JP2018146580A - Defect marking method and defect marking device, method for manufacturing original fabric and original fabric, and method for manufacturing sheet and sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a defect marking method suitable for displaying a position of a defect.SOLUTION: There is provided a defect marking method for performing defect inspection of an object to be inspected, and for applying marking to a defective spot of the object to be inspected on the basis of a result of defect inspection, therein a first print pattern PT1 and a second print pattern PT2 which are adjacent to each other in the other direction intersecting with one direction in a plane of the object to be inspected are printed on a surface of the object to be inspected such that a defect D is positioned between the first print pattern PT1 and the second print pattern PT2, and a position of the defect D is displayed.SELECTED DRAWING: Figure 6

Description

  The present invention relates to a defect marking method and a defect marking apparatus, a raw fabric manufacturing method and a raw fabric, and a sheet manufacturing method and a sheet.

  For example, in the process of manufacturing a long strip of raw material such as resin film or paper, the raw material is inspected for defects while the raw material is being transported, and the defects on the raw material are marked based on the results of the defect inspection. (Referred to as Patent Documents 1 to 4, for example).

  In addition, in the manufacturing process of an optical film (sheet) such as a polarizing plate used in a liquid crystal display panel, information about defects (hereinafter referred to as defect information) such as the position and type of defects, size, and inspection method is referred to as optical film. Recording (printing) is also performed using a print head in a specific area (hereinafter referred to as a recording area) along the edge.

  After the recording of defect information is completed, the optical film is wound around the core material, and when the winding amount reaches a certain amount, it is separated from the optical film on the upstream side in the transport direction and shipped as a raw roll . From the original roll, a sheet (chip) cut in a size and direction predetermined by the product specifications is cut out. In addition, the defective portion is excluded from the product and discarded.

JP 2001-305070 A JP 2002-303580 A JP 2011-102985 A JP 2014-16217 A

  By the way, in the above-described conventional defect marking, when a defective portion is cut out from the original fabric, the side cut out by cutting and the side left uncut by cutting are cut between the marking and the defect. In some cases, the position of the defect is unknown after cutting.

  Moreover, in the invention described in Patent Document 2, marking is performed on a defective portion by applying a scratch mark. However, when a scratch mark is attached, it is impossible to erase the scratch mark after the defect inspection. In this case, a defective portion may be allowed as a product depending on visual inspection (inspection) after marking. However, if a scratch mark is applied, it cannot be used as a product.

  On the other hand, the conventional defect marking described above generally displays only the position of the defect by marking the defective portion. Therefore, in the conventional defect marking, the defect information described above is not recorded. For this reason, for example, when defect information is required when re-inspecting the material roll before shipment, it is necessary to separately record the defect information in a recording area or the like.

  The present invention has been proposed in view of such conventional circumstances, and is a defect marking method and a defect marking apparatus suitable for displaying the position of a defect, a method for producing a raw fabric, a raw fabric, and a sheet. It aims at providing a manufacturing method and a sheet.

  According to an aspect of the present invention, as a means for solving the above-mentioned problem, a defect marking method for marking a defective portion of an inspection object, which is a method of marking a defect in a plane in the surface of the inspection object. The first print pattern and the second print pattern are printed on the surface of the inspection object so that a defect is located between the first print pattern and the second print pattern that are adjacent in the direction of A defect marking method is provided.

  The defect marking method according to the aspect may be a method of recording information on the defect by using one or both of the first print pattern and the second print pattern.

  Further, the defect marking method of the above aspect may be a method of printing by arranging at least one or a plurality of dot-shaped marks in the one direction as the one or both of the print patterns.

  The defect marking method of the above aspect may be a method of printing by arranging at least one or a plurality of linear marks in the one direction as the one or both of the print patterns.

  The defect marking method according to the aspect may be a method of recording information on the defect by changing any one or more of the number, interval, size, and color of the mark.

  The defect marking method according to the aspect may be a method of displaying the position of the defect in the one direction by a print pattern in which at least a part of a plurality of marks arranged in the one direction is changed. .

  In the defect marking method of the above aspect, the defect in the one direction is arranged by disposing at least a part of the plurality of marks arranged in the one direction at a position adjacent to the defect. A method of displaying the position may be used.

  In the defect marking method of the above aspect, in the other direction, by printing a third print pattern adjacent to one or both of the first print pattern and the second print pattern, A method for recording information on the defect may be used.

  Further, the defect marking method of the above aspect may be a method of recording information related to other than the defect by any one of the print patterns.

  Further, the defect marking method of the above aspect may be a method of printing using an ink that can erase the print pattern.

  Moreover, in the defect marking method of the said aspect, the method of marking to the defect location of the elongate strip | belt-shaped original fabric conveyed in the said 1 direction as said to-be-inspected object may be sufficient.

  Moreover, in the defect marking method of the said aspect, the method of marking to the defect location of the sheet | seat obtained by cut | disconnecting a long strip-shaped original fabric as said to-be-inspected object may be sufficient.

  Further, according to the aspect of the present invention, the step of performing a defect inspection on a long strip-shaped raw material conveyed in one direction, and using any one of the defect marking methods, And a step of marking the defect portion of the original fabric on the basis of the result of the defect inspection during the conveyance in the direction.

  Further, according to the aspect of the present invention, the step of performing a defect inspection on a sheet obtained by cutting a long strip-shaped raw material, and the result of the defect inspection using any one of the defect marking methods And a step of marking a defective portion of the sheet based on the above.

  Moreover, according to the aspect of the present invention, the printing apparatus includes a marking device that marks a defective portion of the inspection object, and the printing apparatus has a predetermined direction in another direction that intersects with one direction in the surface of the inspection object. A plurality of printing units that are arranged side by side and print a print pattern on the surface of the inspection object, and a control unit that controls driving of the plurality of printing units, the control unit, A printing unit that prints the first printing pattern and the second printing pattern is selected so that a defect is located between the first printing pattern and the second printing pattern that are adjacent in the other direction. There is provided a defect marking device characterized by performing control.

  Further, in the defect marking device according to the aspect, the control unit may select the first printing pattern and the first printing pattern according to the information on the defect to be recorded for one or both of the selected printing units. The structure which performs control which changes any one or both printing patterns with a 2nd printing pattern may be sufficient.

  Further, the defect marking device of the above aspect may be configured such that at least one or a plurality of dot-like marks are arranged in the one direction as the one or both of the print patterns.

  Further, the defect marking device according to the aspect may be configured to print at least one or a plurality of linear marks in the one direction as the one or both of the print patterns.

  Further, the defect marking device of the above aspect may be configured to change any one or more of the number, interval, size, and color of the marks.

  Further, in the defect marking apparatus according to the aspect, the control unit performs control to change at least some intervals of the plurality of marks arranged in the one direction with respect to any of the selected printing units. It may be.

  Further, in the defect marking device according to the aspect, the control unit may provide a blank with at least a part of a plurality of marks arranged in the one direction, with respect to any of the selected printing units. The structure which performs the control arrange | positioned in the position adjacent to may be sufficient.

  In the defect marking device according to the aspect, the control unit may include a third print pattern that is adjacent to one or both of the first print pattern and the second print pattern in the other direction. The printing unit to be printed is selected, and one or both of the selected printing units are controlled to change the third printing pattern in accordance with information on the defect to be recorded. Also good.

  Further, in the defect marking device according to the aspect, the control unit controls to change any one of the print patterns in accordance with information related to other than the defect to be recorded for any one of the selected print units. The structure which performs this may be sufficient.

  According to an aspect of the present invention, the apparatus includes a defect inspection apparatus that performs a defect inspection on a long strip-shaped original fabric conveyed in one direction, and any one of the defect marking apparatuses. While the sheet is conveyed in the one direction, marking is performed on the defect portion of the original fabric based on the result of the defect inspection.

  Further, according to an aspect of the present invention, the defect includes a defect inspection apparatus that performs a defect inspection on a sheet obtained by cutting a long strip-shaped original fabric, and any one of the defect marking apparatuses. A sheet manufacturing apparatus is provided, wherein marking is performed on a defective portion of the sheet based on a result of the inspection.

  In addition, according to the aspect of the present invention, a long strip-shaped original fabric in which a defective portion is marked, the first printed pattern that is printed on the surface by the marking and is adjacent in the lateral direction and the first 2 is provided, and the position of the defect is displayed when the defect is located between the first print pattern and the second print pattern. Is done.

