX, the optical member F1X is formed by cut | disconnecting the bonding sheet | seat F5 within a manufacturing line so that it may mention later.

(Film bonding system)
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.

  In the following description, the entire process performed by the flow operation on the liquid crystal panel P from the start position to the end position of the bonding process may be referred to as a “production line”. The production line mainly refers to a flow operation performed on the roller conveyor 5, and the operation performed on the production line is referred to as “operation in the production line”. In the present embodiment, the production line includes a cleaning process (not shown) of the liquid crystal panel P provided on the upstream side of the bonding process.

  Moreover, after taking out liquid crystal panel P conveyed on the roller conveyor 5 from the start position of a bonding process to an end position, and processing the liquid crystal panel P in a position different from the roller conveyor 5, Even when the processed liquid crystal panel P is returned, it is handled as a part of the production line if it does not cause stagnation in the flow work.

  Further, the work performed separately from the flow work on the roller conveyor 5 is referred to as “work outside the production line”. Outside the production line, the work can be performed over the necessary time regardless of the conveying speed of the roller conveyor 5.

  The roller conveyor 5 is divided into an upstream conveyor 6 and a downstream conveyor 7 with a first inversion 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. An optical member obtained by cutting the belt-shaped optical member sheet FX 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 suction device 11 that sucks the liquid crystal panel P transported to the end position of the upstream process and transports the liquid crystal panel P to the start position of the upstream conveyor 6 and aligns the liquid crystal panel P. 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 pasting 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 with respect to the first deviation inspection device 14 and reaching the end position of the upstream conveyor 6, the initial position of the downstream conveyor 7 And a first reversing device 15 that conveys the

  In addition, the film bonding system 1 includes 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 from the second dust collector 16. Bonding device 17, second displacement inspection device 18 provided on the panel conveyance downstream side relative to second bonding device 17, autoclave device 100 provided on the panel conveyance downstream side relative to second displacement inspection device 18, and autoclave A second reversing device 19 provided on the downstream side of the panel conveyance with respect to the apparatus 100 and a defect inspection device (automatic inspection device) 21 disposed on the downstream side of the second conveyance device with respect to the panel conveyance are provided.

(First adsorption device)
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.

(First dust collector)
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.

(First bonding device)
The 1st bonding apparatus 13 conveys the 1st optical member sheet | seat F1 along the longitudinal direction, unwinding the 1st optical member sheet | seat F1 from the original fabric roll R1 in which the 1st optical member sheet | seat F1 was wound. The apparatus 22 and the pinching roll 23 which bonds the optical member which the conveying apparatus 22 isolate | separated from the 1st optical member sheet | seat F1 to the lower surface of liquid crystal panel P which the upstream conveyor 6 conveys are provided.

  In the present embodiment, the first optical member sheet F1 has a width corresponding to the width of the liquid crystal panel P. “Having a width corresponding to the width of the liquid crystal panel P” means that the sheet piece of the bonding sheet obtained by half-cutting the first optical member sheet F1 in the sheet width direction is the size of the display area P4 of the liquid crystal panel P. That is, the size is equal to or smaller than the size of the substrate of the liquid crystal panel P to which the sheet piece is bonded (the size excluding the functional portion such as the electronic component mounting portion on the substrate).

  Specifically, the length of the first optical member sheet F1 in the short direction is the same as or longer than the long side of the display area P4 of the liquid crystal panel P, and the liquid crystal panel P on which the sheet piece is bonded. This substrate has a width equal to or narrower than the side corresponding to the long side of the display region P4. The 1st bonding apparatus 13 is the liquid crystal panel P by which the bonding sheet F5 of the 1st optical member sheet | seat F1 is the same as or longer than the short side of the display area P4 of liquid crystal panel P, and a sheet piece is bonded. A sheet piece of the bonding sheet F5 is formed by cutting with a length equal to or shorter than the side corresponding to the short side of the display region P4 in the substrate of the substrate, and on the lower surface of the liquid crystal panel P introduced into the bonding position. On the other hand, the sheet piece of the bonding sheet F5 cut into a predetermined size is bonded.

  The “sheet piece of the bonding sheet F5” produced in the first bonding apparatus 13 corresponds to the optical member bonded to the liquid crystal panel P. The optical member produced as described above has such a size that the peripheral edge can be accommodated in the frame G when the liquid crystal panel P is overlapped.

  The conveying device 22 conveys the bonding sheet F5 using the separator sheet F3a as a carrier, holds the raw fabric roll R1 around which the first optical member sheet F1 is wound, and the first optical member sheet F1 in the longitudinal direction. A plurality of guide rollers 22b for winding the first optical member sheet F1 so as to guide the first optical member sheet F1 unwound from the roll roll R1 and the first optical member sheet F1 unwound from the original roll R1. And a cutting device 22c for half-cutting the first optical member sheet F1 on the transport path, and winding the first optical member sheet F1 that has been half-cut at an acute angle to separate the optical member from the separator sheet F3a, A knife edge 22d that supplies this optical member to the bonding position, and a separator sheet F that has become independent through the knife edge 22d And a winding portion 22e for holding the separator roll R2 winding the a.

  In the present embodiment, the “half cut” means that the separator sheet F3a remains in a predetermined thickness so that the separator sheet F3a is not broken by a tension acting during conveyance of the first optical member sheet F1. Means to cut from the opposite side to the vicinity of the boundary surface between the adhesive layer F2a and the separator sheet F3a. A cutting blade or a laser device can be used to form the cut.

  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 part 22e winds up the separator sheet F3a which passed through the knife edge 22d, while the roll holding part 22a feeds the first optical member sheet F1 in the transport direction. Hereinafter, the upstream side in the transport direction of the first optical member sheet F1 (separator sheet F3a) 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 first optical member sheet F1 being conveyed along the conveyance path, and at least a part of the plurality of guide rollers 22b applies the tension of the first optical member sheet F1 being conveyed. Moveable to adjust.

  When the first optical member sheet F1 is fed out by a predetermined length, the cutting device 22c has one thickness direction of the first optical member sheet F1 over the entire width in the width direction orthogonal to the longitudinal direction of the first optical member sheet F1. Cut the part (half cut).

  The cutting device 22c performs cutting so that the first optical member sheet F1 (separator sheet F3a) is not broken by a tension acting during conveyance of the first optical member sheet F1 (so that a predetermined thickness remains on the separator sheet F3a). The advancing / retreating position of the blade is adjusted, and half cutting is performed to the vicinity of the interface between the adhesive layer F2a and the separator sheet F3a.

  By cutting the bonding sheet F5 in the thickness direction of the first optical member sheet F1 after half-cutting, a cut line extending over the entire width in the width direction of the first optical member sheet F1 is formed. A plurality of score lines are formed so as to be aligned in the longitudinal direction of the belt-shaped first optical member sheet F1. 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 the first optical member sheet F1. The first optical member sheet F1 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 first optical member sheet F1 is a sheet piece in the bonding sheet F5.

  The knife edge 22d is disposed below the upstream conveyor 6 and extends over at least the entire width in the width direction of the first optical member sheet F1. The knife edge 22d is wound so as to be in sliding contact with the separator sheet F3a side of the first optical member sheet F1 after the half cut.

  The knife edge 22d has a first surface that is disposed in an inclined position when viewed from the width direction of the first optical member sheet F1 (the width direction of the upstream conveyor 6), and the first optical member sheet F1 above the first surface. A second surface disposed at an acute angle with respect to the first surface when viewed from the width direction, and a tip portion where the first surface and the second surface intersect.

  The knife edge 22d winds the first optical member sheet F1 at an acute angle at the tip. The first optical member sheet F1 separates the sheet piece (optical member) of the bonding sheet F5 from the separator sheet F3a 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 optical member separated from the separator sheet F3a 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. In the gap, the liquid crystal panel P and the optical member are overlapped and introduced. The liquid crystal panel P and the optical member are sent out to the downstream side of the panel conveyance while being sandwiched between the bonding rollers 23a. Thereby, an optical member is integrally bonded to the lower surface of the liquid crystal panel P. Hereinafter, the panel after this bonding is called single-sided bonding panel (optical member bonding body) P11.

(First displacement inspection device)
The 1st shift | offset | difference test | inspection apparatus 14 is whether the position with respect to liquid crystal panel P of the optical member bonded by the 1st bonding apparatus 13 in the single-sided bonding panel P11 is appropriate (whether a position shift exists in a tolerance range). Inspect. The first misalignment inspection apparatus 14 includes a pair of cameras 14a that image the edge of the optical member 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 the relative positions of the optical member 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 (outside the production line) by a not-shown dispensing means.

(First reversing device)
The first reversing device 15 shown in FIG. 2 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, and the end position of the upstream conveyor 6 via the rotation shaft 15a. And a reversing arm 15b supported between the initial positions of the downstream conveyor 7. The reversing arm 15b holds the single-sided bonding panel P11 that has reached the end position of the upstream conveyor 6 via the first deviation 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 F1X to be 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. However, 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 bonding device 13 and the sheet conveying direction of the second bonding device 17 are arranged at right angles to each other in a plan view, the polarization axis directions are perpendicular to each other on the front and back surfaces of the liquid crystal panel P. The optical member F1X made can be bonded.

