JP2018132597A - Method for manufacturing display panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a display panel that is easily processed and excellent in production efficiency.SOLUTION: There is provided a method for manufacturing a display panel having an optical film with an irregular shape laminated on a surface of an optical display component in which the shape of the contour of a display area is a shape other than a rectangle, the method for manufacturing the display panel including: a margin forming step of, for a laminated film having an optical member that is a quadrangle in plan view and a protective film laminated on a surface of the optical member, cutting the optical member into an irregular shape while leaving the protective film to form, from the optical member, an optical film and a margin portion on the periphery of the optical film; a laminate forming step of laminating, from a side of the optical film, the laminated film on a surface of the optical display component in which the shape of the display area is a shape other than a rectangle and that is a rectangle in plan view to form a laminate of the laminated film and optical display component; and a separation step of separating the protective film and margin portion from the laminate, where in the separation step, the protective film and margin portion are separated from a side of a second side.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a method for manufacturing a display panel.

  The display panel has a structure in which an optical film such as a polarizing film (polarizing plate) is bonded to the surface of an optical display component (substrate) (for example, Patent Document 1). In the case of a conventional display panel having a rectangular planar shape, alignment when a rectangular optical film is bonded to a rectangular optical display component can be performed with reference to each other's outer shape (for example, four corners). Therefore, in the conventional rectangular display panel, the alignment of the optical film is relatively easy.

JP 2007-232911 A

  By the way, recently, there is an increasing demand for a display panel having a planar shape other than a rectangle as a display panel used for a smart watch, an in-vehicle meter, or the like.

  As a method for manufacturing a display panel having a planar shape other than a rectangle, a method of bonding the optical film to the optical display component after processing the planar shapes of the optical display component and the optical film to a shape other than the rectangle can be considered. However, in this case, it is difficult to perform alignment when bonding the optical film to the optical display component based on the outer shape. For this reason, there is a risk that processing becomes more difficult than in the case of a conventional rectangular display panel, and production efficiency may be reduced.

Further, a method of changing the planar shape of the display panel to a shape other than the rectangle after producing a rectangular display panel is also conceivable. However, the optical film hinders the processing of the optical display component, and there is a possibility that the processing becomes difficult or the production efficiency is lowered.
Therefore, there has been a demand for a method for manufacturing a display panel that is easy to process and has excellent production efficiency.

  The present invention has been made in view of such circumstances, and an object of the present invention is to provide a method for manufacturing a display panel that is easy to process and excellent in production efficiency.

  In order to solve the above problems, according to one embodiment of the present invention, an optical film having a deformed shape corresponding to the shape of the display region is bonded to the surface of the optical display component whose contour shape of the display region is a shape other than a rectangle. A method for manufacturing a display panel, wherein a laminated film having an optical member having a square shape in plan view and a protective film bonded to the surface of the optical member, the optical member is cut into an irregular shape while leaving the protective film. A margin forming step of forming an optical film and a margin portion around the optical film from the optical member, and a shape of the display area is a shape other than a rectangle, Laminate film is laminated from the side to form a laminate of laminated film and optical display component, and the protective film and blank area are peeled from the laminate A separation step that provides a method of manufacturing a display panel including a.

  In 1 aspect of this invention, it is preferable to laminate | stack a laminated film and an optical display component so that a part of laminated film may be located in the outer side of the outline of an optical display component in a laminated body formation process.

  In one aspect of the present invention, in the blank forming step, it is preferable to form the optical film at a position biased toward the first side of the optical member.

  In one aspect of the present invention, in the laminated body forming step, the laminated film and the optical display component are arranged such that at least a part of the second side other than the first side is located outside the contour of the optical display component. In the bonding and peeling step, it is preferable to peel off the protective film and the blank portion from the second side.

  In one aspect of the present invention, the optical display component has a first optical axis set in one direction, the optical member has a second optical axis set in one direction, and a laminate is formed. In the process, based on the correspondence relationship between the outer shape of the laminated film and the second optical axis, the optical display component and the laminated film are arranged so that the first optical axis and the second optical axis satisfy a predetermined relationship. It is good also as a manufacturing method to paste.

  In 1 aspect of this invention, it is good also as a manufacturing method which has the outline change process of changing the outline shape of an optical display component after a peeling process.