  Further, the original fabric of the above aspect may have a configuration in which information on the defect is recorded by one or both of the first print pattern and the second print pattern.

  Further, the original fabric of the above aspect may have a configuration in which at least one or a plurality of dot-like marks are printed side by side in the longitudinal direction as one or both of the print patterns.

  Further, the original fabric of the above aspect may be configured such that at least one or a plurality of linear marks are printed side by side in the longitudinal direction as one or both of the print patterns.

  In the original fabric of the above aspect, any one or more of the number, interval, size, and color of the marks may be changed.

  Further, the original fabric of the above aspect may be configured such that the position of the defect in the longitudinal direction is displayed by a printing pattern in which at least a part of the plurality of marks arranged in the longitudinal direction is changed.

  In the original fabric according to the aspect, the position of the defect in the longitudinal direction is displayed by disposing at least a part of the plurality of marks arranged in the longitudinal direction at a position adjacent to the defect. It may be configured.

  Further, the original fabric of the aspect includes a third print pattern that is adjacent to one or both of the first print pattern and the second print pattern in the short-side direction, The information on the defect may be recorded by the print pattern.

  Moreover, the original fabric of the aspect may be configured such that information related to other than the defect is recorded by any one of the print patterns.

  Further, the original fabric of the above aspect may be configured such that the print pattern is printed with erasable ink.

  Further, according to an aspect of the present invention, the sheet is marked on the defective portion, printed on the surface by the marking, and adjacent to the first print pattern in the other direction intersecting the one direction, Provided is a sheet having a second print pattern, wherein the position of the defect is displayed when the defect is located between the first print pattern and the second print pattern. Is done.

  The sheet according to the aspect may have a configuration in which information on the defect is recorded by one or both of the first print pattern and the second print pattern.

  Further, the sheet according to the aspect may have a configuration in which at least one or a plurality of dot-like marks are printed side by side in the one direction as the one or both of the print patterns.

  Further, the sheet according to the aspect may have a configuration in which at least one or a plurality of linear marks are printed side by side in the one direction as the one or both of the print patterns.

  In the sheet according to the aspect, any one or more of the number, interval, size, and color of the marks may be changed.

  Further, the sheet according to the aspect may be configured such that the position of the defect in the one direction is displayed by a print pattern in which at least a part of a plurality of marks arranged in the one direction is changed. .

  Further, in the sheet according to the aspect, the position of the defect in the one direction can be determined by disposing at least a part of the plurality of marks arranged in the one direction at a position adjacent to the defect. The displayed configuration may be used.

  Further, the sheet according to the aspect includes a third print pattern that is adjacent to one or both of the first print pattern and the second print pattern in the other direction. The information on the defect may be recorded by a printing pattern.

  Further, the sheet according to the aspect may have a configuration in which information related to other than the defect is recorded by any one of the print patterns.

  The sheet according to the aspect may have a configuration in which the print pattern is printed with erasable ink.

  As described above, according to an aspect of the present invention, a defect marking method and a defect marking apparatus suitable for displaying the position of a defect, an original fabric manufacturing method and an original fabric, and a sheet manufacturing method and a sheet are provided. It is possible.

It is a top view which shows an example of a liquid crystal display panel. It is sectional drawing of the liquid crystal display panel shown in FIG. It is sectional drawing which shows an example of an optical film. It is a side view which shows the structure of a film manufacturing apparatus and a defect marking apparatus. It is a top view which shows the structure of the defect marking apparatus shown in FIG. It is a top view which shows an example of the 1st printing pattern and the 2nd printing pattern which were printed with the dot-shaped mark. It is a top view which shows an example of the 1st printing pattern and the 2nd printing pattern which were printed with the linear mark. It is a top view which shows the example which added the 3rd printing pattern. It is the top view which illustrated the difference in the kind of defect, and its printing pattern. It is sectional drawing which shows the defect which generate | occur | produced in the 1st manufacturing process and the 2nd manufacturing process. It is a top view which shows an example of the 1st printing pattern printed with respect to the defect which generate | occur | produced in the 1st manufacturing process and the 2nd manufacturing process, and a 2nd printing pattern. It is a top view which shows the modification of a 1st printing pattern and a 2nd printing pattern. It is the top view which illustrated the combination of the printing pattern.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
In the present embodiment, for example, as a production system of an optical display device, a film manufacturing apparatus (raw fabric manufacturing apparatus) constituting a part thereof, and a film manufacturing method (raw fabric manufacturing method) using this film manufacturing apparatus Will be described.

  The film manufacturing apparatus is bonded to a panel-shaped optical display component (optical display panel) such as a liquid crystal display panel or an organic EL display panel, for example, a film-shaped optical such as a polarizing film, a retardation film, or a brightness enhancement film. A member (optical film) is manufactured. The film manufacturing apparatus constitutes a part of a production system for producing an optical display device including such optical display components and optical members.

  In the present embodiment, a transmissive liquid crystal display device is illustrated as an optical display device. The transmissive liquid crystal display device generally includes a liquid crystal display panel and a backlight. In this liquid crystal display device, illumination light emitted from the backlight is incident from the back side of the liquid crystal display panel, and light modulated by the liquid crystal display panel is emitted from the front side of the liquid crystal display panel, thereby displaying an image. It is possible.

(Optical display device)
First, the configuration of the liquid crystal display panel P shown in FIGS. 1 and 2 will be described as an optical display device. FIG. 1 is a plan view showing the configuration of the liquid crystal display panel P. FIG. 2 is a cross-sectional view of the liquid crystal display panel P along the cutting line AA shown in FIG. In FIG. 2, hatching showing a cross section is omitted.

  As shown in FIGS. 1 and 2, the liquid crystal display panel P includes a first substrate P1, a second substrate P2 disposed opposite to the first substrate P1, a first substrate P1, and a second substrate. And a liquid crystal layer P3 disposed between the substrate P2 and the substrate P2.

  The first substrate P1 is made of a transparent substrate having a rectangular shape in plan view. The second substrate P2 is made of a transparent substrate having a rectangular shape that is relatively smaller than the first substrate P1. The liquid crystal layer P3 is a region of a rectangular shape in plan view surrounded by a sealing material (not shown) between the first substrate P1 and the second substrate P2 and surrounded by the sealing material. Arranged inside. In the liquid crystal display panel P, an area that fits inside the outer periphery of the liquid crystal layer P3 in plan view is a display area P4, and an outer area that surrounds the display area P4 is a frame portion G.

  On the back surface (backlight side) of the liquid crystal display panel P, a first optical film F11 serving as a polarizing film and a third optical film F13 serving as a brightness enhancement film are sequentially stacked on the first optical film F11. It is laminated and bonded. A second optical film F12 as a polarizing film is bonded to the surface (display surface side) of the liquid crystal display panel P. Hereinafter, the first, second, and third optical films F11, F12, and F13 may be collectively referred to as an optical film F1X.

(Optical film)
Next, an example of the optical sheet FX constituting the optical film F1X shown in FIG. 3 will be described. FIG. 3 is a cross-sectional view showing the configuration of the optical sheet FX. In FIG. 3, hatching showing a cross section is omitted.

  The optical film F1X is obtained by cutting a sheet piece (chip) having a predetermined length from the long belt-shaped optical sheet (original fabric) FX shown in FIG. Specifically, the optical sheet FX includes a base material sheet F4, an adhesive layer F5 provided on one surface (upper surface in FIG. 3) of the base material sheet F4, and the base material sheet F4 via the adhesive layer F5. Separator sheet F6 provided on one surface of the sheet, and a surface protection sheet F7 provided on the other surface (lower surface in FIG. 3) of the base sheet F4.

  In the case of a polarizing film, for example, the base sheet F4 has a structure in which a polarizer F4a is sandwiched between a pair of protective films F4b and F4c. The adhesive layer F5 is for attaching a sheet piece (optical film F1X) to the liquid crystal display panel P. The separator sheet F6 protects the adhesive layer F5, and is peeled from the adhesive layer F5 before the sheet piece (optical film F1X) is bonded to the liquid crystal display panel P. In addition, the part remove | excluding the separator sheet F6 from the optical film F1X is set as the bonding sheet | seat F8.

