JP2016014715A - Optical member, production system of optical display device, production method of optical display device, and original roll - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an optical member in which an optical pattern is easily recognizable.SOLUTION: An optical member 1 includes: n of first polarizing patterns 31 each formed to have a width W1 and a slow axis in a first direction; (n-1) of second polarizing patterns 32 each formed to have a width W1 and a slow axis in a second direction, alternately arranged with the above n of the first polarizing patterns 31; a third polarizing pattern 33 formed to have a width W2 larger than the width W1 and a slow axis in the second direction, and adjoining to the n-th first polarizing pattern 31; a fourth polarizing pattern 34 having a slow axis in the first direction and adjoining to the third polarizing pattern 33; a fifth polarizing pattern 35 formed to have a width larger than the width W1 and a slow axis in the second direction, and adjoining to the first of the first polarizing pattern 31; and a sixth polarizing pattern 36 having a slow axis in the first direction and adjoining to the fifth polarizing pattern 35.

Description

  The present invention relates to an optical member, an optical display device production system, an optical display device production method, and an original fabric roll.

  In recent years, passive 3D (3 Dimension) liquid crystal display devices called FPR (Film Patterned Retarder) have been developed.

  In this type of 3D liquid crystal display device (display device), for example, a polarizer layer is disposed on the display surface side of the liquid crystal panel, and a patterned retardation layer is disposed further on the viewing side. A polarizing film is disposed on the backlight side of the liquid crystal panel.

  The polarizer layer is a layer having an optical function of absorbing the polarization component of the vibration plane parallel to the absorption axis of the polarizer layer and transmitting the polarization component of the vibration plane orthogonal to the incident light. The transmitted light immediately after passing through the polarizer layer is linearly polarized light.

  The patterned retardation layer is usually formed on a base film. The patterned retardation layer includes a plurality of optical patterns (first region and second region). The first region and the second region are each formed in a band shape, and are alternately arranged corresponding to the pixel arrangement of the liquid crystal panel formed in a matrix.

  FIG. 9 is a plan view for explaining alignment between the liquid crystal panel P and the patterned retardation layer 3 in the 3D liquid crystal display device.

  As shown in the figure, in the liquid crystal panel P, red pixels R, green pixels G, and blue pixels B are periodically arranged along the long side (left and right direction of the liquid crystal panel P). A large number of pixels R, G, B of each color are arranged in the left-right direction to form a pixel column L, and a large number of pixel columns L are arranged over the display area of the liquid crystal panel P.

  On the other hand, the patterned retardation layer 3 has a plurality of first regions 3R and a plurality of second regions 3L extending along the long sides of the patterned retardation layer 3. A large number of first regions 3R and second regions 3L are arranged in the vertical direction corresponding to each pixel column L of the liquid crystal panel P. For example, the first region 3R is arranged on the viewing side of the pixel column L that displays the right-eye image, and the second region 3L is arranged on the viewing side of the pixel column L that displays the left-eye image. The first region 3R and the second region 3L have different phase difference directions, and the right-eye image and the left-eye image are displayed on the viewer side in different polarization states (for example, patents). Reference 1).

  The patterned retardation layer 3 is bonded to the liquid crystal panel P so that the boundary line K between the first region 3R and the second region 3L is located between the pixel columns L, and the liquid crystal panel P is used. An FPR 3D liquid crystal display device is configured.

  The user views the display image through so-called polarized glasses equipped with optical elements having different optical characteristics between the right-eye lens and the left-eye lens. Each image for the left eye is selectively visually recognized. Accordingly, the user can recognize a stereoscopic image obtained by fusing the images of both eyes.

JP 2012-212033 A

  In manufacturing the 3D liquid crystal display device of the FPR method as described above, the first region of the patterned retardation layer and the pixel column of the liquid crystal panel or the second region and the pixel column are accurately associated with each other. It is necessary to bond an optical member including a phase difference layer and a polarizer layer to a liquid crystal panel. If both the first region and the second region of the patterned retardation layer overlap one pixel column, the right eye image that should be recognized only by the right eye is recognized by the left eye. This is because so-called crosstalk occurs, and the image quality of the stereoscopic display image may be deteriorated.

  However, until now, 3D liquid crystal displays have been made while confirming the planar relative position between the liquid crystal panel and the optical member with reference to the alignment mark or black matrix for the liquid crystal panel and the end of the optical member as the reference for the optical member. The device was manufactured.

  In the manufacturing method described above, it is difficult to bond each pixel row so that the first region and the second region overlap each other in a one-to-one manner. That is, even in the 3D liquid crystal display device bonded based on the respective criteria as described above, if each pixel column and the first region and the second region do not overlap one-to-one, crosstalk occurs. Resulting in a defective product. Therefore, in the manufacture of the 3D liquid crystal display device, it is necessary to paste the liquid crystal panel while recognizing the optical pattern (first region and second region) of the optical member.

  The present invention has been made in view of such circumstances, and an object thereof is to provide an optical member capable of easily recognizing an optical pattern. It is another object of the present invention to provide an optical display device production system using such an optical member, an optical display device production method, and an original fabric roll capable of easily producing such an optical member.