  In one embodiment of the present invention, the optical film may be a polarizing film.

  In one aspect of the present invention, the optical display component may be a liquid crystal panel.

  According to one embodiment of the present invention, a method for manufacturing a display panel that is easy to process and excellent in production efficiency is provided.

FIG. 3 is a perspective view showing a configuration of the display panel 1. 3 is a flowchart showing a method for manufacturing the display panel 1. The figure explaining margin formation process S1. The top view of the optical member 51. FIG. The figure explaining laminated body formation process S2. The top view which shows the laminated body 200. FIG. The figure explaining peeling process S3.

  Hereinafter, embodiments 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.

<Display panel>
For example, a display panel 1 illustrated in FIG. 1 is described as an example of a display panel manufactured by applying one embodiment of the present invention. FIG. 1 is a perspective view showing the configuration of the display panel 1.

  In a display panel 1 manufactured by applying one embodiment of the present invention, an optical film 5 is bonded to the surface of an optical display component 10 such as a liquid crystal display panel or an organic EL display panel.

  As shown in FIG. 1, the optical display component 10 has a display region S whose contour shape is circular. Although not shown, the optical display component 10 generally includes signal lines and scanning lines arranged in a matrix, an active matrix display unit, a signal line driving circuit for driving the signal lines, and scanning lines. A scanning line drive circuit for driving. Although not shown, the display unit normally includes active elements and pixels arranged at intersections of signal lines and scanning lines. The planar shape of the display unit corresponds to the contour shape of the display area S.

The optical film 5 has a circular shape corresponding to the circular display region S. As the optical film 5, for example, a polarizing film, a retardation film, an optical compensation film, a reflective polarization type brightness enhancement film, a film having an optical axis such as a prism film, a film having no optical axis such as a diffusion film, and these A film in which a plurality of arbitrarily selected films are laminated can be used.
The manufacturing method of the display panel of this invention is applied suitably when the optical film 5 is a film which has an optical axis. Moreover, it is applied more suitably when the optical film 5 is a polarizing film or a laminated film having a polarizing film.
The optical film 5 used in the present embodiment absorbs linearly polarized light having a vibration surface parallel to the optical axis (second optical axis A2 described later) and transmits linearly polarized light having a vibration surface orthogonal to the optical axis. It is a polarizing film having properties. Usually, the polarizing film is a film in which a dichroic dye is oriented in a polyvinyl alcohol-based resin.

<Method for manufacturing display panel>
As a method of manufacturing a display panel to which one embodiment of the present invention is applied, the case of manufacturing a display panel 1 will be described with reference to FIGS.

  FIG. 2 is a flowchart showing a method for manufacturing the display panel 1. As shown in FIG. 2, the manufacturing method of the display panel according to this embodiment includes a blank forming step S1 for forming an optical film and a blank portion around the optical film from an optical member, and a laminated film and an optical display component. A laminate forming step S2 for forming the laminate, a peeling step S3 for peeling the protective film and the blank portion from the laminate, and a contour changing step S4 for changing the contour shape of the optical display component are included.

[Margin formation step S1]
FIG. 3 is a diagram illustrating the margin forming step S1. As shown in FIG. 3, in the blank forming step S <b> 1, a laminated film 50 having an optical member 51 that is rectangular in plan view and a protect film 52 that is bonded to the surface of the optical member 51 is used.

  The optical film 5 is obtained by cutting the optical member 51 into a circular shape corresponding to the display area S. The optical member 51 has a second optical axis A2 set in one direction. Moreover, although illustration is abbreviate | omitted, on the bonding surface 51s of the optical member 51, the adhesive layer or adhesive layer for bonding the optical film 5 to the optical display component 100 in the subsequent laminated body formation process S2, and And a release film covering the pressure-sensitive adhesive layer or the adhesive layer. This release film is peeled and removed before the laminate forming step S2.

  The protective film 52 is not particularly limited as long as it has adhesiveness to the optical member 51 and can be peeled off in the subsequent peeling step S3. The protective film 52 is made of a film made of a thermoplastic resin such as a polyester such as polyethylene terephthalate (PET) or polyethylene naphthalate (PEN) or a polyolefin such as polyethylene (PE) or polypropylene (PP). An adhesive / peelable resin layer or an adhesive resin layer is laminated (not shown).