  The surface protection sheet F7 protects the surface of the base material sheet F4. The surface protection sheet F7 is peeled off from the surface of the sheet piece (optical film F1X) after the sheet piece (optical film F1X) is attached to the liquid crystal display panel P.

  In addition, about the base material sheet F4, it is good also as a structure which abbreviate | omitted any one among a pair of protective films F4b and F4c. For example, the protective film F4b on the adhesive layer F5 side may be omitted, and the adhesive layer F5 may be directly provided on the polarizer F4a. The protective film F4c on the surface protective sheet F7 side may be subjected to a surface treatment such as a hard coat treatment that protects the outermost surface of the liquid crystal display panel P or an antiglare treatment that provides an antiglare effect. . Moreover, about the base material sheet F4, not only the thing of the laminated structure mentioned above but the thing of a single layer structure may be sufficient. Further, the surface protection sheet F7 can be omitted.

(Film manufacturing apparatus and film manufacturing method)
Next, the film manufacturing apparatus 100 shown in FIG. 4 will be described. FIG. 4 is a side view showing the configuration of the film manufacturing apparatus 100.

  As shown in FIG. 4, the film manufacturing apparatus 100, for example, bonded a long strip-shaped second film F102 serving as a surface protective film to one surface of a long strip-shaped first film F101 serving as a polarizing film. Then, the second film F102 and the third film are formed on both surfaces of the first film F101 by laminating a long belt-like third film F103, which is a surface protective film, on the other surface of the first film F101. The optical film F10X to which F103 is bonded is manufactured.

  Specifically, the film manufacturing apparatus 100 includes a first transport line 101, a second transport line 102, a third transport line 103, a fourth transport line 104, and a fifth transport line 105. The winding unit 106 is roughly provided.

  Among these, the 1st conveyance line 101 forms the conveyance path which conveys the 1st film F101, and the 2nd conveyance line 102 is the 2nd film F102 unwound from the 1st original fabric roll R1. The third conveyance line 103 forms a conveyance path for conveying the single-sided bonded film F104 in which the second film F102 is bonded to one surface of the first film F101, The 4th conveyance line 104 forms the conveyance path | route which conveys the 3rd film F103 unwound from the 2nd original fabric roll R2, and the 5th conveyance line 105 is 1st of the single-sided bonding film F104. The conveyance path which conveys the double-sided bonding film F105 (optical film F10X) by which the 3rd film F103 was bonded to the surface by the side of the film F101 (other surface of the 1st film F101). It is formed. And the manufactured optical film F10X is wound up by the core material as the 3rd original fabric roll R3 in the winding-up part 106. FIG.

  For example, the first transport line 101 is a TAC (Triacetylcellulose) on both sides of a film that is a base material of a polarizer such as PVA (Polyvinyl Alcohol). A long strip-shaped first film F101 obtained by laminating a protective film or the like is transported toward the third transport line 103.

  Specifically, the first transport line 101 includes a pair of first nip rolls 111a and 111b from one side across the upstream side of the third transport line 103 toward the third transport line 103, and A first accumulator 112 including a plurality of first dancer rolls 112a and 112b and a first guide roll 113 are sequentially arranged in the horizontal direction.

  The pair of first nip rolls 111a and 111b rotate in opposite directions while sandwiching the first film F101 therebetween, thereby causing the first film F101 in the direction of arrow a (rightward) shown in FIG. It is what draws out.

  The first accumulator 112 is for absorbing the difference due to the fluctuation of the feeding amount of the first film F101 and reducing the fluctuation of the tension applied to the first film F101. Specifically, the first accumulator 112 includes a plurality of dancer rolls 112a located on the upper side and a plurality located on the lower side between the first nip rolls 111a and 111b and the first guide roll 113. The dancer rolls 112b are alternately arranged.

  In the first accumulator 112, while the first film F101 is alternately wound on the dancer roll 112a on the upper side and the dancer roll 112b on the lower side, while the first film F101 is conveyed, The dancer roll 112a and the lower dancer roll 112b are moved up and down relatively. Thereby, it is possible to accumulate the first film F101 without stopping the first transport line 101. For example, in the first accumulator 112, the distance between the upper dancer roll 112a and the lower dancer roll 112b is increased to increase the accumulation of the first film F101, while the upper dancer roll 112a. By reducing the distance between the dancer roll 112b and the lower dancer roll 112b, accumulation of the first film F101 can be reduced. The first accumulator 112 is operated, for example, at the time of work such as paper splicing after replacing the core material of the raw fabric rolls R1 to R3.

  The first guide roll 113 guides the first film F101 drawn out by the first nip rolls 111a and 111b toward the upstream side of the third transport line 103 while rotating. The first guide roll 113 is not limited to a single arrangement, and may be a plurality of arrangements.

  The second transport line 102 is, for example, a third transport line 103 while unwinding a long belt-shaped second film F102 serving as a surface protection film such as PET (Polyethylene terephthalate) from the first raw roll R1. It is made to convey toward

  Specifically, the second transport line 102 includes a pair of second nip rolls 121a and 121b from the other side across the upstream side of the third transport line 103 toward the third transport line 103, A second accumulator 122 including a plurality of second dancer rolls 122a and 122b and a plurality of second guide rolls 123a and 123b are sequentially arranged in the horizontal direction.

  The pair of second nip rolls 121a and 121b rotate in opposite directions while sandwiching the second film F102 therebetween, thereby causing the second film F102 in the direction of the arrow b (left direction) shown in FIG. It is what draws out.

  The second accumulator 122 is for absorbing the difference due to the fluctuation of the feed amount of the second film F102 and reducing the fluctuation of the tension applied to the second film F102. Specifically, the second accumulator 122 is located between the second nip rolls 121a and 121b and the second guide rolls 123a and 123b, and a plurality of dancer rolls 122a located on the upper side and a lower side. And a plurality of dancer rolls 122b that are arranged alternately.

  In the second accumulator 122, the second film F102 is alternately wound on the upper dancer roll 122a and the lower dancer roll 122b, while the second film F102 is conveyed, The dancer roll 122a and the lower dancer roll 122b are moved up and down relatively in the vertical direction. As a result, the second film F102 can be accumulated without stopping the second transport line 102. For example, in the second accumulator 122, by increasing the distance between the upper dancer roll 122a and the lower dancer roll 122b, the accumulation of the second film F102 is increased, while the upper dancer roll 122a is increased. The accumulation of the second film F102 can be reduced by narrowing the distance between the dancer roll 122b and the lower dancer roll 122b. The second accumulator 122 is operated, for example, at the time of work such as paper splicing after replacing the core material of the raw fabric rolls R1 to R3.

  The plurality of second guide rolls 123a and 123b guide the second film F102 drawn by the second nip rolls 121a and 121b toward the upstream side of the third transport line 103 while rotating. . Note that the second guide rolls 123a and 123b are not limited to a plurality of arrangements, and may be a single arrangement.

  The 3rd conveyance line 103 conveys the elongate strip | belt-shaped single-sided bonding film F104 which bonded the 2nd film F102 on the one surface of the 1st film F101 toward the 5th conveyance line 105. As shown in FIG.

  Specifically, a pair of third nip rolls 131 a and 131 b are arranged on the third transport line 103. The pair of third nip rolls 131a and 131b is located at the junction of the downstream side of the first conveyance line 101 and the downstream side of the second conveyance line 102, and the first film F101 and the second film are interposed therebetween. The direction of the arrow c shown in FIG. 4 (downward direction) shows the single-sided bonding film F104 in which the first film F101 and the second film F102 are bonded by rotating in opposite directions while sandwiching the film F102. It is something to pull out.

  The fourth transport line 104 is, for example, a fifth transport line 105 while unwinding a long strip-shaped third film F103 serving as a surface protection film such as PET (Polyethylene terephthalate) from the second raw roll R2. It is made to convey toward

  Specifically, the fourth transport line 104 includes a pair of fourth nip rolls 141a and 141b from one side across the downstream side of the third transport line 103 toward the third transport line 103, and A third accumulator 142 including a plurality of third dancer rolls 142a and 142b and a plurality of fourth guide rolls 143a and 143b are sequentially arranged in the horizontal direction.