  The reversing arm 15b has the same alignment function as 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.

(Second dust collector)
Returning to FIG. 1, the second dust collecting device 16 is provided on the upstream side of the panel conveyance in the vicinity of the bonding position of the second bonding device 17, and is a single-sided bonding panel immediately before being introduced into the bonding position. Remove the static electricity and collect dust on the lower surface of P11.

(Second bonding device)
The 2nd bonding apparatus 17 is provided with the conveying apparatus 22 and the pinching roll 23 similar to the 1st bonding apparatus 13. FIG. In the 2nd bonding apparatus 17, the optical member formed by cutting the 2nd optical member sheet | seat F2 into a predetermined size is performed with respect to the lower surface of the single-sided bonding panel P11 introduced into the bonding position. .

  In the present embodiment, like the first optical member sheet F1 described above, the second optical member sheet F2 has a width corresponding to the width of the liquid crystal panel P. Specifically, the length of the second optical member sheet F2 in the short direction is the same as or wider than the short side of the display area P4 of the liquid crystal panel P, and the liquid crystal panel P on which the sheet piece is bonded. The width of the substrate is the same as or narrower than the side corresponding to the short side of the display region P4. The 2nd bonding apparatus 17 is the liquid crystal panel P by which the bonding sheet F5 of the 2nd optical member sheet | seat F2 is the same as or longer than the long side of the display area P4 of liquid crystal panel P, and a sheet piece is bonded. A sheet piece of the bonding sheet F5 is formed by cutting with a length equal to or shorter than the side corresponding to the long side of the display region P4 on the substrate of the liquid crystal panel P introduced into the bonding position. On the other hand, the sheet piece of the bonding sheet F5 cut into a predetermined size is bonded.

  The “sheet piece of the bonding sheet F5” produced in the second bonding apparatus 17 corresponds to an optical member bonded to the liquid crystal panel P. The optical member produced as described above has such a size that the peripheral edge can be accommodated in the frame G when the liquid crystal panel P is overlapped.

  In the gap between the pair of bonding rollers 23a of the pinching roll 23 (the bonding position of the second bonding device 17), the single-sided bonding panel P11 and the optical member are introduced in an overlapping state, and the single-sided bonding panel An optical member is integrally bonded to the lower surface of P11. Hereinafter, the panel after this bonding is called double-sided bonding panel (optical member bonding body) P12.

  Whether the position with respect to liquid crystal panel P of the optical member bonded by the 2nd bonding apparatus 17 in the 2nd bonding panel P12 is the 2nd shift inspection apparatus 18 is appropriate (whether a position shift exists in a tolerance range). Inspect. The second misalignment inspection apparatus 18 includes a pair of cameras 18a that image the edge of the optical member on the upstream side and the downstream side of the double-sided bonding panel P12, for example. Imaging data from 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 optical member 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.

(Autoclave device)
The autoclave apparatus 100 performs an autoclave process (first autoclave process) in which the double-sided bonding panel P12 that has passed through the second misalignment inspection apparatus 18 is heated and pressurized. The autoclave apparatus 100 has a chamber 101 in which a plurality of double-sided bonding panels P12 stacked together are carried in and subjected to heat and pressure treatment on the plurality of double-sided bonding panels P12.

In the present specification, “autoclave treatment” refers to exposing a defective product to be treated to a temperature higher than room temperature in a pressurized environment higher than atmospheric pressure and holding it for a certain period of time. As an example, the processing condition is a pressure condition of 0.294 MPa or more and 0.785 MPa or less (3 kgf / cm 2 or more and 8 kgf / cm 2 or less). Time is mentioned.

Pressure condition is preferably not less than 0.392MPa (4kgf / cm 2 or higher) is preferably 0.588MPa or less (6 kgf / cm 2 or less).
The temperature condition is preferably 50 ° C. or higher, and preferably 70 ° C. or lower.
The holding time is preferably 1 minute or longer, and preferably 5 minutes or shorter.
The upper limit value and the lower limit value of the processing conditions can be arbitrarily combined.

  The “holding time” refers to the time from when the inside of the chamber 101 becomes equal to or higher than the set values of pressure and temperature until either one of the pressure or temperature falls below the set value. For this reason, even if one or both of the pressure and temperature fluctuate, if the pressure and temperature are equal to or higher than the set value, the processing time under that condition is included in the holding time.

  In the autoclave apparatus 100, first, a predetermined number of double-sided bonding panels P <b> 12 that are sequentially conveyed are stacked by a stacking unit (not shown) disposed at a position indicated by reference numeral 102 on the upstream side of the chamber 101. In the stacking unit, a predetermined number of sheets are stacked while the autoclaving process is performed in the chamber 101. Therefore, the stacking unit functions as a buffer for preventing the double-sided bonding panel P12 from being delayed during the autoclave process.

  Next, a plurality of stacked double-sided bonding panels P12 are collectively loaded into the chamber 101 and subjected to autoclave processing.

  The maximum time during which the autoclave process can be performed is defined by the conveyance speed of the double-sided bonding panel P12 in the production line and the number of stacked sheets in the stacking unit. For example, when the double-sided bonding panel P12 is carried into the stacking unit every 10 seconds and 20 double-sided bonding panels P12 are stacked in the stacking unit, 20 double-sided bondings are performed every 200 seconds from the stacking unit toward the chamber 101. Panel P12 is carried in. In such a case, in the chamber 101, the autoclave process can be performed for a maximum of 200 seconds including the time of temperature increase / decrease and temperature decrease / decrease.

  Next, in the unillustrated unloading part arranged at the position indicated by reference numeral 103 on the downstream side of the chamber 101, the plural double-sided bonding panels P12 unloaded from the chamber 101 are unloaded one by one and transported downstream. To do. In the unloading part, the double-sided bonding panel P12 is unloaded at a speed equal to or higher than the double-sided bonding panel P12 stacked in the stacking part so that the conveyance of the double-sided bonding panel P12 is not delayed.

  In addition, the downstream side of the second misalignment inspection device 18 may be divided into a plurality of downstream conveyors 7, and the autoclave device 100 may be arranged for each of the branched downstream conveyors 7 so that the autoclave processing is performed in parallel. Good. When autoclaving is performed in parallel, it is preferable because the processable time in each autoclave apparatus becomes long.

  By the autoclave process in the autoclave apparatus 100, about the some double-sided bonding panels P12 containing a defect among the double-sided bonding panels P12 carried into the autoclave apparatus 100, a defect can be lose | disappeared so that it may mention later. The defect inspection device 21 detects a defect that has not disappeared by the autoclave process.

  Here, in the manufacturing method of the optical member bonding body of the present embodiment, the “defect” that is the inspection target of the defect inspection apparatus 21 is a defect that can be optically inspected in the display area of the double-sided bonding panel P12. And it refers to what causes a display defect in the display apparatus manufactured using the double-sided bonding panel P12.

  Examples of such defects include (1) defects that the liquid crystal panel P itself has, (2) defects that the optical member itself has, and (3) defects that occur on the bonding surface between the liquid crystal panel P and the optical member.

  “(1) Defects of the liquid crystal panel P itself” includes, for example, that the liquid crystal of the liquid crystal panel P is not aligned as designed due to disturbance of the liquid crystal alignment film of the liquid crystal panel P. With such a defect, for example, even if a pair of polarizing plates are accurately bonded to crossed Nicols and the liquid crystal panel P is designed to be normally black, light is irradiated from one side of the double-sided bonded panel P12. Since light leaks, it can be confirmed as a bright spot. Moreover, also when the liquid crystal panel P is damaged during conveyance, it is mentioned as a defect which (1) liquid crystal panel P itself has.

  “(2) Defects possessed by the optical member itself” can include deformations such as scratches and dents formed on the surface of the optical member F1X. If there is such a defect, the light emitted through the liquid crystal panel P will be refracted and scattered at the deformed part, so the brightness will be different from other parts that are not deformed. It becomes possible.

  “(3) Defect generated on the bonding surface between the liquid crystal panel P and the optical member” inserts dust and dust (hereinafter, collectively referred to as “foreign matter”) into the bonding surface between the liquid crystal panel P and the optical member. And defects due to air bubbles being formed between the bonding surfaces. A bonding surface is a bonding surface of liquid crystal panel P and the 1st optical member F11 shown in FIG. 4, and a bonding surface of liquid crystal panel P and the 2nd optical member F12. If there is such a defect, the light emitted through the liquid crystal panel P will be refracted and scattered at the defective part, so the brightness will be different from other parts without the defect. It becomes possible.

  When the autoclave treatment is performed on the double-sided bonding panel P12, the defect that the double-sided bonding panel P12 has is a small deformation of the optical member itself among “(2) Defects of the optical member itself” or “(3) Among the “defects that occur on the bonding surface between the liquid crystal panel P and the optical member”, the defects disappear when the air bubbles are sandwiched between the liquid crystal panel P and the optical member and are microscopic objects. Can be expected to do.