  The thickness of the protective film 52 is not particularly limited, but it is preferably 1 μm or more and 100 μm or less, more preferably 1 μm or more and 80 μm or less, from the viewpoint of strength or handleability, and it is 1 μm or more and 50 μm or less. Is more preferable.

In the margin forming step S <b> 1, the optical member 51 is cut into an irregular shape while leaving the protect film 52 in the laminated film 50, and the optical film 5 and the margin portion 6 around the optical film are formed from the optical member 51. The blank portion 6 is a portion that is removed together with the protective film 52 and does not remain on the display panel 1 in the subsequent peeling step S3.
Note that when the optical member 51 is cut, a part of the protect film 52 laminated on the optical member 51 may be cut.

  Here, the position where the optical film 5 is formed in the optical member 51 will be described. In the subsequent peeling step S <b> 3, a part of the laminated film 50 is positioned outside the outline of the optical display component 100 so that the protective film 52 can be easily peeled from the laminated body 200. (See FIG. 6). At this time, it is necessary to form the optical film 5 so that the optical film 5 formed on the laminated film 50 and the display region S of the optical display component 100 overlap each other in a planar manner.

  In order to position a part of the laminated film 50 outside the contour of the optical display component 100, a method using the laminated film 50 having a larger plane area than the optical display component 100 may be employed. However, in this method, since the blank portion 6 of the laminated film 50 increases, the manufacturing cost may increase.

In the present embodiment, the optical film 5 is formed at the following position from the viewpoint of reducing the amount of the blank portion 6 and reducing the manufacturing cost.
FIG. 4 is a plan view of the optical member 51. The optical member 51 has a first side 51a and a second side 51b other than the first side. Here, of the second side 51b, the side facing the first side 51a is referred to as a third side 51c. In the margin forming step S1, the optical film 5 is formed at a position that is biased toward the first side 51a rather than the third side 51c. By forming the optical film 5 at this position, the laminated film 50 and the optical film are arranged such that at least a part of the second side 51b is located outside the contour of the optical display component 100 in the subsequent laminated body forming step S2. The display component 100 can be bonded.

  Examples of the method of cutting the optical member 51 include a method of putting a Thomson blade in a cutting direction, a method of rolling a roll blade in a cutting direction, and a method of burning to a desired depth using a laser. It is not limited. A method using a laser is preferable because cutting waste is not generated. In addition, a method using a Thomson blade is also preferable because it is easy to half-cut only the optical member 51 while controlling the penetration depth of the blade and leaving the protective film 52.

[Laminate Forming Step S2]
FIG. 5 is a diagram for explaining the laminated body forming step S2. FIG. 6 is a plan view showing the stacked body 200. As shown in FIG. 5, in the laminated body forming step S <b> 2, an optical display component 100 having a circular display area S and a rectangular shape in plan view is used.

  The optical display component 10 is obtained by cutting the optical display component 100 into a circular shape. The optical display component 100 has a first optical axis A1 set in one direction.

  As shown in FIG. 5, in the laminated body forming step S <b> 2, the laminated film 50 is bonded to the surface of the optical display component 100 from the optical film 5 side, and the laminated film 50 and the optical display component 100 are the above-described pressure-sensitive adhesive. The laminated body 200 laminated | stacked through the layer or the adhesive bond layer is formed.

In the margin forming step S1 in the previous stage, the optical member 51 is cut leaving the protect film 52. Therefore, in the laminated body forming step S <b> 2, it is easy to confirm the positional relationship between the predetermined side of the laminated film 50 and the predetermined side of the optical display component 100. Therefore, the manufacturing method of this embodiment is easy to process and has excellent production efficiency.
Further, as described above, the optical member 51 has the second optical axis A2, and the angle formed between the predetermined side of the laminated film and the second optical axis A2 is known. Therefore, when laminating the optical display component 100 and the laminated film 50, based on this correspondence, the optical axis so that the first optical axis A1 and the second optical axis A2 satisfy a predetermined relationship. The relative position between the display component 100 and the laminated film 50 can be determined.
In particular, when the planar shape of the display panel is configured by a curve (such as a circle), the conventional manufacturing method may not know the inclination of the optical axis of the optical film with respect to the optical axis of the optical display component. On the other hand, according to this embodiment, it is possible to easily confirm the relative relationship between the optical axes of the optical display component 100 and the laminated film 50. Therefore, in the manufacturing method of this embodiment, production efficiency and the optical axis precision at the time of bonding of an optical film can be improved more.