  The pair of fourth nip rolls 141a and 141b rotate in opposite directions while sandwiching the third film F103 therebetween, thereby causing the third film F103 in the direction of the arrow d (rightward) shown in FIG. It is what draws out.

  The third accumulator 142 is for absorbing the difference due to the variation in the feed amount of the third film F103 and reducing the variation in the tension applied to the third film F103. Specifically, the third accumulator 142 includes a plurality of dancer rolls 142a positioned on the upper side and a position positioned on the lower side between the fourth nip rolls 141a and 141b and the fourth guide rolls 143a and 143b. The plurality of dancer rolls 142b that are arranged alternately are arranged.

  In the third accumulator 142, while the third film F103 is alternately wound on the dancer roll 142a on the upper side and the dancer roll 142b on the lower side, the third film F103 is conveyed, The dancer roll 142a and the lower dancer roll 142b are moved up and down relatively in the vertical direction. Thus, the third film F103 can be accumulated without stopping the fourth transport line 104. For example, the third accumulator 142 increases the accumulation of the third film F103 by increasing the distance between the upper dancer roll 142a and the lower dancer roll 142b, while the upper dancer roll 142a. By reducing the distance between the lower dancer roll 142b and the lower dancer roll 142b, accumulation of the third film F103 can be reduced. The third accumulator 142 is operated, for example, at the time of work such as paper splicing after replacing the core material of the raw fabric rolls R1 to R3.

  The plurality of fourth guide rolls 143a and 143b rotate the third film F103 drawn by the fourth nip rolls 141a and 141b while rotating, respectively, on the downstream side of the third transport line 103 (of the fifth transport line 105). It guides towards the upstream side. Note that the fourth guide rolls 143a and 143b are not limited to a configuration in which a plurality of the fourth guide rolls 143a and 143b are disposed, and may be a configuration in which only one is disposed.

  The 5th conveyance line 105 is the long strip | belt-shaped double-sided bonding film which bonded the 3rd film F103 to the surface (other surface of the 1st film F101) of the 1st film F101 side of the single-sided bonding film F104. F105 (optical film F10X) is conveyed toward the 3rd original fabric roll R3.

  Specifically, the fifth transport line 105 includes a pair of fifth nip rolls 151a and 151b from the other side across the downstream side of the third transport line 103 toward the third original roll R3. The fifth guide roll 153a, the pair of sixth nip rolls 151c and 151d, the fourth accumulator 152 including a plurality of fourth dancer rolls 152a and 152b, and the sixth guide roll 153b are horizontal. They are arranged side by side in the direction.

  The pair of fifth nip rolls 151a and 151b is located at the junction of the downstream side of the third conveyance line 103 and the upstream side of the fifth conveyance line 105, and the single-sided bonding film F104 and the third side are interposed therebetween. The direction of the arrow e shown in FIG. 4 (downward direction) shows the double-sided bonding film F105 in which the single-sided bonding film F104 and the third film F103 are bonded by rotating in opposite directions while sandwiching the film F103. It is something to pull out.

  The fifth guide roll 153a guides the double-sided bonded film F105 drawn out by the fifth nip rolls 151a and 151b toward the fourth accumulator 152 while rotating. Note that the fifth guide roll 153a is not limited to a single arrangement, and may be a plurality of arrangements.

  The pair of sixth nip rolls 151c and 151d rotate in opposite directions while sandwiching the double-sided adhesive film F105 therebetween, thereby causing the double-sided adhesive film F105 in the direction of arrow f (right direction) shown in FIG. It is what draws out.

  In the fourth accumulator 152, the upper side dancer roll 152 a and the lower side dancer roll 152 b are alternately wound on the upper side dancer roll 152 b, while the double sided laminate film F 105 is conveyed alternately, The dancer roll 152a and the lower dancer roll 152b are moved up and down relatively in the vertical direction. Thereby, it becomes possible to accumulate | store the double-sided bonding film F105, without stopping the 5th conveyance line 105. FIG. For example, in the fourth accumulator 152, by increasing the distance between the dancer roll 152a on the upper side and the dancer roll 152b on the lower side, the accumulation of the double-sided bonding film F105 is increased, while the dancer roll 152a on the upper side is increased. By narrowing the distance between the lower dancer roll 152b and the lower side dancer roll 152b, accumulation of the double-sided bonded film F105 can be reduced. For example, the fourth accumulator 152 is operated at the time of work such as paper splicing after the core materials of the raw fabric rolls R1 to R3 are replaced.

  The 6th guide roll 153b guides the double-sided bonding film F105 toward the 3rd original fabric roll R3. Note that the sixth guide roll 153b is not limited to a single arrangement, and may be a plurality of arrangements.

  The double-sided bonded film F105 is wound around the core material as the third original roll R3 of the optical film F10X in the winding unit 106, and then sent to the next step.

(Defect marking device and defect marking method)
Next, the defect marking apparatus 10 provided in the film manufacturing apparatus 100 and a defect marking method using the defect marking apparatus 10 will be described.

  As shown in FIG. 4, the defect marking apparatus 10 constitutes a part of the film manufacturing apparatus 100, and includes a conveyance line L, a first defect inspection apparatus 11, a second defect inspection apparatus 12, The recording device 13, the first length measuring device 14 and the second length measuring device 15, and a control device 16 are generally provided.

  The transport line L forms a transport path for transporting the film to be inspected. In the present embodiment, the transport line L is transported by the first transport line 101, the third transport line 103, and the fifth transport line 105. Line L is configured.

  The 1st defect inspection apparatus 11 performs the defect inspection of the 1st film F101 before the 2nd film F102 and the 3rd film F103 are bonded. Specifically, the first defect inspection apparatus 11 is used for various defects such as a foreign matter defect, a concavo-convex defect, and a bright spot defect generated when the first film F101 is manufactured or when the first film F101 is conveyed. Is detected. The first defect inspection apparatus 11 performs inspection processes such as a reflection inspection, a transmission inspection, an oblique transmission inspection, and a crossed Nicol transmission inspection on the first film F101 conveyed on the first conveyance line 101. By doing so, the defect of the 1st film F101 is detected.

  The first defect inspection apparatus 11 includes a plurality of illumination units 21a, 22a, and 23a that irradiate illumination light to the first film F101 on the upstream side of the first nip rolls 111a and 111b in the first transport line 101. And a plurality of light detectors 21b, 22b, and 23b that detect light transmitted through the first film F101 (transmitted light) or light reflected by the first film F101 (reflected light).

  In the present embodiment, because of the configuration for detecting transmitted light, the plurality of illumination units 21a, 22a, 23a and the light detection units 21b, 22b, 23b arranged in the transport direction of the first film F101 are respectively the first film. They are arranged facing each other across F101. Further, the first defect inspection apparatus 11 is not limited to such a configuration that detects transmitted light, but may have a configuration that detects reflected light or a configuration that detects transmitted light and reflected light. In the case of detecting reflected light, the light detection units 21b, 22b, and 23b may be disposed on the illumination units 21a, 22a, and 23a side.

  The illumination units 21a, 22a, and 23a irradiate the first film F101 with illumination light whose light intensity, wavelength, polarization state, and the like are adjusted according to the type of defect inspection. The light detection units 21b, 22b, and 23b capture an image of the position irradiated with the illumination light of the first film F101 using an image sensor such as a CCD. Images (defect inspection results) captured by the light detection units 21 b, 22 b, and 23 b are output to the control device 16.

  The 2nd defect inspection apparatus 12 performs the defect inspection of the 1st film F101 after the 2nd film F102 and the 3rd film F103 were bonded, ie, the double-sided bonding film F105. Specifically, the second defect inspection apparatus 12 is configured to bond the single-sided bonding film F104 and the double-sided bonding film F105 when the second film F102 and the third film F103 are bonded to the first film F101. Various defects such as a foreign matter defect, a concavo-convex defect, and a bright spot defect generated during conveyance are detected. For example, the second defect inspection apparatus 12 performs inspection processes such as a reflection inspection, a transmission inspection, an oblique transmission inspection, and a crossed Nicols transmission inspection on the double-sided bonded film F105 conveyed by the fifth conveyance line 105. By doing, the defect of the double-sided bonding film F105 is detected.