  That is, when the defect is a small deformation of the optical member itself, when the autoclave process is performed, the optical member is softened and easily deformed by heat. Thereby, it can be expected that a small deformation causing the defect disappears.

  In addition, when the defect is a bubble generated by sandwiching air on the bonding surface, due to heat and pressure, the saturation solubility of air in the sheet piece of the adhesive layer F2a (see FIG. 5) of the optical member increases, Air forming bubbles dissolves in the sheet piece of the adhesive layer F2a. Thereby, it can be expected that bubbles disappear.

  Further, since the air dissolved in the sheet piece of the adhesive layer F2a diffuses into the sheet piece of the adhesive layer F2a, even if the defective product is returned to room temperature under atmospheric pressure after the autoclave treatment, the position where the lost bubbles existed In addition, it can be expected that air will not aggregate again and bubbles will not be regenerated.

  Defects that are expected to disappear by autoclaving are often difficult to find with the defect inspection apparatus 21. Therefore, when the double-sided bonded panel P12 having such fine defects is introduced into the inspection process, false reports and oversights are likely to occur. . Therefore, by eliminating such defects by autoclaving, the inspection results in the inspection process described later are easily stabilized.

  On the other hand, the defect that the double-sided bonded panel P12 has is large in the optical member itself among “(1) defects that the liquid crystal panel P itself has” and “(2) defects that the optical member itself have” such as damage to the liquid crystal panel P. Among the deformations, “(3) Defects that occur on the bonding surface of the liquid crystal panel P and the optical member”, large bubbles or air bubbles that are generated by sandwiching air between the bonding surfaces of the liquid crystal panel P and the optical member, or bonding In the case of a defect caused by the inclusion of a foreign object on the surface, it is expected that the defect will not disappear by autoclaving.

  However, defects that do not disappear by autoclaving as described above are easy to find in the inspection process, so that false information and oversight in the inspection process are unlikely to occur. Therefore, the inspection result in the inspection process described later is easily stabilized.

(Second reversing device)
The 2nd inversion apparatus 19 inverts the front and back about the double-sided bonding panel P12 carried out from the autoclave apparatus 100. FIG. As for the double-sided bonding panel P12 conveyed to the 2nd inversion apparatus 19, although the backlight side has turned upward by passing through the 1st inversion apparatus 15, by the 2nd inversion apparatus 19, to the film bonding system 1 The display surface side of the liquid crystal panel P faces upward as in the case of carry-in.

(Defect inspection equipment)
The defect inspection device 21 is an automatic inspection device that performs AOI inspection (Automatic Optical Inspection) on the liquid crystal panel P (double-sided bonding panel P12) with the display surface facing upward through the second reversing device 19. It is. In the present embodiment, the defect inspection apparatus 21 captures an image from the upper surface side (display surface side) with the camera 21a while applying light from the lower surface side (backlight side) of the double-sided bonding panel P12, and based on this imaging data. The double-sided bonding panel P12 is automatically inspected for defects. As the defect inspection apparatus 21, in addition to the structure shown in this embodiment, any apparatus capable of optically automatically inspecting defects can be used.

  About the double-sided bonding panel P12 to be inspected, since the autoclave processing is performed by the autoclave apparatus 100 in the production line, fine defects that are likely to cause false reports and oversights are reduced. Therefore, the inspection result in the defect inspection apparatus 21 is stabilized.

  Moreover, in the defect inspection apparatus 21, since only the large defect which does not lose | disappear by an autoclave process can be made into an inspection object, the detection of the defect in the defect inspection apparatus 21 becomes easy, and the result of a defect inspection is stabilized.

  Moreover, since the defect inspection apparatus 21 is arrange | positioned on the downstream conveyor 7, all the double-sided bonding panels P12 can be test | inspected in real time in a manufacturing line. For this reason, when defective products are found, the production line is stopped before many defective products are manufactured, and the occurrence position of defective products and measures against the occurrence of defective products can be quickly implemented.

  About the double-sided bonding panel P12 which was inspected in the defect inspection apparatus 21 and a defect was not found, it is conveyed downstream by the downstream conveyor 7, and is carried out from the production line of the film bonding system 1.

  Further, defective products in which defects are found in the defect inspection apparatus 21 are removed from the production line, and a visual inspection (first visual inspection step) is performed outside the production line (offline).

  About double-sided bonding panel P12 which was inspected in visual inspection and a defect was not found, it is carried out to the next process as double-sided bonding panel P12 of a finished product.

  Moreover, about the double-sided bonding panel P12 (defective product) in which a defect was found in the visual inspection, the following regeneration process may be performed. Here, in this embodiment, since the autoclave process is performed about the double-sided bonding panel P12, the number of inferior goods has decreased compared with the case where an autoclave process is not performed. For this reason, there are few defective products to be subjected to the reproduction process, and the reproduction process can be performed with a margin. In the following description, a defective product determined by visual inspection is referred to as a “first visual inspection defective product”.

(Reproduction processing)
For the first visual inspection defective product, first, the type and state of the found defect are confirmed, and it is determined whether or not the defect can be eliminated by performing subsequent processing. Next, one of the following two processes is selected according to the state of the defect, and the process is performed.

  Of the “(2) Defects of the optical member itself”, the defects are small deformations of the optical member itself and “(3) Defects occurring on the bonding surface between the liquid crystal panel P and the optical member”. When it is judged that the air bubbles are sandwiched between the optical member and the air bubbles and are fine and are lost by the autoclave treatment, the first visual inspection defective product is subjected to autoclave treatment (second autoclave treatment). .

  About the 1st visual inspection inferior goods by which the defect was detected, the 1st autoclave process has already been performed with the autoclave apparatus 100 in a manufacturing line. Therefore, when the processing conditions of the second autoclave process are gentler than the processing conditions of the first autoclave process, it is considered that the defect is difficult to disappear.

  Therefore, the second autoclave process may be performed under conditions that are stricter than the process conditions of the first autoclave process. In the second autoclave process, it is possible to set the temperature and pressure set values higher than the set values in the first autoclave process. However, if these set values are increased, the liquid crystal panel P may be damaged. . Therefore, in the second autoclave process, it is preferable that the holding time in the autoclave process is set longer than that in the first autoclave process, thereby making the conditions stricter than the process conditions of the first autoclave process.

The processing conditions of the second autoclave treatment are, for example, 30 seconds or more under a temperature condition of 40 ° C. or more and 80 ° C. or less in a pressure condition of 0.294 MPa or more and 0.785 MPa or less (3 kgf / cm 2 or more and 8 kgf / cm 2 or less). The holding time is 25 minutes or less.

Pressure condition is preferably not less than 0.392MPa (4kgf / cm 2 or higher) is preferably 0.588MPa or less (6 kgf / cm 2 or less).
The temperature condition is preferably 50 ° C. or higher, and preferably 70 ° C. or lower.
The holding time is preferably 1 minute or longer, and preferably 5 minutes or shorter.
The upper limit value and the lower limit value of the processing conditions can be arbitrarily combined.

  Moreover, the defect which the 1st visual inspection inferior goods have is a large deformation | transformation of optical member itself among "(2) Defect which optical member itself has", and the bonding surface of "(3) liquid crystal panel P and an optical member. In the case of “defects that occur in”, when the bubbles are large objects that are caused by air being sandwiched between the bonding surfaces of the liquid crystal panel P and the optical member, or when the foreign objects are sandwiched between the bonding surfaces. In the autoclave process, it is expected that defects will not disappear.

  In that case, the optical member is peeled from the first visual inspection defective product to expose the liquid crystal panel P, and a new sheet piece is bonded to the exposed liquid crystal panel P to form a new double-sided bonded panel P12. Rework processing is performed.

  In addition, the defect that the first visual inspection defective product has is “(1) the defect that the liquid crystal panel P itself has” such as damage to the liquid crystal panel P, and when it is determined that it cannot be reproduced by the autoclave process or the rework process, The first visual inspection defective product is discarded.

  Such a regeneration processing step is performed separately from the above-described production line (offline processing). Therefore, it is possible to spend a sufficient amount of time for each process, and reduction of waste products can be expected.

  About the double-sided bonding panel P12 which passed through the reproduction | regeneration processing process, the presence or absence of a defect is test | inspected in the visual inspection (2nd visual inspection process) isolate | separated from the above-mentioned manufacturing line. If a defect is not found, it will be carried out to the next process as a finished product double-sided bonding panel P12.

  Moreover, about the thing which a defect was found in the 2nd visual inspection process and was determined as inferior goods, it returns to the above-mentioned reproduction | regeneration processing process again, and tries reproduction | regeneration. Here, the first visual inspection defective product in which a defect is found in the second visual inspection step corresponds to the “second visual inspection defective product” in the present invention.

(Manufacturing method of an optical member bonding body)
Drawing 6 is an explanatory view about a manufacturing method of an optical member pasting object in this embodiment, and is a flow figure showing a manufacturing process mentioned above. Hereinafter, the manufacturing flow will be described using the reference numerals shown in FIG. 1 as appropriate.