Moreover, as described above, in the subsequent peeling step S <b> 3, the laminated body 200 includes an optical display component 100 in which a part of the laminated film 50 is rectangular in plan view so that the protective film 52 can be easily peeled off from the laminated body 200. It is located outside the outline of the.
Correspondingly, in the margin forming step S1, from the viewpoint of reducing the amount of the margin portion 6 and reducing the manufacturing cost, as shown in FIG. 6, at a position biased to the first side 51a of the optical member 51. An optical film 5 is formed. In the laminated body forming step S <b> 2, the laminated film 50 and the optical display component 100 are bonded so that at least a part of the second side 51 b is located outside the outline of the optical display component 100.

  In laminated body formation process S2, the laminated | multilayer film 50 can be bonded to the surface of the optical display component 100 using a conventionally well-known bonding apparatus. In the first margin forming step S1, only the optical member 51 is cut leaving the protective film 52, so that the outer shape of the laminated film 50 remains rectangular. Therefore, it can bond easily using a conventionally well-known bonding apparatus similarly to the laminated | multilayer film which is the conventional planar view square shape.

  As a conventionally well-known pasting device, for example, JP 2003-107452 A, JP 2006-058411 A, JP 2008-122555 A, JP 2008-139523 A, JP 2010-072183, Examples thereof include an apparatus described in JP2010-117546A. That is, while conveying an optical display component in a conveyance direction, an optical film is supplied so that an optical display component and an optical film may become a desired positional relationship, and the bonding surface of an optical film is bonded to an optical display component. Any device can be used as long as it is bonded while pressing.

[Peeling step S3]
FIG. 7 is a diagram illustrating the peeling step S3. As shown in FIG. 7, in the peeling step S3, the protective film 52 and the blank portion 6 are peeled from the laminate 200. At this time, the protective film 52 and the blank portion 6 are peeled off from the second side 51b side of the optical member 51.

[Contour changing step S4]
In the contour changing step S4, the contour shape of the optical display component is changed (not shown). A method for cutting the optical display component is not particularly limited, and examples thereof include a scribe cutting process using a blade.

  According to the above method, the optical film 5 and the optical display component 10 can be processed separately. Therefore, the optical film 5 does not hinder the processing of the optical display component 10 and can be processed under optimum conditions. Therefore, in the method for manufacturing a display panel to which one embodiment of the present invention is applied, the display panel is easily processed.

  Moreover, when laminating | stacking the laminated | multilayer film 50, it can carry out similarly to the case where the display panel which is the conventional planar view square shape is manufactured. That is, the laminated film 50 is pasted so that the first optical axis A1 and the second optical axis A2 satisfy a predetermined relationship based on the correspondence relationship between the outer shape of the laminated film 50 and the second optical axis A2. Can be combined. Therefore, since alignment can be performed without performing optical axis measurement of the optical film 5 or the optical display component 100, the display panel manufacturing method to which one embodiment of the present invention is applied is excellent in production efficiency.

Note that one embodiment of the present invention is not necessarily limited to the above-described embodiment, and various modifications can be made without departing from the spirit of the present invention.
Specifically, in the above-described embodiment, the case where the contour changing step S4 is performed after the peeling step S3 is shown, but the contour changing step S4 may not be performed after the peeling step S3. That is, the optical display component 100 may be used as it is to form the optical display component 10 shown in FIG.

Moreover, although it showed as a procedure which goes through blank formation process S1, laminated body formation process S2, peeling process S3, and outline change process S4 in the said embodiment, you may change suitably according to the structure of a display panel.
When manufacturing a display panel having a plurality of optical films, a blank forming step S1 is performed on a plurality of laminated films in advance, and one optical film is laminated on an optical display component, and then another laminated film is produced. You may repeat laminated body formation process S2 and peeling process S3.

  Moreover, in the said embodiment, although the optical member 51 showed the thing of the planar view rectangle, it is not limited to this, What is necessary is just a planar view square shape. Examples of the square in plan view include a rectangle, a square, a rhombus, a parallelogram, a trapezoid, and a plane figure surrounded by four other straight lines.

