JP2019120848A - Continuous inspection method of optical display panel, continuous inspection device, continuous manufacturing method of optical display panel and continuous manufacturing system - Google Patents

Abstract

To provide a continuous inspection method of an optical display panel which can detect a fault at accuracy at the same level or higher than the level even if the number of sets of imaging parts is decreased more than before, and its continuous inspection device.SOLUTION: A continuous inspection method of an optical display panel includes: a first radiation process for radiating a first linear beam which is parallel with a width direction of the optical display panel being an orthogonal direction with respect to a transfer direction of the optical display panel to a line inspection region of the optical display panel from a direction which is inclined to an upstream side of the transfer direction at a first angle (θ) from a vertical direction with respect to one face of the optical display panel; a second radiation process for radiating a second linear beam which is parallel with the width direction of the optical display panel to the line inspection region from a direction which is inclined to a downstream side of the transfer direction at a second angle (θ) from the vertical direction with respect to one face of the optical display panel; and an imaging process for linearly and continuously imaging the line inspection region which is irradiated with the first linear beam and the second linear beam in parallel with the width direction of the optical display panel by one imaging part.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a continuous inspection method and a continuous inspection apparatus of an optical display panel, and a continuous manufacturing method and a continuous manufacturing system of an optical display panel.

  In the inspection method of Patent Document 1, linear light parallel to the width direction of the transfer device is irradiated vertically from one surface of the liquid crystal display panel, and the other surface side of the liquid crystal display panel It discloses that an area irradiated with linear light is imaged by two imaging units symmetrically disposed at positions inclined by a predetermined angle in the opposite direction.

JP 2012-194509 A

  The inspection method of Patent Document 1 includes two imaging units for imaging the inspection region from two different angles, and one of the two imaging units does not strongly scatter downstream in the transport direction with respect to the irradiation direction. The foreign matter strongly scattered to the upstream side is detected, and the foreign matter strongly scattered to the downstream side without being strongly scattered to the upstream side is detected on the other side. That is, since there is a defect (foreign matter) that can be detected only by the first imaging unit on the upstream side in the transport direction and a defect (foreign substance) that can be detected only in the second imaging unit on the downstream side in the transport direction I needed to.

However, installation cost increases by arranging a plurality of imaging units. In addition, the time for adjusting the optical axis of the imaging unit also increases in proportion to the number. The capacity of the storage medium required for long-term storage of the captured image data also increases in proportion to the number.
Further, in the inspection method of Patent Document 1, two image data acquired by two imaging units are subjected to image processing respectively, and a defect position and coordinates obtained from each image data are combined to create single defect information. There is a need to.

Therefore, an object of the present invention is to provide a continuous inspection method of an optical display panel and a continuous inspection apparatus thereof that can detect a defect with the same degree of accuracy or more even if the number of imaging units is reduced compared to the prior art. .
Another object of the present invention is a continuous manufacturing system of an optical display panel and an optical display panel capable of continuously producing a high quality optical display panel at high speed by optically inspecting the optical display panel at high speed while conveying the optical display panel at high speed. It is to provide a continuous manufacturing method.

  As a result of intensive studies to solve the above problems, the present invention has been accomplished as follows.

The present invention is a continuous inspection method of an optical display panel, which continuously optically inspects in a state in which an optical display panel provided with an optical film having at least an optical functional film on both sides or one side is conveyed.
Using a first irradiation unit that emits a first linear light parallel to the width direction of the optical display panel, which is a direction (d2) orthogonal to the transport direction (d1) of the optical display panel, The first linear light is applied to the line inspection area of the optical display panel being conveyed from the direction inclined from the perpendicular to the conveyance direction (d1) at the first angle (θ ₁ ) from the perpendicular to the surface An irradiation step,
Using a second irradiation unit that emits a second linear light parallel to the width direction of the optical display panel, which is a direction (d2) orthogonal to the transport direction (d1) of the optical display panel, The line inspection area of the optical display panel being conveyed is irradiated with the second linear light from a direction inclined to the downstream side of the conveyance direction (d1) at a second angle (θ ₂ ) from perpendicular to the surface A second irradiation step,
The line inspection area irradiated with the first linear light and the second linear light is formed into a line parallel to the width direction of the optical display panel from the other surface of the optical display panel in one imaging unit. And an imaging step of continuously imaging.

  In the above invention, in the imaging step, the line inspection area may be imaged from the other surface of the optical display panel via a slit portion in which an imaging area corresponding to the line inspection area is defined.