  In order to solve the above problems, one embodiment of the present invention is an optical member having a retardation layer, and the retardation layer is formed with a first width and has a slow axis in a first direction. n (n is a natural number) first polarization patterns and the first width, and having a slow axis in a second direction different from the first direction, and the n first polarization patterns (N-1) second polarization patterns adjacent to the first polarization pattern, and a second width larger than the first width, and arranged in the second direction. One third polarization pattern that has a slow axis and is adjacent to the nth first polarization pattern on the opposite side of the second polarization pattern, and has a slow axis in the first direction. A fourth polarization pattern adjacent to the third polarization pattern on the opposite side of the first polarization pattern; and Formed with a third width larger than the first width, having a slow axis in the second direction, and adjacent to the first polarization pattern on the opposite side to the second polarization pattern. One fifth polarization pattern and one sixth polarization pattern that has a slow axis in the first direction and is adjacent to the fifth polarization pattern on the opposite side of the first polarization pattern; , An optical member is provided.

  In one aspect of the present invention, the width of the fourth polarization pattern and the width of the sixth polarization pattern may be larger than the first width.

  In one aspect of the present invention, the second width may be larger than the third width by the first width.

  One embodiment of the present invention is an optical display device production system for bonding an optical member to an optical display component, including a bonding apparatus for bonding the optical member to the optical display component, and the optical display. The component includes n first pixel columns and n second pixel columns arranged alternately with the n first pixel columns, and the optical member is the optical member described above, The n first polarization patterns of the optical member correspond to the n first pixel columns of the optical display component, and the (n−1) second polarization patterns of the optical member are the Corresponding to the (n−1) second pixel columns of the optical display component, the bonding apparatus is a boundary between the third polarization pattern and the fourth polarization pattern or the fifth polarization pattern and the sixth. Using the boundary with the polarization pattern as a reference of the optical member, the first to nth The first pixel array and the first to n-th first polarization patterns overlap each other, and the first to (n−1) -th second pixel array and the first to (n−1) -th array. Of the optical display device that aligns the optical display component and the optical member such that the second polarization pattern of the second pixel pattern overlaps each other, and the n-th second pixel column and the third polarization pattern overlap each other. Provide production system.

  Another embodiment of the present invention is a method for producing an optical display device for bonding an optical member to an optical display component, the method including a bonding step of bonding the optical member to the optical display component, and the optical display. The component includes n first pixel columns and n second pixel columns arranged alternately with the n first pixel columns, and the optical member is the optical member described above, The n first polarization patterns of the optical member correspond to the n first pixel columns of the optical display component, and the (n−1) second polarization patterns of the optical member are the Corresponding to the (n−1) second pixel columns of the optical display component, and in the bonding step, a boundary between the third polarization pattern and the fourth polarization pattern or the fifth polarization pattern and the sixth The first to the nth one with the boundary with the polarization pattern as the reference of the optical member The first pixel column and the first to n-th first polarization patterns in FIG. 1 overlap each other, and the second pixel column from the first to (n−1) th and the first to (n−1). An optical display that aligns the optical display component and the optical member such that the second polarization pattern up to the first overlaps each other and the second pixel column and the third polarization pattern overlap each other. Provide device production methods.

  One embodiment of the present invention is a raw roll in which a long optical member original having a retardation layer is wound, wherein the optical member original is formed with a first width, N first polarization patterns having a slow axis in the direction of (n is a natural number) and the first width, and having a slow axis in a second direction different from the first direction. , (N-1) second polarization patterns that are alternately arranged with the n first polarization patterns and are adjacent to the first polarization pattern, and a second width that is greater than the first width. A third polarization pattern that has a slow axis in the second direction and is adjacent to the nth first polarization pattern on the opposite side of the second polarization pattern; and One fourth polarization having a slow axis in the direction of and adjacent to the third polarization pattern on the opposite side to the first polarization pattern The second polarization pattern with respect to the first first polarization pattern is formed with a turn and a third width larger than the first width and having a slow axis in the second direction. One fifth polarization pattern adjacent on the opposite side and one slow polarization axis in the first direction and adjacent to the fifth polarization pattern on the opposite side of the first polarization pattern And a sixth polarizing pattern.

  ADVANTAGE OF THE INVENTION According to this invention, the optical member which can recognize an optical pattern easily can be provided. Moreover, the production system of the optical display device using such an optical member, the production method of the optical display device, and the raw fabric roll which can manufacture such an optical member easily can be provided.

It is a top view which shows schematic structure of a display apparatus. It is sectional drawing which shows schematic structure of a display apparatus. It is a schematic diagram of a patterned retardation layer. It is a schematic diagram of the optical member original fabric used when manufacturing an optical member. It is a schematic diagram which shows a mode that an optical member is manufactured. It is a schematic diagram which shows schematic structure of the production system of an optical display device. It is explanatory drawing which shows the production method of an optical display device. It is a schematic diagram which shows the production method of an optical display device. It is a top view for demonstrating position alignment with the liquid crystal panel P and the patterned phase difference layer 3 in 3D liquid crystal display device.

  Hereinafter, an optical member according to an embodiment of the present invention will be described with reference to the drawings. In all the drawings below, the dimensions and ratios of the constituent elements are appropriately changed in order to make the drawings easy to see.

<Optical display device>
FIG. 1 is a plan view showing a display device (optical display device) 100 manufactured using the optical member of this embodiment. FIG. 2 is a cross-sectional view of the display device 100 taken along line II-II in FIG. The display device 100 of this embodiment is an FPR 3D liquid crystal display device. As shown in the figure, the display device 100 includes a liquid crystal panel (optical display component) P, a polarizing film F11, and an optical member 1.