  Moreover, in the said embodiment, although the optical display component 100 showed the thing of the planar view rectangle, it is not limited to this, What is necessary is just a planar view rectangle (rectangle, square, etc.).

  Moreover, in the said embodiment, although the outline shape of the display area S in the optical display component 10 showed the circular shape, it is not limited to this. The contour shape of the display area S is a shape other than a rectangle depending on the application of the display panel 1. As a shape other than a rectangle, for example, an ellipse, a polygon (for example, a triangle, a pentagon, a hexagon, an octagon, etc.), or a round or cut is provided at at least one of the four corners of the rectangle. Examples thereof include a shape and a shape in which a cutout is provided in a part of a rectangle.

Moreover, in the said embodiment, although the shape of the optical film 5 showed the circular thing, it is not limited to this. Furthermore, the shape of the optical film 5 is not necessarily the same as the contour shape of the display region S. The optical film 5 may be an irregular shape corresponding to the display area S.
Similarly, the optical display component 10 has a circular shape, but is not limited thereto. Furthermore, the shape of the optical display component 10 is not necessarily the same as the contour shape of the display region S.

  Moreover, in laminated body formation process S2, although the example which bonds the laminated | multilayer film 50 and the optical display component 100 was shown so that a part of laminated film 50 might be located in the outer side of the outline of the optical display component 100, it was not necessarily shown. It is not limited to this.

  Moreover, although the example which bonds the laminated | multilayer film 50 to the optical display component 100 through the adhesive layer or adhesive bond layer previously formed in the optical film 5 was shown, it does not restrict to this. The pressure-sensitive adhesive or adhesive may be formed in advance on the optical display component 100, or may be formed on both the optical film 5 and the optical display component 100.

  DESCRIPTION OF SYMBOLS 1 ... Display panel, 5 ... Optical film, 6 ... Blank part 10,100 ... Optical display component, 50 ... Laminated film, 51 ... Optical member, 51a ... 1st edge | side, 51b, 51c ... 2nd edge | side, 52 ... Protect film, 200 ... Laminate, A1 ... First optical axis, A2 ... Second optical axis, S ... Display area, S1 ... Margin formation process, S2 ... Laminate formation process, S3 ... Peeling process, S4 ... Contour change process

Claims (8)

A display panel manufacturing method in which an optical film having a deformed shape corresponding to the shape of the display region is bonded to the surface of the optical display component whose contour shape of the display region is a shape other than a rectangle,
For a laminated film having an optical member that is a quadrangle in a plan view and a protective film that is bonded to the surface of the optical member, the optical member is cut into the deformed shape, leaving the protective film, and from the optical member A margin forming step of forming the optical film and a margin portion around the optical film;
The laminate of the laminated film and the optical display component is formed by laminating the laminated film from the side of the optical film on the surface of the optical display component having a rectangular shape in plan view and the display area having a shape other than rectangular. A laminate forming step of forming
A peeling step of peeling the protective film and the blank portion from the laminate.   2. The display panel according to claim 1, wherein, in the laminated body forming step, the laminated film and the optical display component are bonded so that a part of the laminated film is positioned outside a contour of the optical display component. Production method.   The manufacturing method of the display panel according to claim 1, wherein, in the margin forming step, the optical film is formed at a position biased toward the first side of the optical member. In the laminated body forming step, the laminated film and the optical display component are bonded so that at least a part of the second side other than the first side is located outside the outline of the optical display component. ,
The method for manufacturing a display panel according to claim 3, wherein in the peeling step, the protective film and the blank portion are peeled from the second side. The optical display component has a first optical axis set in one direction,
The optical member has a second optical axis set in one direction,
In the laminated body forming step, the first optical axis and the second optical axis satisfy a predetermined relationship based on the correspondence relationship between the outer shape of the laminated film and the second optical axis. The manufacturing method of the display panel of any one of Claims 1-4 which bonds the said optical display component and the said laminated | multilayer film.   The manufacturing method of the display panel of any one of Claims 1-5 which has an outline change process which changes the outline shape of the said optical display component after the said peeling process.   The method for manufacturing a display panel according to claim 5, wherein the optical film is a polarizing film.   The method for manufacturing a display panel according to claim 1, wherein the optical display component is a liquid crystal panel.

Images