  In the above invention, the imaging unit may be disposed in a direction perpendicular to the other surface of the optical display panel.

In the above invention, in the first irradiation step and the second irradiation step, the first angle (θ ₁ ) and the second angle (θ ₂ ) have the same value, and the irradiation direction of the first linear light and the above The irradiation direction of the second linear light may be symmetrical.

In the above invention, in the case where the optical display panel provided with the optical film on one side is being optically inspected continuously in the state of conveying, the optical film corresponds to the optical axis of the optical functional film contained in the optical film. A predetermined distance between the first and second irradiation units and the one imaging unit and an inspection filter having an optical axis from the other surface different from one surface of the optical display panel on which the optical film is provided Set up and perform imaging.
The “predetermined distance” needs, for example, a distance that does not touch the surface of the optical display panel, and can be set in consideration of the arrangement relationship of the panel conveyance unit, the illumination unit, and the imaging unit.
When the optical functional film has a polarizing film, the inspection filter has a polarizing film, and the inspection filter is disposed such that the absorption axes of the respective films are orthogonal to each other.
Further, the inspection filter may be fixedly arranged, or may be configured to be movable according to the transport state of the optical display panel.

Another invention is a continuous inspection apparatus of an optical display panel which continuously optically inspects in a state of conveying an optical display panel provided with an optical film having at least an optical functional film on both sides or one side. ,
The first linear light parallel to the width direction of the optical display panel, which is a direction (d2) orthogonal to the transport direction (d1) of the optical display panel, A first irradiation unit that irradiates the line inspection area of the optical display panel being conveyed from the direction inclined to the upstream side in the conveyance direction (d1) by the angle (θ ₁ );
Second linear light parallel to the width direction of the optical display panel, which is a direction (d2) orthogonal to the transport direction (d1) of the optical display panel, A second irradiation unit configured to irradiate the line inspection area of the optical display panel being conveyed from the direction inclined to the downstream side in the conveyance direction (d1) at an angle (θ ₂ );
The line inspection area irradiated with the first linear light and the second linear light is continuously imaged in a line parallel to the width direction of the optical display panel from the other surface of the optical display panel. And an imaging unit.

In the above invention, the optical display panel may further include a slit portion disposed on the other surface side of the optical display panel and defining an imaging region corresponding to the line inspection region.
The imaging unit may capture an image by interposing the slit unit.

  In the present invention, the “one imaging unit” may be a monocular imaging unit or a compound eye imaging unit. A line sensor camera disposed in a line, or a plurality of monocular cameras disposed in a straight line (one row) corresponding to a predetermined linear imaging area (a predetermined area parallel to the film width direction) Good.

  In the above invention, the imaging unit may be disposed in a direction perpendicular to the other surface of the optical display panel.

In the above invention, the first angle (θ ₁ ) and the second angle (θ ₂ ) have the same value, and the irradiation direction of the first linear light and the irradiation direction of the second linear light are symmetrical. As described above, the first irradiation unit and the second irradiation unit may be disposed.

In the above invention, in the case where the optical display panel provided with the optical film on one side is being optically inspected continuously in the state of conveying the optical display panel, the first and second irradiation units and the one imaging unit And a predetermined distance different from the other surface of the optical display panel on which the optical film is provided and a predetermined positional relationship with the optical axis of the optical functional film included in the optical film. It further has an inspection filter provided as described above.
The “predetermined distance” needs, for example, a distance that does not touch the surface of the optical display panel, and can be set in consideration of the arrangement relationship of the panel conveyance unit, the illumination unit, and the imaging unit.
When the optical functional film has a polarizing film, the inspection filter has a polarizing film, and the inspection filter is disposed such that the absorption axes of the respective films are orthogonal to each other.
Further, the inspection filter may be fixedly arranged, or may be configured to be movable according to the transport state of the optical display panel.
When the illumination unit, the optical display panel provided with the optical film on the illumination unit side, and the imaging unit are arranged in order, the inspection filter is disposed between the optical display panel and the imaging unit. When the slit unit is disposed between the optical display panel and the imaging unit, the inspection filter may be disposed between the imaging unit and the slit unit or between the optical display panel and the slit unit.
When the illumination unit, the optical display panel provided with the optical film on the imaging unit side, and the imaging unit are arranged in order, the inspection filter is disposed between the illumination unit and the optical display panel, and the illumination light is for inspection The light passing through the filter is configured to be incident on the inspection area.