  The second defect inspection apparatus 12 includes a plurality of illumination units 24a and 25a that irradiate the double-sided bonding film F105 with illumination light downstream of the fifth nip rolls 151a and 151b in the fifth transport line 105, and It has the some light detection part 24b, 25b which detects the light (transmitted light) which permeate | transmitted the double-sided bonding film F105, or the light (reflected light) reflected by the double-sided bonding film F105.

  In this embodiment, because of the configuration for detecting transmitted light, a plurality of illumination units 24a and 25a and light detection units 24b and 25b arranged in the conveyance direction of the double-sided bonding film F105 sandwich the double-sided bonding film F105, respectively. Opposed to each other. The second defect inspection apparatus 12 is not limited to such a configuration that detects transmitted light, but may have a configuration that detects reflected light or a configuration that detects transmitted light and reflected light. In the case of detecting the reflected light, the light detection units 24b and 25b may be arranged on the illumination units 24a and 25a side.

  The illumination units 24a and 25a irradiate the double-sided bonding film F105 with illumination light whose light intensity, wavelength, polarization state, and the like are adjusted according to the type of defect inspection. The light detection units 24b and 25b capture an image of the position irradiated with the illumination light of the double-sided bonding film F105 using an imaging element such as a CCD. Images (defect inspection results) captured by the light detection units 24 b and 25 b are output to the control device 16.

  The recording device 13 is a printing device that marks a defective portion based on the result of defect inspection by the first defect inspection device 11 and the second defect inspection device 12. The recording device 13 is provided on the downstream side of the second defect inspection device 12 in the fifth transport line 105. The recording device 13 has a plurality of print heads 13a adopting, for example, an ink jet method. The print head 13a may employ a laser system.

  As shown in FIG. 5, the plurality of print heads 13 a are arranged side by side in a direction (width direction) that intersects the conveyance direction of the double-sided bonded film F <b> 105. In each print head 13a, a nozzle portion (print portion) 13b for discharging ink is arranged side by side at a predetermined interval in a direction (width direction) intersecting the transport direction of the double-sided bonded film F105. The nozzle portions 13b of the respective print heads 13a face the double-sided bonding film F105 and are arranged at equal intervals from one end side to the other end side in the width direction of the double-sided bonding film F105.

  Moreover, the 7th guide roll 153c which contact | connects the double-sided bonding film F105 is arrange | positioned in the position facing the some print head 13a. And the nozzle part 13b of each printing head 13a discharges ink toward the surface of the double-sided bonding film F105 from the opposite side to the position which contact | connects the 7th guide roll 153c of the double-sided bonding film F105. Thereby, it is possible to print (mark) a dot-shaped mark on the surface of the double-sided bonding film F105.

  The first length measuring device 14 and the second length measuring device 15 measure the transport amount of the first film F101. Specifically, in the present embodiment, in the first transport line 101, a rotary encoder that constitutes the first length measuring device 14 on the first nip roll 111 a that is upstream of the first accumulator 112, A rotary encoder constituting the second length measuring device 15 is arranged on the third nip roll 131a on the downstream side of the one accumulator 112.

  The first length measuring device 14 and the second length measuring device 15 are provided with a rotary encoder according to the amount of rotational displacement of the first nip roll 111a and the third nip roll 131a rotating in contact with the first film F101. The conveyance amount of one film F101 is measured. The measurement results of the first length measuring device 14 and the second length measuring device 15 are output to the control device 16.

  In the present embodiment, since there is only one accumulator between the first defect inspection apparatus 11 and the recording apparatus 13, one length measuring device is provided upstream and downstream of the accumulator. It is an arranged configuration. On the other hand, when a plurality of accumulators exist between the first defect inspection apparatus 11 and the recording apparatus 13, the upstream side of the most upstream accumulator and the downstream side of the most downstream accumulator The length measuring device may be arranged one by one.

  The control device 16 performs overall control of each part of the film manufacturing apparatus 100. Specifically, the control device 16 includes a computer system as an electronic control device. The computer system generally includes an arithmetic processing unit such as a CPU and an information storage unit such as a memory and a hard disk.

  The information storage unit of the control device 16 stores an operating system (OS) that controls the computer system, a program that causes the arithmetic processing unit to execute various processes in each unit of the film manufacturing apparatus 100, and the like. In addition, the control device 16 may include a logic circuit such as an ASIC that executes various processes required for controlling each part of the film manufacturing apparatus 100. The control device 16 includes an interface for performing input / output with an external device of the computer system. For example, an input device such as a keyboard or a mouse, a display device such as a liquid crystal display, or a communication device can be connected to this interface.

  The control device 16 functions as a control unit that controls driving of the nozzle portions 13b of the plurality of print heads 13a based on the results of the defect inspection of the first defect inspection device 11 and the second defect inspection device 12 described above. . That is, the control device 16 analyzes the images captured by the light detection units 21b, 22b, and 23b and the light detection units 24b and 25b, and determines the presence / absence (position) and type of the defect. And when it determines with a defect existing in the 1st film F101 and the double-sided bonding film F105, the defect marking which marks the defect location of the double-sided bonding film F105 by controlling the drive of the applicable nozzle part 13b is performed. Do.

  Moreover, in the defect marking apparatus 10, defect marking is performed at a predetermined timing after the defect inspection so that there is no deviation between the defect inspection position of the double-sided bonded film F105 and the marking position of the defective portion. For example, in the present embodiment, after the time when the defect inspection by the first defect inspection apparatus 11 or the second defect inspection apparatus 12 is performed, the conveyance amount of the film conveyed on the conveyance line L is calculated and calculated. When the transported amount coincides with the offset distance, defect marking is performed by the recording device 13.

  Here, the offset distance refers to the transport distance of the film between the first defect inspection device 11 and the second defect inspection device 12 and the recording device 13. Strictly speaking, the offset distance is determined by the position where the defect inspection is performed by the first defect inspection apparatus 11 and the second defect inspection apparatus 12 (defect inspection position) and the position where the recording apparatus 13 performs marking (marking position). ) Is defined as the transport distance of the film. Further, the offset distance varies when the first accumulator 112 is operated.

  The offset distance when the first accumulator 112 is not in operation (hereinafter referred to as the first offset distance) is stored in advance in the information storage unit of the control device 16. Specifically, the first defect inspection apparatus 11 and the second defect inspection apparatus 12 include a plurality of light detection units 21b, 22b, and 23b and light detection units 24b and 25b, and the light detection units 21b, 22b, Defect inspection is performed every 23b, 24b, 25b. Therefore, the information storage unit of the control device 16 stores the first offset distance for each of the light detection units 21b, 22b, 23b, 24b, and 25b.

  When the offset distance varies due to the operation of the first accumulator 112, the offset distance is corrected based on the difference in the transport amount of the first film F101 between the upstream side and the downstream side of the first accumulator 112. Calculate the value. That is, the control device 16 calculates the accumulation amount of the first film F101 by the first accumulator 112 from the measurement results of the first length measuring device 14 and the second length measuring device 15, and this first accumulator 112 A correction value for the offset distance is calculated based on the accumulated amount of the film F101.

  In the defect marking device 10, when the first accumulator 112 is in operation, the timing at which the recording device 13 performs marking is corrected based on the offset distance correction value. For example, in the present embodiment, the offset distance correction value is calculated based on the measurement results of the first length measuring device 14 and the second length measuring device 15. Based on the correction value and the first offset distance, the control device 16 calculates an offset distance (hereinafter referred to as a second offset distance) when the first accumulator 112 is in operation.

  In the present embodiment, the time when the defect inspection by the first defect inspection device 11 and the second defect inspection device 12 is performed based on the measurement result of the first length measuring device 14 or the second length measuring device 15. Thereafter, the transport amount of the film transported on the transport line L is calculated, and when the calculated transport amount coincides with the second offset distance, defect marking is performed by the recording device 13.

  Further, in the present embodiment, when the first accumulator 112 is operated, information indicating that the first accumulator 112 has been operated (hereinafter referred to as accumulator operation information) is bonded on both sides separately from the defect marking. You may record on the film F105. When accumulator operation information is recorded, a marking position shift or the like can be detected by an operator carefully inspecting a defect portion to which the accumulator operation information is attached. Thereby, the possibility that the non-defective portion is erroneously determined as a defective portion is reduced, and the yield is improved.