  As shown in FIGS. 1 and 2, the liquid crystal panel P includes a first substrate P1 having a rectangular shape in a plan view, and a relatively small rectangular shape arranged to face the first substrate P1. And a liquid crystal layer P3 sealed between the first substrate P1 and the second substrate P2. The liquid crystal panel P has a rectangular shape that conforms to 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.

  Alignment marks Am for positioning are provided at the four corners of the liquid crystal panel P in plan view. Although the figure shows that the alignment marks Am are provided at all four corners, for example, a total of three alignment marks may be provided at three of the four corners, and a total of two alignments may be provided at diagonal positions of the four corners. A mark may be provided.

  A polarizing film F11 is bonded to the backlight side of the liquid crystal panel P. The polarizing film F11 is bonded to the liquid crystal panel P through the adhesive layer. The polarizing film F11 has an optical function of absorbing the polarization component of the vibration plane parallel to the absorption axis and transmitting the polarization component of the vibration plane orthogonal to the incident light. The transmitted light immediately after passing through the polarizing film F11 is linearly polarized light.

  On the other hand, the optical member 1 is bonded to the display surface side of the liquid crystal panel P. The optical member 1 has a polarizer layer 2 and a patterned retardation layer (retardation layer) 3, and is bonded to the liquid crystal panel P so that the polarizer layer 2 side faces the liquid crystal panel P.

  The polarizer layer 2 has an optical function of absorbing the polarization component of the vibration plane parallel to the absorption axis and transmitting the polarization component of the vibration plane orthogonal to the incident light. The transmitted light immediately after passing through the polarizer layer 2 is linearly polarized light.

  The polarizing film F11 and the optical member 1 are bonded to the liquid crystal panel P so that the polarizing film F11 and the polarizer layer 2 of the optical member 1 are in a crossed Nicols arrangement.

<Optical member>
FIG. 3 is a schematic view in a plan view of the patterned retardation layer (retardation layer) 3 included in the optical member 1. In the description of the optical member 1 below, the size of the optical member 1 and the relative position when the optical member 1 is bonded to the liquid crystal panel P to form the display device 100 while using the reference numerals shown in FIGS. Describe.

  The patterned retardation layer 3 is a member having a rectangular shape in plan view. The patterned retardation layer 3 has a first region 3R and a second region 3L that change the polarization state of incident linearly polarized light.

  The first region 3R and the second region 3L have different refractive index anisotropies. The first region 3R has a slow axis in the first direction, and changes linearly polarized light emitted through the polarizer layer 2 to, for example, right-handed circularly polarized light (first polarization state). The second region 3L has a slow axis in a second direction different from the first direction, and converts linearly polarized light emitted through the polarizer layer 2 into, for example, left-handed circularly polarized light (second polarized light). Change to state).

  The first region 3R and the second region 3L extend in a band shape in the longitudinal direction of the patterned retardation layer 3, and alternately in a direction crossing the extending direction of the first region 3R and the second region 3L. Arranged. The adjacent first region 3R and the second region 3L are in contact with each other.

  In the following description, the extending directions of the first region 3R and the second region 3L in the patterned retardation layer 3 are defined as the “longitudinal direction” of the patterned retardation layer 3, the first region 3R, and the second region 3L. The arrangement direction may be referred to as the “width direction” of the patterned retardation layer 3.

  When the patterned retardation layer 3 overlaps the display region P4 of the liquid crystal panel P in the display device 100 shown in FIG. 2, the “excess region” protrudes from the overlapping portion with the display region P4 in the width direction of the display device 100. So that it is larger than the display area P4 in plan view. In such a patterned retardation layer 3, the first region 3R and the second region 3L are provided not only in the portion overlapping the display region P4 but also in the surplus region.

  The patterned retardation layer 3 can be divided into a plurality of regions each having a different width. That is, the patterned retardation layer 3 has a first polarization pattern 31, a second polarization pattern 32, a third polarization pattern 33, a fourth polarization pattern 34, a fifth polarization pattern 35, and a sixth polarization pattern 36. .

  The first polarization pattern 31 is a first region 3R formed with a first width W1. The patterned retardation layer 3 has n first polarization patterns 31 (n is a natural number).

  The second polarization pattern 32 is the second region 3L formed with the first width W1. The patterned retardation layer 3 has (n−1) second polarization patterns 32 (n is a natural number). The second polarization pattern 32 is alternately arranged with the n first polarization patterns 31 and is adjacent to the first polarization pattern 31.

  That is, as shown in the figure, the first polarization pattern 31 and the second polarization pattern 32 are composed of a first first polarization pattern 31, a first second polarization pattern 32, a second first polarization pattern 31 (n). -1) The second polarization pattern 32 of the first and the first polarization pattern 31 of the nth are alternately arranged. The total number of the first polarization pattern 31 and the second polarization pattern 32 is an odd number.

  The width W1 is a width corresponding to the width of the pixel column of the liquid crystal panel P. The width “corresponding to the width of the pixel column” is a width that allows the first polarization pattern 31 or the second polarization pattern 32 and the pixel column of the liquid crystal panel P to be bonded in a one-to-one correspondence. That is. For example, when the first polarization pattern 31 and the pixel row are bonded to each other, the first polarization pattern 31 may overlap the adjacent pixel row regardless of the posture of the optical member 1. The width is not a width “corresponding to the width of the pixel column” in the present specification.