According to the present invention, the number of imaging units can be reduced while securing the inspection capability with a simple configuration in which only two illumination processes and one imaging process are performed.
In addition, processing image data obtained from a single imaging unit with a defect that can be detected only by the imaging unit on the upstream side in the transport direction and a defect that can be detected only by the imaging unit on the downstream side in the transport direction It can be determined by It is not necessary to image-process two pieces of image data acquired by two imaging units as in the prior art to create single defect information, and the work and complexity for that can be reduced.

Further, in the present invention, the slit portion disposed on the other surface side of the optical display panel is a distance from the other surface of the optical display panel to the slit portion (D ₂ ) than a distance (D ₂ ) from the imaging portion to the slit portion. It is preferable to arrange the slit portion so that ₁ ) becomes smaller (D ₁ <D ₂ ).
Vicinity of the optical display panel than near the imaging unit (e.g., within 150mm from _{D 1} exceeds the 0 mm, preferably within 100mm, more preferably 30mm or less) it is preferable to arrange the slit portion.
By arranging the slit portion in the vicinity of the optical display panel, when the optical display panel enters or leaves the imaging field of the imaging unit, it is affected by stray light (or reflected light) from the edge portion of the optical display panel. It can prevent that it can not inspect. In addition, it is not preferable to dispose the slit in the vicinity of the imaging unit, because the amount of light received by the imaging unit itself is reduced or regulated.

In the method for continuously producing an optical display panel according to another invention, a first optical film having at least an optical functional film is bonded to a first surface of an optical cell, and a second optical film having at least an optical functional film is an optical cell Manufacturing process for producing an optical display panel by bonding two surfaces;
And a step included in the continuous inspection method of the optical display panel,
The manufacturing process and the process included in the continuous inspection method are performed by a series of transport devices for transporting the optical cell and the optical display panel.

In the continuous production system of optical display panels according to another invention, a first optical film having at least an optical functional film is bonded to a first surface of the optical cell, and a second optical film having at least the optical functional film is at least a second of the optical cell. A manufacturing apparatus for manufacturing an optical display panel by laminating two surfaces;
A continuous inspection device of the optical display panel;
The manufacturing device and the continuous inspection device are arranged in a series of transport devices that transport the optical cell and the optical display panel.

In the manufacturing process and manufacturing apparatus of the above invention,
The above-described optical system conveys a sheet-like first optical film obtained by cutting the first long optical film while feeding the first long mold release film and the first long optical film from the first optical film roll Affixing to the first side of the cell or affixing a sheet-like first optical film to the first side of the optical cell;
And / or a sheet-like second optical film obtained by cutting the second long optical film while feeding out the second long release film and the second long optical film from the second optical film roll, Affixing to the second surface of the optical cell to be conveyed such that the optical axis of one optical film and the optical axis of the second optical film form a predetermined angular arrangement, or a sheet-like second optical film May be attached to the second surface of the optical cell such that the optical axis of the sheet-like first optical film and the optical axis of the sheet-like second optical film have a predetermined angular arrangement.

  According to this configuration, while the optical display panel is being transported, two types of linear light (L1, L2) inclined at a predetermined angle are emitted to the optical display panel, and the transmitted light transmitted through the optical display panel ( Contamination foreign matter mixed between the optical cell and the optical film over the entire surface of the optical display panel while conveying the optical display panel at high speed by continuously imaging the P) in a line shape and continuously by a single imaging unit Can be imaged with clear contrast. That is, since the optical display panel can be inspected with high accuracy while being transported at high speed, a high quality optical display panel can be continuously produced at high speed.

  In this inspection, not only foreign substances (for example, bonded air bubbles, cullet, lint, dust, dust, etc.) mixed between the optical cell and the optical film can be detected with high accuracy.

  The direction of irradiation of the first and second linear light beams by the first and second irradiation units is inclined at a predetermined angle from the vertical with respect to the optical display panel, so that the transportation direction of one of the linear light beams is conveyed. The optical display can be detected simultaneously with a single imaging unit, a foreign substance strongly scattering upstream without strongly scattering on the downstream side of the direction and a foreign substance strongly scattering downstream without strongly scattering upstream, in the single imaging unit. The panel can be inspected more accurately.

Further, from the viewpoint of inspecting the optical display panel with high accuracy, the first angle (θ ₁ ) is 1 ° to 60 °, preferably 5 ° to 45 °, more preferably 10 ° to 30 ° from the vertical. . The second angle (θ ₂ ) is 1 ° to 60 °, preferably 5 ° to 45 °, and more preferably 10 ° to 30 ° from the vertical.