  By the way, in the defect marking device 10 of the present embodiment, for example, as shown in FIG. 6, the first print pattern PT1 and the second print pattern PT1 that are adjacent to the surface of the double-sided bonding film F105 in the width direction are provided. The first print pattern PT1 and the second print pattern PT2 are printed so that the defect D is positioned between the print pattern PT2.

  In the present embodiment, a plurality of dot marks DM are printed side by side in the transport direction (longitudinal direction) of the double-sided bonding film F105 as the first print pattern PT1 and the second print pattern PT2. The mark DM is of a size that can be visually recognized by visual observation, and specifically has a diameter of 5 mm or less (more preferably 1 mm or more and 3 mm or less).

  The control device 16 selects the two nozzle portions 13b that print the first print pattern PT1 and the second print pattern PT2 from the plurality of nozzle portions 13b arranged in the width direction of the double-sided bonding film F105. And these two selected nozzle parts 13b put the first print pattern PT1 and the second print pattern PT2 on both sides in the width direction (short direction) of the double-sided bonded film F105 with the defect D in between. Print.

  In this case, when the defect D is positioned between the first print pattern PT1 and the second print pattern PT2, the position of the defect D between them can be displayed. Thereby, the position of the defect D can be easily grasped in the visual inspection (inspection) after marking.

  Further, the size of the defect D between the first print pattern PT1 and the second print pattern PT2 can be recognized based on the distance between the first print pattern PT1 and the second print pattern PT2. Therefore, about the two nozzle parts 13b selected, not only when selecting the adjacent nozzle part 13b among the several nozzle parts 13b arranged in the width direction of the double-sided bonding film F105, the position of the defect D and The two nozzle portions 13b may be appropriately selected according to the size.

  Moreover, when the defect D is located between the first print pattern PT1 and the second print pattern PT2, when the defective portion is cut out from the double-sided bonding film F105, the first print pattern PT1 and the second print pattern PT2 The print pattern PT2 is cut between the defect D and one of the print patterns PT2.

  In this case, either the first print pattern PT1 or the second print pattern PT2 remains on the side cut out by cutting and the side left by cutting. Thereby, whether the defect D is located on the side cut out by cutting or the side left by cutting is determined by the first print pattern PT1 or the second print pattern PT2 remaining after cutting. It is possible to easily confirm the position of the defect.

  The first print pattern PT1 and the second print pattern PT2 can be printed using erasable ink. As described above, depending on the visual inspection after inspection (inspection), a defective portion may be allowed as a product. In this case, by erasing the first print pattern PT1 and the second print pattern PT2, this portion can be used as a product, and the yield can be improved.

  For erasable ink, a solvent appropriately selected from ketones (methyl ethyl ketone, acetone, etc.), esters (ethyl acetate, propyl = acetate succinpropyl, etc.), alcohols (ethanol, 2-propanol, etc.) On the other hand, an oil-based ink to which a colorant, a film-forming resin or the like is added can be used. Furthermore, you may add a hardening | curing agent, surfactant, etc. as needed. On the other hand, the same solvent as the above solvent can be used as a solvent for erasing ink. Note that the use of aromatic hydrocarbons such as toluene and xylene is not preferable because the material of the optical film (polarizing plate) is affected.

  Further, in the defect marking device 10 of the present embodiment, information on the defect D is recorded by one or both of the first print pattern PT1 and the second print pattern PT2.

  Specifically, when printing the first print pattern PT1 and the second print pattern PT2, the control device 16 provides information (defect information) regarding the defect D to be recorded to the selected nozzle portion 13b. In response, control for changing one or both of the first print pattern PT1 and the second print pattern PT2 (in this embodiment, the first print pattern PT1 and the second print pattern PT2). I do.

  For example, in the present embodiment, the number and interval of the marks DM constituting the first print pattern PT1 and the second print pattern PT2 are changed according to the defect information to be recorded. Thereby, it is possible to record the defect information at the same time as marking the defect portion.

  The defect information is information on the defect D such as the position, type, size, and inspection method (type of defect inspection) of the defect D. In the first print pattern PT1 and the second print pattern PT2, the number and interval of the marks DM are set in advance so that the defect information can be identified.

  For example, in the first print pattern PT1 and the second print pattern PT2 shown in FIG. 6, five marks DM are printed side by side in the transport direction (longitudinal direction) which is one direction of the double-sided bonding film F105. Yes. Among these, two marks DM are arranged separately on the upstream side and three marks DM are arranged on the downstream side. Further, a space (spaced portion) K for one mark is provided between the upstream mark DM and the downstream mark DM.

  The blank K is arranged in the same row as the defect D in the width direction (short direction) which is the other direction of the double-sided bonded film F105. That is, this blank K displays the position of the defect D in the transport direction (longitudinal direction) of the double-sided bonded film F105. In addition, when the defect D is larger than the blank K, it is preferable to arrange the blank K at a position adjacent to the center of the defect D.

  In this case, not only between the first print pattern PT1 and the second print pattern PT2, but also the fact that the defect D is located between the upstream mark DM and the downstream mark DM can be displayed by the blank K. . Thereby, it is possible to grasp the position of the defect D more easily. Further, when a chip is cut out across the defect D, it is possible to determine whether or not the defect D exists in the chip by looking at the remaining mark DM. Thereby, the utilization efficiency of the double-sided bonding film F105 can be improved.

  Moreover, from the difference in the number of marks DM on the upstream side and the downstream side, even after being cut out from the double-sided adhesive film F105, the transport direction (direction indicated by the arrow in FIG. 6) of the double-sided adhesive film F105 is easily achieved. I can grasp.

  Furthermore, the amount of deviation in timing between the defect inspection position and the marking position can be grasped from the amount of deviation in the transport direction (longitudinal direction) of the double-sided laminated film F105 of the defect D and the blank K. Then, it is possible to easily adjust the marking timing by the recording device 13 based on the deviation amount.

  Regarding the size of the blank K, the interval (center-to-center distance) T2 between the marks DM on both sides of the blank K is made larger than the interval (center-to-center distance) T1 between the marks DM arranged at regular intervals in the transport direction. Is preferred. More specifically, a range of 1.2 ≦ T2 / T1 ≦ 3.0 is preferable, and a range of 1.5 ≦ T2 / T1 ≦ 2.5 is more preferable.

  As described above, according to the present embodiment, the position of the defect D can be displayed and the defect information can be recorded by the first print pattern PT1 and the second print pattern PT2 described above.

In addition, this invention is not necessarily limited to the thing of the said embodiment, A various change can be added in the range which does not deviate from the meaning of this invention.
For example, the first print pattern PT1 and the second print pattern PT2 are not limited to the case where the number and interval of the marks DM described above are changed. In addition, for example, size (diameter) and color (red, blue) , Black, etc., preferably black). In other words, any one or more of the number, interval, size (diameter), and color of the dot-shaped marks DM may be changed. Thereby, it is possible to set these print patterns PT1 and PT2 more finely and record more information.

  Further, for example, as shown in FIG. 7, the first print pattern PT1 and the second print pattern PT2 are not limited to the dot-shaped marks DM described above, but in the transport direction (longitudinal direction) of the double-sided bonded film F105. A linear mark LM may be printed.

  In this case, not only the inkjet print head 13a described above, but also, for example, a plurality of markers (printing units) arranged in a direction (width direction) intersecting the conveyance direction of the double-sided bonding film F105 can be used. The marker is not particularly limited, for example, a pen marker or a laser marker.

  When recording defect information by printing linear marks LM, at least one or more marks LM are arranged in the transport direction (longitudinal direction) of the double-sided bonding film F105 according to the defect information to be recorded. Then, any one or more of the number, interval, size (length, thickness), and color of the linear marks LM are changed. Thereby, defect information can be recorded as in the case of printing the dot-shaped mark DM. Moreover, when providing the blank K in the linear mark LM, it is preferable that the space | interval of the blank K shall be about 3-5 mm.

  Further, for example, as shown in FIGS. 8A, 8B, and 8C, in the width direction (short direction) of the double-sided bonded film F105, the first print pattern PT1 and the second print pattern PT2 A third print pattern PT3 adjacent to either one or both of them may be printed.

  In this case, the control device 16 selects the nozzle portion 13b for printing the third print pattern PT3 separately from the two nozzle portions 13b for printing the first print pattern PT1 and the second print pattern PT2 described above. . For the nozzle portion 13b for printing the third print pattern PT3, at least one or a plurality of nozzle portions 13b can be selected according to the defect information to be recorded.