  In a 3D liquid crystal display device, in general, image display is performed using the same number of pixel columns in order to display a right-eye image and a left-eye image at the same resolution. For example, a display device capable of full HD (High Definition) display has 1080 pixel columns in the vertical direction corresponding to a resolution of horizontal 1920 × vertical 1080. When 3D display is performed in such a display device, the image for the right eye and the image for the left eye are each displayed using 540 pixel columns. The patterned retardation layer 3 of the optical member 1 used in such a display device has 540 first polarization patterns 31 and 539 second patterns.

  The third polarization pattern 33 is a second region 3L formed with a second width W2 that is larger than the first width W1. The patterned retardation layer 3 has one third polarization pattern 33. The third polarization pattern 33 is adjacent to the nth first polarization pattern 31 on the side opposite to the second polarization pattern 32. The “n-th” in the “n-th first polarization pattern 31” means “the n-th as the first polarization pattern 31”.

  The fourth polarization pattern 34 is the first region 3R. The patterned retardation layer 3 has one fourth polarization pattern 34. The fourth polarization pattern 34 is adjacent to the third polarization pattern 33 on the side opposite to the first polarization pattern 31.

  The fifth polarization pattern 35 is a second region 3L formed with a third width W3 that is larger than the first width W1. The patterned retardation layer 3 has one fifth polarization pattern 35. The fifth polarization pattern 35 is adjacent to the first first polarization pattern 31 on the side opposite to the second polarization pattern 32.

  The sixth polarization pattern 36 is the first region 3R. The patterned retardation layer 3 has one sixth polarization pattern 36. The sixth polarization pattern 36 is adjacent to the fifth polarization pattern 35 on the side opposite to the first polarization pattern 31.

  Further, in the figure, the width of the fourth polarization pattern 34 is indicated by a symbol W4, and the width of the sixth polarization pattern 36 is indicated by a symbol W5. In the optical member 1 of the present embodiment, the width W4 and the width W5 are illustrated as being larger than the width W1. For example, the width W4 and the width W5 may be approximately the same as the width W1.

  Furthermore, in the optical member 1 of the present embodiment, the width W2 of the third polarization pattern 33 is larger than the width W3 of the fifth polarization pattern 35 by the width W1.

  In such an optical member 1, n first polarization patterns 31 and (n−1) second polarization patterns 32 are provided as optical patterns having a width W 1, and include an odd number of optical patterns. It is. In addition, two optical patterns (a third polarization pattern 33 and a fourth polarization pattern 34) are provided on the nth first polarization pattern 31 side, and two optical patterns are provided on the first first polarization pattern 31 side. Optical patterns (fifth polarization pattern 35 and sixth polarization pattern 36) are provided. That is, in the optical member 1, optical patterns (first region 3R, second region 3L) that remain symmetrically in the vertical direction with respect to the central optical pattern (first region 3R, first polarization pattern 31) are arranged. .

  Therefore, the optical member 1 can be used even if upside down. Therefore, when the optical member 1 is bonded to the liquid crystal panel P, there is no limitation on the bonding direction, and work efficiency is improved.

  The width W2 of the third polarization pattern 33 only needs to be larger than the width W1, and may be the same as the width W3 of the fifth polarization pattern 35, for example. When the width W2 and the width W3 are the same size, the center axis in the longitudinal direction of the optical member 1 extends from the end of the fifth polarization pattern 35 to the end of the third polarization pattern 33 in the width direction of the optical member 1. Is line symmetric. Therefore, there is no restriction | limiting of the bonding direction at the time of bonding of the optical member 1, and work efficiency improves.

(Optical member manufacturing method)
Such an optical member 1 is manufactured as follows, for example. FIG. 4 is a schematic diagram of the optical member original fabric 10 used when the optical member 1 is manufactured, and is a schematic diagram showing the patterned retardation layer 30 included in the optical member original fabric 10. FIG. 4 is a diagram corresponding to FIG.

  The optical member original fabric 10 has a belt shape, and an optical pattern extends continuously in the longitudinal direction. The patterned retardation layer 30 has a plurality of first regions 3R and a plurality of second regions 3L, and the first regions 3R and the second regions 3L are alternately arranged in a direction intersecting with the extending direction of the optical member original fabric 10. Are arranged. Moreover, the optical member original fabric 10 may have a polarizer layer (not shown) formed continuously in the longitudinal direction.

  Further, the patterned retardation layer 30 can divide the optical pattern into a plurality of regions having different widths corresponding to the above-described patterned retardation layer 3. That is, the patterned retardation layer 30 includes the first polarization patterns 31A and 31B, the second polarization patterns 32A and 32B, the third polarization patterns 33A and 33B, the fourth polarization pattern 34B, the fifth polarization patterns 35A and 35B, and the sixth. A polarization pattern 36A and a seventh polarization pattern 37 are provided.

  The first polarization pattern 31A is a first region 3R formed with a first width W1. The patterned retardation layer 30 has n first polarization patterns 31A (n is a natural number).

  The second polarization pattern 32A is the second region 3L formed with the first width W1. The patterned retardation layer 30 has (n−1) second polarization patterns 32A (n is a natural number). The second polarization pattern 32A is alternately arranged with the n first polarization patterns 31A, and is adjacent to the first polarization pattern 31A.

  The first polarization pattern 31B is a first region 3R formed with a first width W1. The patterned retardation layer 30 has n first polarization patterns 31B (n is a natural number).

  The second polarization pattern 32B is the second region 3L formed with the first width W1. The patterned retardation layer 30 has (n−1) second polarization patterns 32B (n is a natural number). The second polarization pattern 32B is alternately arranged with the n first polarization patterns 31B, and is adjacent to the first polarization pattern 31B.