  In the flowchart, the process indicated by reference sign S1 indicates a process performed within the manufacturing line, and the process indicated by reference sign S2 indicates a process performed outside the manufacturing line.

(Optical member bonding body formation process)
First, in the manufacture of the double-sided bonded panel P12, the liquid crystal panel P is carried into the production line (step S11), and dirt such as dust and dust adhering to the surface of the liquid crystal panel P is washed (step S12).

  Next, in the above-described film bonding system 1, the first optical member sheet F1 and the second optical member sheet F2 are unwound from the raw roll R1, respectively, while the first optical member sheet F1 and the second optical member sheet F2 are unwound. Each of the first optical member F11 and the second optical member F12 is formed by cutting to a length corresponding to the long side or the short side of the display region P4. Here, “cut to the length corresponding to the long side or the short side of the display region P4” means that the size of the sheet piece obtained by cutting is equal to or larger than the size of the display region P4 of the liquid crystal panel P. In addition, the long side of the display region P4 or the size of the optical display component to which the sheet piece is bonded is smaller than the size of the substrate (excluding the functional part such as the electronic component mounting portion on the substrate). It means cutting with a length not less than the length of the short side and not more than the length corresponding to the side of the substrate of the liquid crystal panel P to which the sheet piece is bonded.

  Then, the 1st optical member F11 and the 2nd optical member F12 are bonded together on both surfaces of liquid crystal panel P, and double-sided bonding panel P12 is formed (step S13).

(First autoclave treatment)
Next, autoclave treatment is performed in the production line (inline) for the obtained double-sided bonded panel P12 (step S14).

(Automatic inspection process)
Subsequently, about the double-sided bonding panel P12 by which the autoclave process was carried out, a defect inspection is performed using the defect inspection apparatus 21 arrange | positioned in a manufacturing line (inline) (step S15).

  About double-sided bonding panel P12 determined as a non-defective product as a result of the inspection, for example, after collecting a plurality of sheets, they are carried out for the next process (step S16).

(First visual inspection process)
On the other hand, as a result of the defect inspection, the double-sided bonded panel P12 determined as a defective product having a defect is visually inspected for defects outside the production line (offline) (step S21).

  As a result of the visual inspection, the double-sided bonded panel P12 determined to be non-defective is carried out for the next process (step S16).

(Regeneration process)
On the other hand, about the double-sided bonding panel P12 determined as a defective product having a defect (first visual inspection defective product) as a result of visual inspection, the type and state of the found defect are confirmed, and subsequent processing is performed. It is determined whether the defect can be eliminated (step S22).

  When the defects of the first visual inspection defective product are small deformations of the optical member itself, or bubbles that are generated by sandwiching air between the bonding surfaces of the liquid crystal panel P and the optical member (in the flow diagram, “ Autoclave processing is performed (denoted as “defect / small”) (step S23).

  On the other hand, if the defect of the first visual inspection defective product is a large object that is a large deformation of the optical member itself or air bubbles that are generated by sandwiching air between the bonding surfaces of the liquid crystal panel P and the optical member (in the flow diagram) A rework process is performed (denoted “defect / medium”) (step S24).

  In addition, when it is determined that the defect possessed by the first visual inspection defective product is one that cannot be reproduced by the autoclave process or the rework process, such as damage to the liquid crystal panel P (denoted as “defect / large” in the flow diagram). Discard.

  Next, the double-sided bonding panel P12 that has been subjected to autoclave processing or rework processing is visually inspected for defects (second visual inspection step, step S25).

If a defect is not found, it will be carried out to the next process as a finished product double-sided bonding panel P12. If a defect is found and determined as a defective product (second visual inspection defective product), the process returns to step S22 again, and the reproduction process is attempted again.
The manufacturing method of the optical member bonding body of this embodiment is performed as mentioned above.

  According to the manufacturing method of the above optical member bonding body, all the optical member bonding bodies conveyed on the line are made to autoclave. Therefore, about the optical member bonding body which has the fine defect which is hard to be noticed by humans and disappears by the autoclave treatment, the defect disappears and can be made a non-defective product, and the yield is improved.

  Further, in the automatic inspection using the automatic inspection apparatus, false alarms are likely to occur, but in the present embodiment, the double-sided bonding panel P12 to be inspected is autoclaved by the autoclave apparatus 100 in the production line. Minor defects that tend to cause false alarms and oversights are reduced. Therefore, even if the defect inspection apparatus 21 is used, the inspection result is stable, and the advantage of inspection automation can be enjoyed.

  Moreover, the deformation | transformation of optical member itself can be eliminated by the autoclave process, and the defect of an optical member bonding body can be lose | disappeared. Even when the optical member itself has a deformed portion that causes a defect, since it can be an optical member bonded body having no defect, the optical member yield is improved, and as a result, the optical member The yield of the bonded body can be improved.

  Further, after the autoclave treatment, the optical member bonded body conveyed on the line is sequentially automatically inspected by an automatic inspection device. Since the products are sequentially inspected on the production line, the occurrence of defective products on the production line can be detected within a short time from the occurrence of defective products. Therefore, the generation of defective products can be suppressed, and the manufacturing yield can be improved.

  In addition, a defective product in which a defect is detected by an automatic inspection device on the production line is to be visually inspected outside the production line. If a commercially available optical automatic inspection device is used, there is a risk of overkill, and optical member bonded bodies that are determined as defective by automatic inspection include those that should be determined as non-defective products in actual use. However, by performing repeated visual inspections, there is little risk of overkill, and the accuracy of defect inspection is maintained at an appropriate level in accordance with actual use.

  In addition, since fine defects have disappeared due to the autoclave treatment, the number of defective products having defects can be reduced, and the process load of visual inspection can be reduced.

  Furthermore, by eliminating fine defects by autoclaving, it is sufficient to detect large defects that are easy to determine mainly by visual inspection, and it is easy to detect defects with sufficient accuracy in actual use.

  Therefore, according to the manufacturing method of the optical member bonding body of the present embodiment, the optical member bonding that enables defect detection with accuracy with no excess or deficiency in actual use and that can be stably manufactured without impairing the manufacturing yield. A method for producing a coalescence is provided.

  The present invention is not limited to the above embodiment. For example, although the case where a polarizing film is bonded to a liquid crystal panel has been described, the optical display component to which the optical member is bonded is not limited to the liquid crystal panel, and can also be applied to an organic EL panel. The present invention is not limited to a polarizing film, and can be applied to an antireflection film, a light diffusion film, and the like.

  In the present embodiment, the defect inspection apparatus 21 is arranged on the production line and the defects are automatically inspected in the production line. However, the present invention is not limited to this, and an inspector is placed at the position where the defect inspection apparatus 21 is arranged. It is good also as arranging and carrying out the visual inspection by an inspector.

  In this case, since the inspector performs a visual inspection, compared with the case where it is automated using a measuring device, there is a false report (determining a non-defective product as a defective product) or an oversight (determining a defective product as a non-defective product). The result of defect inspection is stable. When the visual inspection is performed in the production line, the visual inspection (step S21 in FIG. 6) performed again after the inspection can be omitted.

  When visual inspection is performed in a production line, the line conveyance speed of the double-sided bonding panel P12 is often faster than the time required for the inspector to visually check one double-sided bonding panel P12. For this reason, it is preferable to arrange a plurality of inspectors at the defect inspection position and share them for visual inspection.

  A plurality of inspectors may be arranged and inspected in a line in the extending direction of the downstream conveyor 7, and after setting a plurality of inspection lines, inspectors are arranged on the plurality of inspection lines and conveyed. It is good also as test | inspecting in each test | inspection line by distributing the double-sided bonding panel P12 performed to each test | inspection line.

In this way, when visual inspection is performed by an inspector on a production line, there is less risk of overkill than when performing a defect inspection with a commercially available optical automatic inspection device, and the accuracy of defect inspection is more suitable for actual use. At the appropriate level.

  In the present embodiment, the defective product detected in the second visual inspection process is subjected to the regeneration process again. However, if the regeneration process is performed a plurality of times, the heat history increases and the optical member is attached. Since the quality of coalescence is likely to deteriorate, defective products detected in the second visual inspection process may be discarded.

  However, from the viewpoint of improving yield, it is better to have fewer waste products. For example, an upper limit value that can be applied to the regeneration process step is set in advance, and defective products that have passed the regeneration process step a set number of times. It is good practice to discard them.

[Second Embodiment]
Drawing 7 is an explanatory view showing the production system of other optical member bonding objects used for implementation of the manufacturing method of the optical member bonding object concerning this embodiment. FIG. 7: is a schematic block diagram about the film bonding system 2 which comprises a part of production system of an optical member bonding body, and is a figure corresponding to FIG. In FIG. 7, for convenience of illustration, the film bonding system 2 is described in two upper and lower stages. In the following description, detailed description of contents common to the above description is omitted.

  In the film bonding system 2 shown in FIG. 7, the first optical member sheet F1 has a width that is longer than the long side of the display region P4 of the liquid crystal panel P in the longitudinal direction. Further, the second optical member sheet F2 has a width that is shorter in the lateral direction than the short side of the display area P4 of the liquid crystal panel P.