  In other words, as shown in FIG. 8A, the third print pattern PT3 is printed adjacent to one of the first print pattern PT1 and the second print pattern PT2, or FIG. As shown in FIG. 8B, when printing is performed adjacent to both sides of the first printing pattern PT1 and the second printing pattern PT2, as shown in FIG. 8C, the width direction ( For example, when printing a plurality of images in the short direction), it is possible to select appropriately according to defect information to be recorded.

  In addition, the third print pattern PT3 can be printed between the first print pattern PT1 and the second print pattern PT2. In this case, it is possible to print on the upstream side, the downstream side, or both sides of the transport direction (longitudinal direction) of the double-sided bonded film F105 with the defect D in between.

  Further, the third print pattern PT3 can be printed with the dot mark DM or the line mark LM, similarly to the first print pattern PT1 and the second print pattern PT2. The method for changing the third print pattern PT3 is the same as that for changing the first print pattern PT1 and the second print pattern PT2.

  Therefore, as for the defect information, more information can be recorded by the combination of the first print pattern PT1, the second print pattern PT2, and the third print pattern PT3.

  For the defect information recorded by any of the first, second and third print patterns PT1, PT2 and PT3 described above, which print pattern is to be changed, for example, depending on the type of the defect D, etc. It may be set in advance which of the number, interval, size (diameter, length, thickness), and color of the mark DM (LM) constituting the print pattern to be changed. Thereby, it is possible to identify the type or the like of the defect D according to a preset rule.

  For example, for the type of defect D, for example, the foreign substance system shown in FIG. 9A, the bubble system shown in FIG. 9B, the bright spot system shown in FIG. 9C, and the soot system shown in FIG. And so on. Among these, the foreign substance system shown to Fig.9 (a) is the defect D which arises when a foreign substance mixes in the double-sided bonding film F105. On the other hand, the bubble system shown in FIG. 9B is a defect D caused by bubbles generated in the double-sided bonded film F105. Such bubbles may bite around the foreign matter when the foreign matter is mixed. On the other hand, the bright spot system shown in FIG. 9C is a defect D generated in the first film F101 serving as a polarizing film. When the analyzer is arranged in crossed Nicols with respect to the polarizing film, the bright spot (light This is a defect D observed as missing). On the other hand, the flaw-type defect D shown in FIG. 9D is a defect D caused by wrinkles generated on the double-sided bonded film F105.

  In the present embodiment, the number of marks DM arranged on the upstream side of the upstream mark DM and the downstream mark DM across the blank K is made different depending on the type of the defect D. For example, the number of marks DM arranged on the upstream side is three for the foreign substance system shown in FIG. 9 (a), one for the bubble system shown in FIG. 9 (b), and the bright spot system shown in FIG. 9 (c). And two in the saddle system shown in FIG. 9 (d). Thereby, the type of the defect D can be easily identified from the number of marks DM arranged on the upstream side.

  In the present invention, it is also possible to record information related to other than the defect D by changing any one of the first, second and third print patterns PT1, PT2 and PT3. .

  For example, as information related to other than the defect D, it is possible to record manufacturing information such as a manufacturing condition, a manufacturing place, the occurrence frequency of the same type of defect, and the presence or absence of the periodicity. Further, by combining these pieces of manufacturing information, it is possible to specify the cause, location, process, and the like of the defect D. As a result, it is possible to reduce the occurrence of the defect D by taking measures such as performing maintenance of the equipment that caused the defect D.

  Here, in the manufacturing process of the polarizing film described above, FIG. 10A shows a case where a defect D1 occurs in the process of bonding the protective film (TAC) to both surfaces of the polarizer (PVA) (first process). Show. Moreover, the case where the defect D2 generate | occur | produces in the process (2nd process) which bonds an adhesive and a separator on the surface of one protective film (TAC) after the 1st process in FIG.10 (b). Show.

  Then, for the defect D1 generated in the first step, for example, a first print pattern PT1 and a second print pattern PT2 as shown in FIG. 11A are printed. On the other hand, for the defect D2 generated in the second step, for example, the first print pattern PT1 and the second print pattern PT2 as shown in FIG. 11B are printed.

  In this case, with respect to the positions of the defects D1 and D2 shown in FIGS. 11A and 11B, the first print pattern PT1 and the second print pattern PT2 are printed on both sides of the respective defects D1 and D2. In addition, by providing a blank K between the marks DM arranged at regular intervals, the position can be displayed.

  The information recorded in the defects D1 and D2 is determined by the first print pattern PT1 and the second print pattern PT2, and the types (defect information) of the defects D1 and D2, the first process, and the second process. Information (manufacturing information) indicating whether or not the defects D1 and D2 have occurred in any of the processes is recorded.

  Specifically, the types of the defects D1 and D2 are distinguished by the color of the mark DM constituting the first and second print patterns PT1 and PT2. For example, the types of the defects D1 and D2 can be identified by the difference in the color of the mark DM such as a transmission defect (blue), a cross defect (red), and a reflection defect (green).

  On the other hand, in the first and second print patterns PT1 and PT2, one of the first process and the second process is performed depending on the number of marks DM upstream (the smaller number of marks DM) than the blank K. Information on whether or not the defects D1 and D2 have occurred in the process is recorded. For example, if the number of the marks DM upstream of the first and second print patterns PT1 and PT2 is 1, this indicates that the defect D1 has occurred in the first step, and if the number is two, It shows that the defect D2 occurred in the process.

  In addition to the first and second print patterns PT1, PT2 shown in FIG. 11B, a third print pattern PT3 as shown in FIG. 11C may be printed. For the third print pattern PT3, information (defect information) indicating the number of layers of the laminated polarizing films in which the defect D2 exists is recorded according to the number of marks DM. For example, since the third print pattern PT3 shown in FIG. 11C is composed of three marks DM, it is identified that the defect D2 exists in the third layer (TAC) in the stacking order. can do.

  As described above, in the present invention, the positions of the defects D1 and D2 are displayed by printing the first, second, and third print patterns PT3 described above on the polarizing film, and the defect D1. , D2 and the like can be recorded.

  Moreover, in this invention, instead of providing the blank K mentioned above, for example like 1st printing pattern PT1 and 2nd printing pattern PT2 which are shown in FIG. 12, double-sided bonding film You may display the position of the defect D in the conveyance direction (longitudinal direction) of F105.

  Furthermore, in this invention, in order to display the position of the defect D in the conveyance direction (longitudinal direction) of the double-sided bonded film F105, the size of the mark DM is used instead of providing the blank K described above (changing the interval between the marks DM). It is also possible to display the position of the defect D using the third print pattern PT3.

  In the present invention, as shown in FIGS. 13A to 13G, for example, as shown in FIGS. 13A to 13G, a defect D can be obtained by combining any one of the first, second, and third print patterns PT1, PT2, and PT3. Various print patterns can be printed around the.

  Among these, in the print pattern shown in FIG. 13A, the first, second, and third print patterns PT1, PT2, PT3 are printed so that the four marks DM surround the defect D in four directions. Yes. On the other hand, in the print pattern shown in FIG. 13B, the first, second, and third print patterns PT1, PT2, and PT3 are printed such that the four marks DM surround the defect D in three directions. . On the other hand, in the print pattern shown in FIG. 13C, the first, second, and third print patterns PT1, PT2, and PT3 are printed so that the five marks DM surround the defect D with two adjacent sides. Has been. On the other hand, in the print pattern shown in FIG. 13D, the first, second, and third print patterns PT1, PT2, and PT3 are printed so that the six marks DM surround the periphery of the defect D with three adjacent sides. Has been. On the other hand, in the print pattern shown in FIG. 13E, the first, second, and third print patterns PT1, PT2, and PT3 are printed so that the four marks DM surround the defect D with four sides. . On the other hand, in the print pattern shown in FIG. 13F, the first, second, and third print patterns PT1, PT2, and PT3 are formed so that the six marks DM surround the defect D with two opposite sides. Is printed. On the other hand, in the print pattern shown in FIG. 13G, the first, second, and third print patterns PT1, PT2, PT3 are printed so that the eight marks DM surround the defect D in four directions. .