  The third polarization pattern 33A is a second region 3L formed with a second width W2 that is larger than the first width W1. The patterned retardation layer 30 has one third polarization pattern 33A. The third polarization pattern 33A is adjacent to the nth first polarization pattern 31A on the opposite side to the second polarization pattern 32A.

  The third polarization pattern 33B is a second region 3L formed with a second width W2 that is larger than the first width W1. The patterned retardation layer 30 has one third polarization pattern 33B. The third polarization pattern 33B is adjacent to the nth first polarization pattern 31B on the side opposite to the second polarization pattern 32B.

  The fourth polarization pattern 34B is the first region 3R. The patterned retardation layer 30 has one fourth polarization pattern 34B. The fourth polarization pattern 34B is adjacent to the third polarization pattern 33B on the side opposite to the first polarization pattern 31B.

  The fifth polarization pattern 35A is a second region 3L formed with a third width W3 that is larger than the first width W1. The patterned retardation layer 30 has one fifth polarization pattern 35A. The fifth polarization pattern 35A is adjacent to the first first polarization pattern 31A on the side opposite to the second polarization pattern 32A.

  The fifth polarization pattern 35B is a second region 3L formed with a third width W3 that is larger than the first width W1. The patterned retardation layer 30 has one fifth polarization pattern 35B. The fifth polarization pattern 35B is adjacent to the first polarization pattern 31B on the opposite side to the second polarization pattern 32B.

  The sixth polarization pattern 36A is the first region 3R. The patterned retardation layer 30 has one sixth polarization pattern 36A. The sixth polarization pattern 36A is adjacent to the fifth polarization pattern 35A on the side opposite to the first polarization pattern 31A.

  The seventh polarization pattern 37 is a second region formed with a width A. The width A is equal to or greater than the total size of the width W3 of the fourth polarization pattern 34B and the width W5 of the sixth polarization pattern 36A. The patterned retardation layer 30 has one seventh polarization pattern 37. The seventh polarization pattern 37 is provided between the third polarization pattern 33A and the fifth polarization pattern 35B, and is adjacent to the third polarization pattern 33A and the fifth polarization pattern 35B.

  Such a patterned retardation layer 30 is divided along the dividing line PL set in the same direction as the extending direction of the optical pattern in the seventh polarizing pattern 37 located at the center in the width direction, thereby obtaining 2 Two patterned retardation layers 3A and 3B can be formed. Further, by dividing along the dividing line PL, the seventh polarization pattern 37 is divided into a fourth polarization pattern 34A included in the patterned retardation layer 3A and a sixth polarization pattern 36B included in the patterned retardation layer 3B. Divided.

  That is, the patterned retardation layer 3A has a first polarization pattern 31A, a second polarization pattern 32A, a third polarization pattern 33A, a fourth polarization pattern 34A, a fifth polarization pattern 35A, and a sixth polarization pattern 36A. . Further, the patterned retardation layer 3B includes a first polarization pattern 31B, a second polarization pattern 32B, a third polarization pattern 33B, a fourth polarization pattern 34B, a fifth polarization pattern 35B, and a sixth polarization pattern 36B. .

  For example, as shown in FIG. 5, the optical member original fabric 10 is sequentially unwound from the original fabric roll 51 and conveyed, and the optical member original fabric 10 is centered in the width direction using a dividing device 90 provided in the conveying path. By dividing (slit processing) by the set dividing line PL, the optical material is divided into two optical member stocks 11 and 12. In the figure, as the splitting device 90, a device that emits laser light LB and cuts the original fabric is shown.

  The obtained optical member original fabric 11 and optical member original fabric 12 are wound on the downstream side in the transport direction, so that the original optical rolls of the two optical member original fabrics 11 and 12 having the same optical pattern can be easily manufactured. Can do.

  The optical member 1 described above can be manufactured by sequentially unwinding the two optical member original fabrics 11 and 12 thus obtained from the original fabric rolls and cutting them into a predetermined size in the longitudinal direction.

<Optical display device production system, optical display device production method>
FIG. 6 is a schematic diagram of an optical display device production system 500 according to this embodiment. The production system 500 includes an optical display device production system according to the present invention.

  The production system 500 includes a conveyor 510, a cleaning device 520, a first transport device 530, a first bonding device 540, a second transport device 550, a second bonding device 560, and each part of the production system 500. And a control device 590 for controlling.

  The conveyor 510 conveys the liquid crystal panel P from the one end side 510a toward the other end side 510b. That is, the conveyor 510 is a transport path of the liquid crystal panel P from the one end side 510a to the other end side 510b.

  The cleaning device 520 is disposed in the transport path of the liquid crystal panel P by the conveyor 510. The cleaning device 520 performs, for example, brushing or rinsing with respect to the front and back surfaces of the liquid crystal panel P. Thereafter, the front and back surfaces of the liquid crystal panel P are drained. Note that the cleaning device 520 is not limited to such a water-washing type cleaning, and for example, the front and back surfaces of the liquid crystal panel P may be subjected to dry cleaning such as static electricity removal or dust collection.

  The 1st conveyance apparatus 530 hold | maintains liquid crystal panel P in the panel delivery position 510c set in the downstream of the washing | cleaning apparatus 520 in the conveyance path | route of liquid crystal panel P, and conveys it to the 1st bonding apparatus 540. Moreover, the 1st conveying apparatus 530 conveys liquid crystal panel P from the 1st bonding apparatus 540 to the panel delivery position 510c.