  In such a film bonding system 2, the bonding sheet F5 of the belt-shaped first optical member sheet F1 is cut out with a length longer than the short side of the display region P4 of the liquid crystal panel P to produce the first sheet piece F1m. Then, the liquid crystal panel P is bonded to the liquid crystal panel P during the conveyance of the liquid crystal panel P using the roller conveyor 5. Similarly, the bonding sheet F5 of the band-shaped second optical member sheet F2 is cut out with a length longer than the long side of the display area P4 of the liquid crystal panel P to produce a second sheet piece F2m, and the roller conveyor 5 is used. The liquid crystal panel P is bonded to the liquid crystal panel P while it is being transported. In the following description, the first sheet piece F1m and the second sheet piece F2m may be collectively referred to as “sheet piece FXm”.

  Then, the 1st optical member F11 and the 2nd optical member F12 are formed by cut | disconnecting the excess part of the outer side of the display area from the 1st sheet piece F1m and the 2nd sheet piece F2m. Each part of the film bonding system 2 is comprehensively controlled by a control unit (not shown).

  The film bonding system 2 includes a first suction device 11 that sucks the liquid crystal panel P transported to the carry-out end of the preceding step and transports it to the carry-in end of the upstream conveyor 6 and performs alignment (positioning) of the liquid crystal panel P. The 1st dust collector 12 provided in the panel conveyance downstream of the 1st adsorption | suction apparatus 11, the 1st bonding apparatus 13 provided in a panel conveyance downstream rather than the 1st dust collector 12, and the 1st bonding apparatus The first reversing device 31A disposed on the panel transport downstream side with respect to 13, the first cutting device 32A disposed on the panel transport downstream side with respect to the first reversing device 31A, and the panel transport downstream with respect to the first cutting device 32A. A recovery device (not shown) disposed at the first recovery position 33A on the side, and a first swivel device 34 disposed on the downstream side of the panel transport with respect to the recovery device.

  Moreover, the film bonding system 2 is arrange | positioned in the panel conveyance downstream rather than the 2nd dust collector 16 and the 2nd dust collector 16 arrange | positioned in the panel conveyance downstream rather than the carrying-in end of the downstream conveyor 7. FIG. The 2nd bonding apparatus 17, the 2nd inversion apparatus 31B arrange | positioned in the panel conveyance downstream rather than the 2nd bonding apparatus 17, and the 2nd cutting apparatus arrange | positioned in the panel conveyance downstream rather than the 2nd inversion apparatus 31B. 32B, a collection device (not shown) disposed at the second collection position 33B on the downstream side of the panel conveyance with respect to the second cutting device 32B, an autoclave device 100 disposed on the downstream side of the conveyance of the panel with respect to the collection device, and an autoclave A second swiveling device 35 disposed on the downstream side of the panel transport with respect to the apparatus 100 and a defect inspection device 21 disposed on the downstream side of the transporting of the panel with respect to the second swiveling device 35 are provided.

  Further, as will be described in detail later, a detection device used for setting a cut position in the first cutting device 32A is provided on the upstream side of the first cutting device 32A in the panel conveyance, and upstream of the second cutting device 32B in the panel conveyance direction. On the side, a detection device used for setting a cut position in the second cutting device 32B is provided.

(First bonding device)
The 1st bonding apparatus 13 bonds the sheet piece (1st sheet piece F1m) of the bonding sheet | seat F5 cut into the predetermined size with respect to the lower surface of liquid crystal panel P introduced into the bonding position.

  The 1st bonding apparatus 13 conveys the 1st optical member sheet | seat F1 along the longitudinal direction, unwinding the 1st optical member sheet | seat F1 from the original fabric roll R1 in which the 1st optical member sheet | seat F1 was wound. The apparatus 22 and the pinching roll 23 which bonds the 1st sheet piece F1m separated from the 1st optical member sheet | seat F1 by the conveying apparatus 22 to the lower surface of liquid crystal panel P conveyed by the upstream conveyor 6 are provided. Yes.

  The conveyance device 22 conveys the bonding sheet F5 using the separator sheet F3a as a carrier, and performs a half cut on the roll holding unit 22a, the plurality of guide rollers 22b, and the first optical member sheet F1 on the conveyance path. A device 22c, a knife edge 22d that feeds the first sheet piece F1m to the bonding position while peeling the first sheet piece F1m from the separator sheet F3a by winding the half-cut first optical member sheet F1 at an acute angle. And a winding part 22e.

  The 1st optical member sheet | seat F1 has a width | variety wider than the width | variety of the liquid crystal panel P in planar view by the horizontal direction (sheet width direction) orthogonal to the conveyance direction.

  The cutting device 22c is configured such that the length of the display area P4 in the length direction in which the first optical member sheet F1 is orthogonal to the sheet width direction (the length of the other side of the long side and the short side of the display area P4, In this embodiment, every time a length longer than the short side length of the display area P4 is extended, the first optical member sheet F1 is half-cut across the entire width along the sheet width direction. Thereby, the 1st sheet piece F1m larger than the display area P4 of liquid crystal panel P is formed from the bonding sheet | seat F5 which the 1st optical member sheet | seat F1 has.

  The first optical member sheet F1 after the half cut is formed with a cut line in which at least the optical member main body F1a and the surface protection film F4a are cut in the thickness direction over the entire width in the width direction of the first optical member sheet F1. The The cut lines are formed at intervals having a length corresponding to the short side length of the display region P4 in the longitudinal direction of the belt-shaped first optical member sheet F1. The first optical member sheet F1 is divided into a plurality of sections in the longitudinal direction by the plurality of score lines. In the 1st optical member sheet | seat F1, each division part pinched | interposed into a pair of cutting line adjacent in a longitudinal direction turns into 1st sheet piece F1m.

  The size of the first sheet piece F1m can be larger than the liquid crystal panel P, for example. In the first sheet piece F1m, the size of the portion that protrudes outside the liquid crystal panel P (the size of the surplus portion of the first sheet piece F1m) is appropriately set according to the size of the liquid crystal panel P. For example, in the case where the first sheet piece F1m is applied to a medium-to-small size liquid crystal panel P of 5 inches to 10 inches, one side of the first sheet piece F1m and one side of the liquid crystal panel P at each side of the first sheet piece F1m Is set to a length in the range of 2 mm to 5 mm.

The knife edge 22d is disposed below the upstream conveyor 6 and extends over at least the entire width in the width direction of the first optical member sheet F1. The knife edge 22d is wound so that the separator sheet F3a side of the first optical member sheet F1 after the half cut comes into sliding contact.
The first optical member sheet F1 peels the separator sheet F3a from the first sheet piece F1m when the traveling direction changes so as to be bent at an acute angle at the tip of the knife edge 22d. The front end portion of the knife edge 22d is disposed close to the panel conveyance downstream side of the pinching roll 23, and the first sheet piece F1m separated from the separator sheet F3a by the knife edge 22d is conveyed by the upstream conveyor 6 to the liquid crystal panel P. It is introduced between the pair of laminating rollers 23 a of the pinching roll 23 while overlapping with the lower surface of.

  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 position of this gap becomes the bonding position of the first bonding device 13. The liquid crystal panel P and the first sheet piece F1m are overlapped and introduced into the gap between the pair of bonding rollers 23a, and the liquid crystal panel P and the first sheet piece F1m are sandwiched between the bonding rollers 23a and downstream of the panel conveyance. Sent to the side. Thereby, the 1st sheet piece F1m is integrally bonded by the lower surface of liquid crystal panel P, and it becomes 1st optical member bonding body (bonding body) PA1.

(First reversing device)
The first reversing device 31A conveys the first optical member bonding body PA1 to the cutting position of the first cutting device 32A, reverses the front and back of the second optical member bonding body PA2 during the conveyance, and the first of the liquid crystal panel P The sheet piece F1m is transferred to the first cutting device 32A in a state where the upper surface is the bonded surface.

(First cutting device)
32 A of 1st cutting devices cut off the surplus part arranged outside the part corresponding to the pasting surface of liquid crystal panel P and the 1st sheet piece F1m from the 1st sheet piece F1m pasted on liquid crystal panel P, The 1st optical member F11 (refer FIG. 4) of the magnitude | size corresponding to the bonding surface of liquid crystal panel P and 1st sheet piece F1m is formed. A first optical member F11 is bonded to the front and back surfaces of the liquid crystal panel P by cutting off an excess portion of the first sheet piece F1m from the first optical member bonding body PA1 by the first cutting device 32A. Optical member bonding body PA2 is formed.
The configuration of the first cutting device 32A will be described in detail later.

(Recovery device)
A collection device (not shown) disposed at the first collection position 33A holds, for example, an excess portion cut by the first cutting device 32A and peels off from the first optical member F11 formed by the first cutting device 32A. Then, the unnecessary surplus part is collected. After the recovery process of the surplus portion, the second optical member bonding body PA2 moves in the direction of the first turning device 34. Note that the recovery device may not be used as long as the cut surplus portion is removed by free fall during cutting by the first cutting device 32A.