  The recording device 13 is arranged on the downstream side of the second defect inspection device 12, but can also be arranged on the downstream side of the first defect inspection device 11. In this case, it is possible to record defect information by the recording device 13 after performing the defect inspection by the first defect inspection device 11.

  Further, the recording device 13 is not limited to one that records defect information after the above-described defect inspection. For example, in a long-distance conveyance line, a plurality of recording devices may be arranged, distance information may be recorded at fixed distances, and distance correction may be performed based on the recorded distance information. A recording apparatus that records such distance information may be disposed, for example, on the upstream side of the first defect inspection apparatus 11.

  The recording device 13 is not limited to the configuration including the plurality of print heads 13a in which the plurality of nozzle portions 13b are arranged side by side. For example, when a traverse type print head is used, By moving the print head, it is possible to mark a defective portion regardless of the shape of the film and the transport direction.

  In addition, the defect marking apparatus 10 is not restricted to what constitutes a part of the film manufacturing apparatus 100, and can be a defect marking apparatus independent of the film manufacturing apparatus 100. Specifically, while conveying the double-sided bonding film F105 unwound from the third original fabric roll R3, the double-sided bonding film F105 is inspected for defects, and the double-sided adhesive film is based on the result of the defect inspection. It is possible to adopt a configuration in which after marking the defective portion of F105, the core material is wound again.

  Moreover, in the said film manufacturing apparatus 100, you may mark a defect location in an additional process process, without marking a defect location. Specifically, while conveying the double-sided bonding film F105 unwound from the third original fabric roll R3, after another film is bonded to one or both sides of the double-sided bonding film F105, the defect inspection is performed. In combination with the result of the defect inspection of the film manufacturing apparatus 100, marking may be performed on the defective portion.

  In addition, about the raw material used as the test object (inspection object) of this invention, it is not necessarily limited to optical films, such as the polarizing film mentioned above, retardation film, and a brightness enhancement film, A marking is given to a defect location. It may be a long strip-shaped raw material such as film or paper.

  Further, the inspection object (inspection object) of the present invention may be a sheet (chip) obtained by cutting a long strip-shaped raw material. That is, in the present invention, not only when performing the defect inspection of the original fabric while conveying the above-described original fabric, and marking the defective portion of the original fabric based on the result of the defect inspection, the defect of the sheet after cutting An inspection may be performed, and marking may be performed on a defective portion of the sheet based on the result of the defect inspection. Further, during the inspection of the defect of the sheet and the marking of the defective part of the sheet, the sheet may be subjected to processing (for example, bonding of another film, surface treatment of the sheet, etc.). As a result, as in the case where the object to be inspected is a raw fabric, the defect marking method (apparatus) of the present invention is used to display the position of the defect on the sheet that is the object to be inspected, and the defect is related to the defect. It is possible to record information and the like. Furthermore, the present invention can be widely applied to those to which the present invention can be applied in addition to the above-described original fabric and sheet.

DESCRIPTION OF SYMBOLS 100 ... Film manufacturing apparatus (raw fabric manufacturing apparatus) 101 ... 1st conveyance line 102 ... 2nd conveyance line 103 ... 3rd conveyance line 104 ... 4th conveyance line 105 ... 5th conveyance line 106 ... winding 111a, 111b ... first nip roll 112 ... first accumulator 112a, 112b ... first dancer roll 113 ... first guide roll 121a, 121b ... second nip roll 122 ... second accumulator 122a, 122b ... second dancer rolls 123a, 123b ... second guide rolls 131a, 131b ... third nip rolls 141a, 141b ... fourth nip rolls 142 ... third accumulators 142a, 142b ... third dancer rolls 143a, 143b ... Fourth guide roll 151 , 151b ... fifth nip roll 152 ... fourth accumulator 152a, 152b ... fourth dancer roll 153a ... fifth guide roll 153b ... sixth guide roll 153c ... seventh guide roll 10 ... defect marking device L ... Transport line 11 ... First defect inspection device 12 ... Second defect inspection device 13 ... Recording device (printing device) 13a ... Print head 13b ... Nozzle portion (printing portion) 14 ... First length measuring device 15 ... First 2 length measuring devices 16 ... control device (control unit) 21a, 22a, 23a, 24a, 25a ... illumination unit 21b, 22b, 23b, 24b, 25b ... light detection unit P ... liquid crystal display panel (optical display device) F1X ... Optical film F10X ... Optical film F101 ... First film F102 ... Second film F103 ... Third film F 104 ... Single-sided adhesive film F105 ... Double-sided adhesive film (raw fabric) DM ... Dot-shaped mark LM ... Linear mark PT1 ... First print pattern PT2 ... Second print pattern PT3 ... Third print pattern D ... defect K ... blank

Claims (20)

A defect marking method for marking a defect portion of an inspection object,
The surface of the inspection object is arranged such that a defect is located between the first print pattern and the second print pattern that are adjacent to each other in the other direction intersecting the one direction in the surface of the inspection object. A defect marking method, wherein the defect position is displayed by printing the first print pattern and the second print pattern.   The defect marking method according to claim 1, wherein information on the defect is recorded by one or both of the first print pattern and the second print pattern.   3. The defect marking method according to claim 2, wherein at least one or a plurality of dot-like marks are arranged in the one direction as the one or both of the print patterns.   4. The defect marking method according to claim 2, wherein at least one or a plurality of linear marks are printed side by side in the one direction as the one or both of the print patterns.   5. The defect marking method according to claim 3, wherein information related to the defect is recorded by a print pattern in which any one or more of the number, interval, size, and color of the mark is changed.   The position of the defect in the one direction is displayed by a print pattern in which at least a part of a plurality of marks arranged in the one direction is changed. Defect marking method as described.   The position of the defect in the one direction is displayed by disposing at least a part of a space between the plurality of marks arranged in the one direction at a position adjacent to the defect. Item 7. The defect marking method according to Item 6.   In the other direction, information on the defect is recorded by printing a third print pattern adjacent to one or both of the first print pattern and the second print pattern. The defect marking method according to any one of claims 1 to 7.   The defect marking method according to claim 1, wherein information related to other than the defect is recorded by any one of the print patterns.   The defect marking method according to any one of claims 1 to 9, wherein the printing pattern is printed using an erasable ink.   The defect marking method according to any one of claims 1 to 10, wherein marking is performed on a defect portion of a long strip-shaped original fabric conveyed in the one direction as the inspection object.   The defect marking method according to any one of claims 1 to 10, wherein marking is performed on a defective portion of a sheet obtained by cutting a long strip-shaped raw material as the inspection object. A step of performing a defect inspection on a long strip-shaped raw material conveyed in one direction;
A method for manufacturing an original fabric, comprising the step of marking the defect portion of the original fabric using the defect marking method according to claim 11. A step of performing a defect inspection on a sheet obtained by cutting a long strip-shaped raw fabric,
A method for producing a sheet, comprising: marking a defect portion of the sheet using the defect marking method according to claim 12. Equipped with a printing device that marks the defective part of the inspection object,
The printing device is arranged in a line at a predetermined interval in another direction intersecting one direction in the plane of the inspection object, and a plurality of printing units that print a print pattern on the surface of the inspection object And a control unit that controls driving of the plurality of printing units,
The control unit prints the first print pattern and the second print pattern so that a defect is located between the first print pattern and the second print pattern that are adjacent in the other direction. A defect marking device characterized by performing control for selecting a printing unit.   The control unit selects one of the first print pattern and the second print pattern in accordance with information on the defect to be recorded for one or both of the selected print units. The defect marking device according to claim 15, wherein control is performed to change both print patterns. It is a long strip-shaped raw material with markings on the defective part,
The first printed pattern and the second printed pattern which are printed on the surface by the marking and are adjacent in the short direction, and a defect is located between the first printed pattern and the second printed pattern. The original fabric, wherein the position of the defect is displayed.   The raw material according to claim 17, wherein information on the defect is recorded by one or both of the first print pattern and the second print pattern. It is a sheet with markings on the defective part,
The first printing pattern and the second printing pattern, which are printed on the surface by the marking and have the first printing pattern and the second printing pattern which are adjacent in another direction intersecting with one direction, The sheet is characterized in that the position of the defect is displayed by the defect being located between the sheets.   The sheet according to claim 19, wherein information on the defect is recorded by one or both of the first print pattern and the second print pattern.

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