  The 1st bonding apparatus 540 bonds the polarizing film F11 cut out from the raw fabric F1 to the surface at the side of the backlight of liquid crystal panel P. As shown in FIG. The 1st bonding apparatus 540 has the cutting part 541, the bonding roller 542, the bonding stage 543, and the imaging device 544.

  The cutting unit 541 sequentially cuts into a predetermined size while unwinding the roll-shaped raw fabric F1 to create the polarizing film F11. Cutting may be performed with a cutting blade or may be performed with laser light.

  The laminating roller 542 can repeatedly hold and peel the polarizing film F11 created by the cutting portion 541 on the outer peripheral surface of the roll. In addition, the bonding roller 542 can move between the cutting unit 541 and the bonding stage 543.

  On the bonding stage 543, the liquid crystal panel P conveyed by the first conveying device 530 is placed, and the polarizing film F11 is bonded to the liquid crystal panel P.

  The imaging device 544 is located above the bonding stage 543, and images the liquid crystal panel P placed on the bonding stage 543 and the polarizing film F11 to be bonded. There may be a plurality of imaging devices 544.

  In the 1st bonding apparatus 540, after the bonding roller 542 hold | maintains the polarizing film F11 created by the cutting part 541, the bonding roller 542 moves to the bonding stage 543. On the other hand, the imaging device 544 images the liquid crystal panel P on the bonding stage 543, and the polarizing film F11 and the liquid crystal panel P are bonded based on the image information. The laminating roller 542 contacts the one end of the polarizing film F11 and one end of the liquid crystal panel P, and then moves the polarizing film F11 that has been moved and held to the other end side of the liquid crystal panel P while rotating. Paste to P.

  The liquid crystal panel P is transported to the panel delivery position 510c by the first transport device 530 after the polarizing film F11 is bonded.

  The 2nd conveyance apparatus 550 hold | maintains liquid crystal panel P in the panel delivery position 510d set in the downstream of the panel delivery position 510c in the conveyance path | route of the liquid crystal panel P, and conveys it to the 2nd bonding apparatus 560. Moreover, the 2nd conveying apparatus 550 conveys liquid crystal panel P from the 2nd bonding apparatus 560 to the panel delivery position 510d.

  The 2nd bonding apparatus 560 bonds the optical member 1 cut out from the original fabric roll of the optical member original fabric 11 to the surface at the display surface side of the liquid crystal panel P. The 2nd bonding apparatus 560 has the cutting part 561, the bonding roller 562, the bonding stage 563, and the imaging device 564. The 2nd bonding apparatus 560 has the same structure as the 1st bonding apparatus 540.

  In the bonding stage 563 of the 2nd bonding apparatus 560, the optical member 1 and liquid crystal panel P are bonded as follows.

  For example, when bonding the optical member 1 and a liquid crystal panel, first, as shown to Fig.7 (a), using several imaging device (not shown), the 3rd polarization pattern 33 and the 4th polarization pattern 34 are used. An area including the boundary is imaged. In the figure, a region to be imaged is indicated by a symbol PA1.

  When the first region 3R and the second region 3L are imaged, an image that looks different in color and brightness is obtained based on the difference in optical characteristics between the first region 3R and the second region 3L. Therefore, it is possible to distinguish the third polarization pattern 33 and the fourth polarization pattern 34 based on the captured image. For example, by binarizing the captured image, the boundary between the third polarization pattern 33 and the fourth polarization pattern 34 is clarified, and the coordinates of the boundary between the third polarization pattern 33 and the fourth polarization pattern 34 in the captured image are detected. To do.

  The boundary detected in this way may be one point, and is detected at a plurality of points, and corresponds to the boundary between the third polarization pattern 33 and the fourth polarization pattern 34 based on the detected coordinates of the boundary between the plurality of points. A straight line (boundary line BL1) may be approximated. As approximation, a generally known statistical method can be used. For example, an approximation method for obtaining a regression line (approximate line) using the least square method for the coordinates of the boundary of a plurality of points can be mentioned.

  Similarly, the region including the boundary between the fifth polarization pattern 35 and the sixth polarization pattern 36 is imaged. In the figure, the area to be imaged is indicated by symbol PA2. Next, the boundary between the first region 3Rz and the second region 3Lz is detected based on the captured image. FIG. 7A shows that the boundary line BL2 is obtained.

  Next, using the boundary line BL1 and the boundary line BL2 as a reference for the optical member 1, an intermediate position M between the boundary line BL1 and the boundary line BL2 is calculated. The intermediate position M can be easily obtained from the separation distance Wa between the boundary line BL1 and the boundary line BL2.

  In the optical member 1, the intermediate position M is ideally a position that overlaps the boundary between the n / 2-th first polarization pattern 31 and the n / 2-th second polarization pattern 32. Even if the optical member 1 does not exhibit a shape exactly as designed due to a manufacturing error or deformation, the intermediate position M is the n / 2nd first polarization pattern 31 and the n / 2nd first polarization pattern 31. It is considered to be located in the vicinity of the boundary with the two-polarization pattern 32.

  7B, only the boundary (boundary line BL1) between the third polarization pattern 33 and the fourth polarization pattern 34 is detected by the above method, and the third polarization pattern 33 and the fourth polarization are detected. When the design value of the distance from the boundary with the pattern 34 to the boundary between the n / 2nd first polarization pattern 31 and the n / 2nd second polarization pattern 32 is Wb, the boundary lines BL1 to Wb The intermediate position M may be obtained as the position.