(First turning device)
The first swivel device 34 holds the second optical member bonding body PA2 that has reached the carry-out end of the upstream conveyor 6 via the first cutting device 32A by suction or pinching, and the second optical member bonding body PA2 is displayed. The second optical member bonding body PA2 is turned so as to be conveyed in the direction along the long side of the region P4. Thereby, as for 2nd optical member bonding body PA2, the polarization axis of each polarizing film bonded by the front and back of liquid crystal panel P becomes mutually orthogonal.

  Here, the 1st turning apparatus 34 is provided with the alignment camera 34c similar to the alignment camera 11b of the 1st adsorption | suction apparatus 11, and has the alignment function similar to the panel holding | maintenance part 11a of the 1st adsorption | suction apparatus 11. .

(Second bonding device)
The 2nd bonding apparatus 17 is a sheet piece (2nd sheet piece F2m) bonding of the bonding sheet F5 cut to the predetermined size with respect to the lower surface of 2nd optical member bonding body PA2 introduced into the bonding position. Do. The 2nd bonding apparatus 17 is provided with the conveying apparatus 22 and the pinching roll 23 similar to the 1st bonding apparatus 13. FIG.

  The cutting device 22c of the 2nd bonding apparatus 17 is the length (display area P4 of display area P4) in the length direction where the 2nd optical member sheet | seat F2 used with this 2nd bonding apparatus 17 orthogonally crosses the said sheet | seat width direction. Each time a longer length than the length of the other of the long side and the short side (corresponding to the long side length of the display area P4 in this embodiment) is extended, the full width along the sheet width direction Then, the second optical member sheet F2 is half-cut. Thereby, the 2nd sheet piece F2m larger than the display area P4 of liquid crystal panel P is formed from the bonding sheet | seat F5 which the 2nd optical member sheet | seat F2 has.

  Cut lines are formed in the second optical member sheet F2 after the half cut at intervals having a length corresponding to the long side length of the display region P4 in the longitudinal direction of the band-shaped second optical member sheet F2. The second optical member sheet F2 is divided into a plurality of sections in the longitudinal direction by the plurality of score lines. In the 2nd optical member sheet | seat F2, each division part pinched | interposed into a pair of cutting line adjacent in a longitudinal direction turns into 2nd sheet piece F2m.

  The magnitude | size of the 2nd sheet piece F2m can be made larger than the liquid crystal panel P, for example. In the second sheet piece F2m, the size of the portion that protrudes outside the liquid crystal panel P (the size of the surplus portion of the second sheet piece F2m) is appropriately set according to the size of the liquid crystal panel P. For example, when the second sheet piece F2m is applied to a medium-sized liquid crystal panel P of 5 inches to 10 inches, one side of the second sheet piece F2m and one side of the liquid crystal panel P at each side of the second sheet piece F2m Is set to a length in the range of 2 mm to 5 mm.

  The pinching roll 23 has a pair of bonding rollers 23a arranged in parallel with each other in the axial direction, a predetermined gap is formed between the pair of bonding rollers 23a, and the position of this gap is the second position. It becomes the bonding position of the bonding apparatus 17. In the gap, the second optical member bonding body PA2 and the second sheet piece F2m are introduced in an overlapping state, and the second optical member bonding body PA2 and the second sheet piece F2m are sandwiched between the bonding rollers 23a. While being done, it is sent out to the panel conveyance downstream side. Thereby, the 2nd sheet piece F2m is united with the other surface (surface on the opposite side to the surface where the 1st optical member F11 of 2nd optical member bonding body PA2 was bonded) of 2nd optical member bonding body PA2. Are bonded together to form a third optical member bonded body (bonded body) PA3.

(Second reversing device)
The second reversing device 31B conveys the third optical member bonding body PA3 to the cutting position of the second cutting device 32B, reverses the front and back of the third optical member bonding body PA3 during the conveyance, and the second of the liquid crystal panel P. The sheet piece F2m is transferred to the second cutting device 32B in a state where the surface on which the sheet piece F2m is bonded is used as the upper surface.

(Second cutting device)
The 2nd cutting device 32B is the surplus arrange | positioned on the outer side of the part corresponding to the bonding surface of liquid crystal panel P and 2nd sheet piece F2m from 2nd sheet piece F2m bonded by 3rd optical member bonding body PA3. A part is cut | disconnected and the 2nd optical member F12 (refer FIG. 4) of the magnitude | size corresponding to the bonding surface of liquid crystal panel P and the 2nd sheet piece F2m is formed. The second optical member F12 is bonded to the other side of the front and back surfaces of the liquid crystal panel P by cutting off the excess portion of the second sheet piece F2m from the third optical member bonding body PA3 by the second cutting device 32B, and the liquid crystal The 4th optical member bonding body (optical member bonding body) PA4 by which the 1st optical member F11 is bonded by the one surface of the panel P is formed.

Here, the first cutting device 32A and the second cutting device 32B are, for example, CO 2 laser cutters. The part corresponding to the bonding surface of the liquid crystal panel P and the first sheet piece F1m or the second sheet piece F2m from the first sheet piece F1m or the second sheet piece F2m by the first cutting device 32A or the second cutting device 32B. The first optical member F11 and the second optical member F12 having a size corresponding to the bonding surface between the liquid crystal panel P and the first sheet piece F1m or the second sheet piece F2m are formed. To do.

  The cutting device 32 is bonded to the liquid crystal panel P along the outer peripheral edge of the bonding surface of the liquid crystal panel P and the sheet piece FXm bonded to the liquid crystal panel P, which is detected by the detection device described later. The sheet piece FXm is cut endlessly. Outside the display area P4, there is provided a frame portion G (see FIG. 4) having a predetermined width for arranging a sealant or the like for bonding the first and second substrates P1 and P2 of the liquid crystal panel P. The sheet piece FXm is cut by the cutting device 32 within the width of G.

  The detection of the outer peripheral edge of the bonding surface and the cutting by the cutting device are performed in detail as follows.

  FIG. 8 is a schematic diagram of the first detection device 61 that detects the outer periphery of the bonding surface. The 1st detection apparatus 61 with which the film bonding system 2 of this embodiment is provided is the bonding surface (henceforth, 1st bonding surface (below) of liquid crystal panel P and 1st sheet piece F1m in 1st optical member bonding body PA1. Bonding surface) may be referred to as SA1.) An imaging device 63 that captures an image of the outer peripheral edge ED, an illumination light source 64 that illuminates the outer peripheral edge ED, an image that is captured by the imaging device 63, and an image And a control unit 65 that performs calculation for detecting the outer peripheral edge ED.

  Such a first detection device 61 is provided on the upstream side of the panel conveyance of the first cutting device 32A in FIG. 7, and is provided between the first reversing device 31A and the first cutting device 32A.

  The imaging device 63 is fixed and arranged inside the first bonding surface SA1 with respect to the outer peripheral edge ED, and the normal line of the first bonding surface SA1 and the normal line of the imaging surface 63a of the imaging device 63 are arranged. The posture is inclined so as to form an angle θ (hereinafter referred to as an inclination angle θ of the imaging device 63). The imaging device 63 directs the imaging surface 63a to the outer peripheral edge ED, and captures an image of the outer peripheral edge ED from the side on which the first sheet piece F1m is bonded in the first optical member bonding body PA1.

  The inclination angle θ of the imaging device 63 is preferably set so that the outer peripheral edge of the first substrate P1 that forms the first bonding surface SA1 can be reliably imaged. For example, when the liquid crystal panel P is formed by so-called multiple chamfering, in which the mother panel is divided into a plurality of liquid crystal panels, the liquid crystal panel P is shifted to the outer peripheral edge of the first substrate P1 and the second substrate P2 constituting the liquid crystal panel P. May occur, and the end surface of the second substrate P2 may be displaced outward from the end surface of the first substrate P1. In such a case, the inclination angle θ of the imaging device 63 is preferably set so that the outer peripheral edge of the second substrate P2 does not enter the imaging field of the imaging device 63.

  In such a case, the inclination angle θ of the imaging device 63 is adapted to the distance between the first bonding surface SA1 and the center of the imaging surface 63a of the imaging device 63 (hereinafter referred to as the height H of the imaging device 63). It is preferable to set so as to. For example, when the height H of the imaging device 63 is 50 mm or more and 100 mm or less, the inclination angle θ of the imaging device 63 is preferably set to an angle in the range of 5 ° or more and 20 ° or less. However, when the deviation amount is empirically known, the height H of the imaging device 63 and the inclination angle θ of the imaging device 63 can be obtained based on the deviation amount. In the present embodiment, the height H of the imaging device 63 is set to 78 mm, and the inclination angle θ of the imaging device 63 is set to 10 °.

  The inclination angle θ of the imaging device 63 may be 0 °. FIG. 9 is a schematic diagram illustrating a modification of the first detection device 61, and is an example in the case where the inclination angle θ of the imaging device 63 is 0 °. In this case, each of the imaging device 63 and the illumination light source 64 may be disposed at a position overlapping the outer peripheral edge ED along the normal direction of the first bonding surface SA1.