  Based on the intermediate position M thus obtained, the boundary between the n / 2-th first polarization pattern 31 and the n / 2-th second polarization pattern 32 is detected.

  From the obtained detection result, alignment is performed so that the first polarization pattern 31 and the second polarization pattern 32 overlap the pixel row of the liquid crystal panel P in 1: 1, and the optical member 1 and the liquid crystal panel P are bonded. (Bonding step).

  For example, as shown in FIG. 8, a liquid crystal panel P including n first pixel columns L1 and n second pixel columns L2 arranged alternately with the first pixel columns L1 is prepared. The n first polarization patterns 31 of the optical member 1 correspond to the n first pixel rows L1 of the liquid crystal panel P, and the (n−1) second polarization patterns 32 of the optical member 1 are liquid crystal panels. This corresponds to P (n-1) second pixel rows L2.

  For the liquid crystal panel P, it is possible to easily detect the n / 2nd first pixel column L1 and the n / 2nd second pixel column L2 based on the alignment mark and the distance from the panel edge. it can.

  On the other hand, an intermediate position M is obtained at the center in the longitudinal direction of the optical member 1, and a boundary between adjacent optical patterns from the intermediate position M in the vicinity of the intermediate position M is detected.

  When the liquid crystal panel P and the optical member 1 are bonded together, a pixel column (n / 2nd first pixel column L1 and n / 2nd second pixel column) located in the center in the width direction of the liquid crystal panel P is used. L2) and an optical member based on the relative position between the optical pattern obtained from the intermediate position M (the boundary between the n / 2nd first polarization pattern 31 and the n / 2nd second polarization pattern 32). 1 and liquid crystal panel P are bonded together.

  As a result, the first pixel array from the first to the nth and the first polarization pattern 31 from the first to the nth overlap each other, and the second pixel array from the first to the (n−1) th and the first pixel array. To the (n-1) -th second polarization pattern 32 and the n-th second pixel column and the third polarization pattern 33 are overlapped with each other so that the liquid crystal panel P and the optical member 1 are aligned. I do. At that time, the position and orientation are adjusted as appropriate so that the optical pattern and the pixel column correspond one-to-one.

  Since the user of the display device most closely observes the vicinity of the center of the display area, the user is likely to notice when crosstalk occurs in the center of the display area. On the other hand, as in this embodiment, the position of the optical member 1 is adjusted with reference to the center of the optical member 1 (intermediate position M at the center in the longitudinal direction), and the pixel located at the center in the width direction of the liquid crystal panel P. When both are bonded based on the relative position between the row and the intermediate position M, the optical member 1 and the liquid crystal panel P are bonded with the highest accuracy at the center of the display area. Therefore, the display device manufactured by the manufacturing method of the present embodiment is less likely to cause crosstalk at the center of the display area, and can display a high-quality image.

  In the patterned retardation layer 3, when all the first regions 3R and the second regions 3L are formed with the same width, since the individuality of each optical pattern is poor, the arbitrary first regions 3R and second regions In many cases, it is difficult to recognize the number of the optical pattern in the region 3L from the end.

  In such a case, even if an optical member is imaged by the above-described method and the boundary between the first area 3R and the second area 3L is detected, a large number of first areas are included in the areas PA1 and PA2 to be imaged. 3R and the second region 3L are likely to be included. Then, in the captured image, the boundary is likely to be unclear due to moire, blurring of the image, and the like, and erroneous detection that cannot detect the desired boundary between the first region 3R and the second region 3L is likely to occur.

  In contrast, in the optical member 1 of the present embodiment, the third polarization pattern 33, the fourth polarization pattern 34, the fifth polarization pattern 35, and the sixth polarization pattern that are wider than the first polarization pattern 31 and the second polarization pattern 32. 36, and the boundary between the third polarization pattern 33 and the fourth polarization pattern 34 and the boundary between the fifth polarization pattern 35 and the sixth polarization pattern 36 are detected.

  Since the third to sixth polarization patterns are wider than the first polarization pattern 31 and the second polarization pattern 32, the number of areas included in the areas PA1 and PA2 to be imaged is reduced. For example, according to the design of the third to sixth polarization patterns and the field of view of the imaging device, it is possible to include only the third polarization pattern 33 and the fourth polarization pattern 34 in the area PA1 to be easily imaged. False detection can be suppressed. Similarly, erroneous detection of the boundary between the fifth polarization pattern 35 and the sixth polarization pattern 36 can also be suppressed in the area PA2 to be imaged.

  The third polarization pattern 33 is formed wider than the first polarization pattern 31 and the second polarization pattern 32. When the optical member 1 is used for the display device 100, the width W1 of the third polarization pattern 33 from the first polarization pattern 31 side overlaps the display area P4 of the liquid crystal panel P in a plane and is used for image display. The remaining width W3 does not overlap the display area P4 of the liquid crystal panel P in a planar manner, and does not contribute to image display. Therefore, there is no possibility that the portion of the third polarization pattern 33 that does not overlap the display area P4 in plan view overlaps with other pixel columns and affects the display quality.

  Therefore, according to the optical member 1 having the above configuration, the optical pattern can be easily recognized. Therefore, when manufacturing a 3D liquid crystal display device, a 3D liquid crystal display device capable of recognizing an optical pattern and bonding so that the optical pattern corresponds to the pixel column of the liquid crystal panel on a one-to-one basis and suppressing crosstalk. It can be manufactured easily.

  Further, according to the optical display device production system having the above configuration, the optical pattern can be easily recognized, and the optical pattern and the pixel column of the liquid crystal panel can be easily associated one to one to suppress crosstalk. The 3D liquid crystal display device can be easily produced.

  In addition, according to the method for producing an optical display device having the above-described configuration, the optical pattern is easily recognized, and the optical pattern and the pixel column of the liquid crystal panel are easily associated on a one-to-one basis to suppress crosstalk. The 3D liquid crystal display device can be easily produced.

  Moreover, according to the original fabric roll having the above configuration, an optical member capable of easily recognizing an optical pattern can be easily manufactured.

  In the optical member 1 of the present embodiment, the second region 3L can be further formed outside the fourth polarization pattern 34 or outside the sixth polarization pattern 36. However, in order to suppress erroneous detection, it is preferable that the second region 3L does not continue outside the fourth polarization pattern 34 or the sixth polarization pattern 36.

  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.

  DESCRIPTION OF SYMBOLS 1 ... Optical member, 3 ... Patterned phase difference layer (retardation layer), 3L, 3Lx, 3Ly, 3Lz ... 2nd area | region, 3R, 3Rx, 3Ry, 3Rz ... 1st area | region, 31 ... Effective area | region, 32 ... 1st area 1 surplus area, 33 ... second surplus area, L ... pixel column, P ... liquid crystal panel (optical display component)

Claims (6)

An optical member having a retardation layer,
The retardation layer is formed with a first width and has n (n is a natural number) first polarization patterns having a slow axis in a first direction;
Formed with the first width, having a slow axis in a second direction different from the first direction, arranged alternately with the n first polarization patterns, and adjacent to the first polarization pattern (N-1) second polarization patterns to be
The second polarization pattern is formed with a second width larger than the first width, has a slow axis in the second direction, and is opposite to the second polarization pattern with respect to the nth first polarization pattern. One adjacent third polarization pattern;
A fourth polarization pattern having a slow axis in the first direction and adjacent to the third polarization pattern on the opposite side of the first polarization pattern;
The third polarization width is larger than the first width, has a slow axis in the second direction, and is opposite to the second polarization pattern with respect to the first polarization pattern. One adjacent fifth polarization pattern;
An optical member including a sixth polarization pattern having a slow axis in the first direction and adjacent to the fifth polarization pattern on the side opposite to the first polarization pattern.   The optical member according to claim 1, wherein a width of the fourth polarization pattern and a width of the sixth polarization pattern are larger than the first width.   The optical member according to claim 1, wherein the second width is larger than the third width by the first width. An optical display device production system for bonding an optical member to an optical display component,
Including a bonding apparatus for bonding the optical member to the optical display component;
The optical display component includes n first pixel columns, and n second pixel columns arranged alternately with the n first pixel columns,
The optical member is the optical member according to any one of claims 1 to 3,
The n first polarization patterns of the optical member correspond to the n first pixel columns of the optical display component,
The (n-1) second polarization patterns of the optical member correspond to (n-1) second pixel columns of the optical display component,
The bonding apparatus uses the boundary between the third polarization pattern and the fourth polarization pattern or the boundary between the fifth polarization pattern and the sixth polarization pattern as a reference for the optical member. The first pixel column and the first to n-th first polarization patterns overlap each other, and the second pixel column from the first to the (n−1) th and the first to the (n−1) th. Of the optical display device that aligns the optical display component and the optical member such that the second polarization pattern of the second pixel pattern overlaps each other, and the n-th second pixel column and the third polarization pattern overlap each other. Production system. An optical display device production method for bonding an optical member to an optical display component,
Including a bonding step of bonding the optical member to the optical display component;
The optical display component includes n first pixel columns, and n second pixel columns arranged alternately with the n first pixel columns,
The optical member is the optical member according to any one of claims 1 to 3,
The n first polarization patterns of the optical member correspond to the n first pixel columns of the optical display component,
The (n-1) second polarization patterns of the optical member correspond to (n-1) second pixel columns of the optical display component,
In the bonding step, the boundary between the third polarization pattern and the fourth polarization pattern or the boundary between the fifth polarization pattern and the sixth polarization pattern is used as a reference of the optical member, and the first to nth The first pixel column and the first to n-th first polarization patterns overlap each other, and the second pixel column from the first to the (n−1) th and the first to the (n−1) th. Of the optical display device that aligns the optical display component and the optical member such that the second polarization pattern of the second pixel pattern overlaps each other, and the n-th second pixel column and the third polarization pattern overlap each other. Production method. A raw roll in which a long optical member original having a retardation layer is wound,
The optical member original fabric is formed with a first width and has n (n is a natural number) first polarization patterns having a slow axis in a first direction;
Formed with the first width, having a slow axis in a second direction different from the first direction, arranged alternately with the n first polarization patterns, and adjacent to the first polarization pattern (N-1) second polarization patterns to be
The second polarization pattern is formed with a second width larger than the first width, has a slow axis in the second direction, and is opposite to the second polarization pattern with respect to the nth first polarization pattern. One adjacent third polarization pattern;
A fourth polarization pattern having a slow axis in the first direction and adjacent to the third polarization pattern on the opposite side of the first polarization pattern;
The third polarization width is larger than the first width, has a slow axis in the second direction, and is opposite to the second polarization pattern with respect to the first polarization pattern. One adjacent fifth polarization pattern;
An original fabric roll including a sixth polarization pattern having a slow axis in the first direction and adjacent to the fifth polarization pattern on the side opposite to the first polarization pattern.

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