  The distance between the first bonding surface SA1 and the center of the imaging surface 63a of the imaging device 63 (hereinafter referred to as the height H1 of the imaging device 63) is easy to detect the outer peripheral edge ED of the first bonding surface SA1. The position is preferably set. For example, the height H1 of the imaging device 63 is preferably set in a range of 50 mm or more and 320 mm or less.

  The illumination light source 64 is fixed and arranged on the side opposite to the side on which the first sheet piece F1m is bonded in the first optical member bonded body PA1. The illumination light source 64 is arrange | positioned rather than the outer periphery ED on the outer side of 1st bonding surface SA1. In the present embodiment, the optical axis of the illumination light source 64 and the normal line of the imaging surface 63a of the imaging device 63 are parallel.

  In addition, the illumination light source 64 may be arrange | positioned at the side (namely, the same side as the imaging device 63) by which the 1st sheet piece F1m in 1st optical member bonding body PA1 was bonded.

  If the outer peripheral edge ED imaged by the imaging device 63 is illuminated by the illumination light emitted from the illumination light source 64, the optical axis of the illumination light source 64 and the normal line of the imaging surface 63a of the imaging device 63 intersect. It may be.

  FIG. 10 is a plan view showing a position where the outer peripheral edge of the bonding surface is detected. Inspection area | region CA is set on the conveyance path | route of 1st optical member bonding body PA1 shown to a figure. Inspection area | region CA is set in the position corresponding to the outer periphery ED of 1st bonding surface SA1 in the liquid crystal panel P conveyed. In the figure, the inspection area CA is set at four locations corresponding to the four corners of the first bonding surface SA1 having a rectangular shape in plan view, and the corners of the first bonding surface SA1 are detected as the outer peripheral edge ED. It has a configuration. In the figure, among the outer peripheral edges of the first bonding surface SA1, the hook-shaped part corresponding to the corner is shown as the outer peripheral edge ED.

  The first detection device 61 in FIG. 8 detects the outer peripheral edge ED in the four inspection areas CA. Specifically, the imaging device 63 and the illumination light source 64 are arranged in each inspection area CA, and the first detection device 61 has a corner portion of the first bonding surface SA1 for each liquid crystal panel P to be transported. And the outer peripheral edge ED is detected based on the imaging data. Data of the detected outer peripheral edge ED is stored in the control unit 65 shown in FIG.

  In addition, if the outer periphery of 1st bonding surface SA1 is detectable, the setting position of inspection area | region CA is not restricted to this. For example, each inspection area | region CA may be arrange | positioned in the position corresponding to a part (for example, center part of each side) of each edge | side of 1st bonding surface SA1. In this case, it becomes the structure which detects each edge | side (four sides) of 1st bonding surface SA1 as an outer periphery.

  In addition, the imaging device 63 and the illumination light source 64 are not limited to the configuration arranged in each inspection area CA, and are configured to be able to move along a movement path set along the outer peripheral edge ED of the first bonding surface SA1. It may be. In this case, the imaging device 63 and the illumination light source 64 are configured to detect the outer peripheral edge ED when the imaging device 63 and the illumination light source 64 are positioned in each inspection area CA, so that one imaging device 63 and one illumination light source 64 are provided. In this case, the outer periphery ED can be detected.

  The cutting position for the first sheet piece F1m by the first cutting device 32A is set based on the detection result of the outer peripheral edge ED of the first bonding surface SA1.

  For example, the control unit 65 shown in FIG. 8 is configured such that the first optical member F11 is outside the liquid crystal panel P (the outside of the first bonding surface SA1) based on the stored data of the outer peripheral edge ED of the first bonding surface SA1. ), The cut position of the first sheet piece F1m can be set so as not to protrude. Further, the setting of the cut position is not necessarily performed by the control unit 65 of the first detection device 61, and may be performed by using a calculation unit separately using the data of the outer peripheral edge ED detected by the first detection device 61. I do not care.

  The first cutting device 32A cuts the first sheet piece F1m at the cutting position set by the control unit 65.

  Returning to FIG. 7, the first cutting device 32 </ b> A has detected a portion corresponding to the first bonding surface SA <b> 1 and a surplus portion outside the first sheet piece F <b> 1 m bonded to the liquid crystal panel P. The first optical member F11 (see FIG. 4) having a size corresponding to the first bonding surface SA1 is cut out along the cutting position set based on the outer peripheral edge ED. Thereby, 2nd optical member bonding body PA2 by which the 1st optical member F11 overlapped and bonded on the upper surface of liquid crystal panel P is formed.

  Here, the “part corresponding to the first bonding surface SA1” means that the outer shape of the liquid crystal panel P (contour shape in plan view) is not less than the size of the display area of the liquid crystal panel P facing the first sheet piece F1m. ) And a region that avoids a functional part such as an electric component mounting portion in the liquid crystal panel P.

  In the present embodiment, the surplus portion is laser-cut along the outer peripheral edge of the liquid crystal panel P at three sides excluding the functional portion in the liquid crystal panel P having a rectangular shape in plan view, and the liquid crystal panel P at one side corresponding to the functional portion. It is possible to adopt a configuration in which the surplus portion is laser-cut at a position that appropriately enters the display region P4 side from the outer peripheral edge. For example, when the first substrate P1 is a TFT substrate, it is possible to adopt a configuration in which a cut is made at a position shifted by a predetermined amount from the outer peripheral edge of the liquid crystal panel P toward the display region P4 so as to exclude the functional portion on one side corresponding to the functional portion.

  FIG. 11 is a schematic diagram of the second detection device 62 that detects the outer peripheral edge of the bonding surface. The 2nd detection apparatus 62 with which the film bonding system 2 of this embodiment is provided is the bonding surface (henceforth the 2nd bonding surface (below) of liquid crystal panel P and 2nd sheet piece F2m in 3rd optical member bonding body PA3. The image pickup device 63 that picks up the image of the outer peripheral edge ED of the bonding surface) SA2), the illumination light source 64 that illuminates the outer peripheral edge ED, and the image picked up by the image pickup device 63 are stored in the image. And a control unit 65 that performs calculation for detecting the outer peripheral edge ED. The second detection device 62 has the same configuration as the first detection device 61 described above.

  Such a 2nd detection apparatus 62 is provided in the panel conveyance upstream of the 2nd cutting device 32B in FIG. 7, Comprising: Between the 2nd inversion apparatus 31B and the 2nd cutting apparatus 32B, it is provided. The 2nd detection apparatus 62 detects the outer periphery ED of 2nd bonding surface SA2 similarly to the above-mentioned 1st detection apparatus 61 in the test | inspection area | region set on the conveyance path | route of 3rd optical member bonding body PA3. .

  The cutting position of the second sheet piece F2m by the second cutting device 32B is set based on the detection result of the outer peripheral edge ED of the second bonding surface SA2.

  For example, the control unit 65 shown in FIG. 11 is configured such that the second optical member F12 is outside the liquid crystal panel P (the outside of the second bonding surface SA2) based on the stored data of the outer peripheral edge ED of the second bonding surface SA2. ), The cut position of the second sheet piece F2m can be set so as not to protrude. Further, the setting of the cut position is not necessarily performed by the control unit 65 of the second detection device 62, and may be performed by using a calculation unit separately using the data of the outer peripheral edge ED detected by the second detection device 62. I do not care.

  The second cutting device 32B cuts the second sheet piece F2m at the cutting position set by the control unit 65.

  The 2nd cutting device 32B follows the detected outer periphery ED for the part corresponding to 2nd bonding surface SA2 among the 2nd sheet pieces F2m bonded by liquid crystal panel P, and the excess part of the outer side. The second optical member F12 (see FIG. 4) having a size corresponding to the second bonding surface SA2 is cut out. Thereby, 4th optical member bonding body PA4 by which the 2nd optical member F12 was bonded on the upper surface of 2nd optical member bonding body PA2 is formed.

  Here, the “part corresponding to the second bonding surface SA2” means that the outer shape of the liquid crystal panel P (contour shape in plan view) is not less than the size of the display area of the liquid crystal panel P facing the second sheet piece F2m. ) And a region that avoids a functional part such as an electric component mounting portion in the liquid crystal panel P.

  Thus, in the cutting device 32, the outer periphery of the bonding surface is detected for each of the plurality of liquid crystal panels P using the detection device, and the sheets bonded to the individual liquid crystal panels P based on the detected outer periphery. The cutting position of the piece FXm is set. As a result, the optical member having a desired size can be separated regardless of the individual differences in the sizes of the liquid crystal panel P and the sheet piece FXm, so that the quality variation due to the individual differences in the sizes of the liquid crystal panel P and the sheet piece FXm can be reduced. In addition, the frame portion around the display area can be reduced to enlarge the display area and downsize the device.

In the above embodiment, the CO 2 laser is used as an example of the cutting device 32, but the cutting device 32 is not limited to this. It is also possible to use other cutting means such as a cutting blade as the cutting device 32.

(Recovery device)
A collection device (not shown) disposed at the second collection position 33B holds, for example, an excess portion cut by the second cutting device 32B and peels off from the second optical member F12 formed by the second cutting device 32B. Then, the unnecessary surplus part is collected. 4th optical member bonding body PA4 moves to the direction of the 2nd turning apparatus 35 after the collection process of a surplus part. Note that the recovery device may not be used as long as the cut surplus portion is removed by free fall at the time of cutting by the second cutting device 32B.

(Second turning device)
The 2nd turning apparatus 35 turns 4th optical member bonding body PA4 so that 4th optical member bonding body PA4 may be conveyed in the direction in alignment with the short side of display area P4.

  Then, similarly to 1st Embodiment, the defect of 4th optical member bonding body PA4 carried out from the manufacturing line is visually inspected. About the handling (reproduction | regeneration process outside a manufacturing line) of 4th optical member bonding body PA4 after a visual inspection, it is the same as that of 1st Embodiment.

(Manufacturing method of an optical member bonding body)
With reference to FIG. 6, the manufacturing method of the optical member bonding body in 2nd Embodiment is demonstrated.

  First, in the manufacture of the double-sided bonded panel P12, the liquid crystal panel P is carried into the production line (step S11), and dirt such as dust and dust adhering to the surface of the liquid crystal panel P is washed (step S12).

  Next, in the above-described film bonding system 1, the first optical member sheet F1 is cut while being unwound from the original roll R1, and is larger than the display region P4 (for example, larger than the liquid crystal panel P), the first sheet piece F1m. Form. Then, the 1st sheet piece F1m is bonded together to liquid crystal panel P, and 1st optical member bonding body PA1 is formed.

  Then, in 1st optical member bonding body PA1, the outer periphery of the bonding surface of 1st sheet piece F1m and liquid crystal panel P is detected, and the excess part of 1st sheet piece F1m is cut along the detected outer periphery. The 2nd optical member bonding body PA2 is formed.

  Similarly, the second optical member sheet F2 is cut while being unwound from the original roll R1, and a second sheet piece F2m larger than the display region P4 (for example, larger than the liquid crystal panel P) is formed, and the second optical member affixed The third optical member bonded body PA3 is formed by bonding to the combined PA2.

  Then, in 3rd optical member bonding body PA3, the outer periphery of the bonding surface of 2nd sheet piece F2m and liquid crystal panel P is detected, The excess part of 2nd sheet piece F2m is cut along the detected outer periphery. And 4th optical member bonding body PA4 is formed (step S13).

Then, about obtained 4th optical member bonding body PA4, step S14-S16, S21-S25 are given similarly to 1st Embodiment.
The manufacturing method of the optical member bonding body of this embodiment is performed as mentioned above.

  Also by the manufacturing method of the optical member bonding body as described above, as in the first embodiment, it is possible to detect defects with accuracy without excess or deficiency on actual use, and stable manufacturing without impairing the manufacturing yield. A manufacturing method of a possible optical member pasting object is provided.

  In addition, in this embodiment, in the 1st bonding apparatus 13 or the 2nd bonding apparatus 17, liquid crystal panel P or 1st while peeling the produced 1st sheet piece F1m and 2nd sheet piece F2m from the separator sheet F3a. Although it was set as the structure bonded directly to 2 optical member bonding body PA2, it is not restricted to this. In the bonding apparatus, the produced first sheet piece F1m and the second sheet piece F2m are attached and held, and have a bonding head that is transported and bonded onto the liquid crystal panel P or the second optical member bonding body PA2. It doesn't matter.

  The preferred embodiments of the present invention have been described above with reference to the accompanying drawings, but it goes without saying that the present invention is not limited to such examples. Various shapes, combinations, and the like of the constituent members shown in the above-described examples are examples, and various modifications can be made based on design requirements and the like without departing from the gist of the present invention.

  ED ... outer peripheral edge, F1X ... optical member, F11 ... first optical member (optical member), F12 ... second optical member (optical member), FX ... optical member sheet, F1 ... first optical member sheet (optical member sheet) F2 ... second optical member sheet (optical member sheet), P4 ... display region, R1 ... raw roll, FXm ... sheet piece, F1m ... first sheet piece (sheet piece), F2m ... second sheet piece (sheet piece) ), P ... liquid crystal panel (optical display component), P11 ... single-sided bonding panel (optical member bonding body), P12 ... double-sided bonding panel (optical member bonding body), PA1 ... first optical member bonding body (bonding body). , PA3 ... third optical member bonding body (bonding body), PA4 ... fourth optical member bonding body (optical member bonding body)

Claims (10)

  1. It is a manufacturing method of an optical member bonding body formed by bonding an optical member to an optical display component,
    A plurality of optical members obtained by unwinding a belt-shaped optical member sheet from a raw fabric roll and cutting the optical member sheet are bonded to a plurality of the optical display components, and a plurality of the optical member bonded bodies are bonded. An optical member bonding body forming step to be formed;
    A first autoclave treatment step for heating and pressurizing the plurality of optical member laminates;
    After the first autoclave treatment step, an inspection step for optically inspecting defects for each of the plurality of optical member bonded bodies subjected to the heat and pressure treatment,
    The manufacturing method of the optical member bonding body which performs the said optical member bonding body formation process, a said 1st autoclave process process, and the said test | inspection process in the continuous manufacturing line.
  2. It is a manufacturing method of an optical member bonding body formed by bonding an optical member to an optical display component,
    A bonded body forming a plurality of bonded bodies by unwinding a belt-shaped optical member sheet from a raw roll and cutting a plurality of sheet pieces obtained by cutting the optical member sheet to the plurality of optical display components. Forming process;
    In the bonding body, a detection step of detecting the outer peripheral edge of the bonding surface of the sheet piece and the optical display component;
    In the said bonding body, the excess part arrange | positioned outside the part corresponding to the said bonding surface from the said sheet piece bonded to the said optical display component is cut | disconnected along the said outer periphery, and it respond | corresponds to the said bonding surface. An optical member bonding body forming step of forming the optical member bonding body including the optical member of a size to be
    A first autoclave treatment step for heating and pressurizing the plurality of optical member laminates;
    After the first autoclave treatment step, an inspection step for optically inspecting defects for each of the plurality of optical member bonded bodies subjected to the heat and pressure treatment,
    The manufacturing method of the optical member bonding body which performs the said bonding body formation process, the said detection process, an optical member bonding body formation process, a said 1st autoclave process process, and the said test | inspection process in the continuous manufacturing line.
  3.   The manufacturing method of the optical member bonding body of Claim 2 which detects the outer periphery of the bonding surface of the said sheet piece and the said optical display component for every said some optical display component in the said detection process.
  4. The inspection process is an automatic inspection process for optically automatically inspecting the defect using an automatic inspection apparatus arranged in the production line,
    The optical member bonded body according to any one of claims 1 to 3, further comprising a first visual inspection step for visually inspecting the defective product detected in the automatic inspection step, separated from the production line. Manufacturing method.
  5.   The manufacturing method of the optical member bonding body according to any one of claims 1 to 3, wherein the inspection step is a first visual inspection step for visually inspecting a defect.
  6. A second autoclave that heats and pressurizes the first visual inspection defective product according to the state of the defect of the first visual inspection defective product with respect to the first visual inspection defective product detected in the first visual inspection process. The optical member is peeled off from the processing or the first visual inspection defective product to expose the optical display component, and the new optical member prepared in advance is bonded to the exposed surface of the optical display component. A reprocessing process for selecting and implementing any one of the rework processes for forming a new optical member bonded body,
    The manufacturing method of the optical member bonding body according to claim 4 or 5, wherein the regeneration treatment step is performed separately from the manufacturing line.
  7. For each of the plurality of optical member bonded bodies that have undergone the regeneration treatment step, it has a second visual inspection step for visually inspecting defects,
    The manufacturing method of the optical member bonding body of Claim 6 which performs a said 2nd visual inspection process separately from the said manufacturing line.
  8.   The manufacturing method of the optical member bonding body of Claim 7 which performs the said reproduction | regeneration process again about the 2nd visual inspection defect product detected at the said 2nd visual inspection process.
  9.   In the first autoclave treatment step, a plurality of the optical member bonding bodies sequentially conveyed through the optical member bonding body forming step are distributed to a plurality of processing lines, and a heating and pressurizing process is performed for each of the processing lines. The manufacturing method of the optical member bonding body of any one of claim | item 1 -8.
  10.   In the inspection step, a plurality of the optical member bonded bodies that are heated and pressurized in a plurality of the processing lines and sequentially conveyed are introduced into one inspection line, and the defects are optically detected in the inspection line. The manufacturing method of the optical member bonding body of Claim 9 to test | inspect.
JP2013180590A 2013-08-30 2013-08-30 Method for manufacturing optical member laminate Pending JP2015049349A (en)

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JP2013180590A JP2015049349A (en) 2013-08-30 2013-08-30 Method for manufacturing optical member laminate
PCT/JP2014/072687 WO2015030158A1 (en) 2013-08-30 2014-08-29 Production method for laminated optical member
TW103129793A TW201522932A (en) 2013-08-30 2014-08-29 Optical member affixed body production method

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