In the present invention, in the “optical film roll”, a long release film and a long optical film (pressure-sensitive adhesive layer, optical functional film and surface protective film) are laminated in this order to form a roll. There is.
"Roll-to-panel method" cuts the pressure-sensitive adhesive layer, the optical function film and the surface protection film in the width direction while leaving the release film from the release film and the long optical film drawn from the optical film roll This method is a method of peeling a long release film from a sheet-like optical film obtained by half-cutting and cutting, and bonding the sheet-like optical film to an optical cell through the exposed pressure-sensitive adhesive layer.

On the other hand, there is a "sheet-to-panel method" as a bonding method of an optical film different from the roll-to-panel method. The “sheet-to-panel method” is a sheet-like optical film previously made into a sheet-like form, exposed through a pressure-sensitive adhesive layer exposed by peeling a sheet-like release film or a long release film. It is a method of bonding to an optical cell.
"Cured optical film roll" refers to a roll in which a sheet-like optical film (pressure-sensitive adhesive layer, optical functional film and surface protective film) is laminated on a long release film and configured in a roll shape. .

The schematic which showed an example of the continuous manufacturing system of the optical display panel. Schematic which showed an example of the order which laminates | stacks an optical film on an optical cell. Schematic which showed the aspect which test | inspects a foreign material. Schematic which showed an example of the inspection apparatus. The flowchart which showed an example of the processing flow of the inspection apparatus. Schematic which showed an example of the mode of conveyance of the optical display panel from test | inspection standby to completion | finish of test | inspection. The schematic which showed an example of the inspection apparatus of another embodiment. The schematic which showed an example of the inspection apparatus of another embodiment.

  Hereinafter, the continuous manufacturing system and the continuous manufacturing method of the optical display panel will be more specifically described with reference to FIG. 1, but the present invention is not limited to the aspect of the present embodiment.

(Embodiment 1)
The optical display panel is described as a liquid crystal display panel, the optical cell as a liquid crystal cell, and the optical film as a polarizing film.

  The continuous manufacturing system of the liquid crystal display panel has a continuous manufacturing apparatus 100. The continuous production apparatus 100 is a first sheet obtained by cutting and processing the first elongated polarizing film 11 while feeding out the first elongated release film 12 and the first elongated polarizing film 11 from the first optical film roll R1. The leaf-like polarizing film 111 is attached to the first surface 4 a of the liquid crystal cell 4. In addition, the continuous manufacturing apparatus 100 is obtained by cutting and processing the second elongated polarizing film 21 while respectively feeding out the second elongated release film 22 and the second elongated polarizing film 21 from the second optical film roll R2. The second sheet-like polarizing film 211 is attached to the second surface 4 b of the liquid crystal cell 4 so that the absorption axis of the first sheet-like polarizing film 111 and the absorption axis of the second sheet-like polarizing film 211 are orthogonal to each other. The liquid crystal display panel Y is manufactured.

  The continuous liquid crystal display panel manufacturing system includes a continuous inspection apparatus 300 that optically inspects the liquid crystal display panel Y while conveying it. In the continuous manufacturing system of the liquid crystal display panel, the continuous manufacturing apparatus 100 and the continuous inspection apparatus 300 are arranged in a series of transport devices 400 that transport the liquid crystal cell 4 and the liquid crystal display panel Y.

(Optical film roll)
As an optical film roll formed by winding a long polarizing film, for example, in the form of a continuous web having (1) a releasing film and a long polarizing film including a pressure-sensitive adhesive layer formed on the releasing film. What rolled the elongate optical film laminated body in roll shape is mentioned. In this case, in order to form a sheet-like polarizing film (sheet piece) from the long polarizing film, the continuous production system of the liquid crystal display panel leaves the release film and includes the long polarizing film (including the pressure-sensitive adhesive layer). It has a cutting device which cuts (half cuts) (makes a cutting line) in a direction orthogonal to the feed direction of the release film at a predetermined interval.
In addition, as an optical film roll, for example, (2) a sheet-like polarizing film (adhesive layer) adjacent to each other via a cutting line in the direction orthogonal to the release film on the release film and the release film (A so-called slitted polarizing film roll) wound in a roll shape.

The first optical film roll R1 shown in FIG. 1 has an absorption parallel to the feeding direction (longitudinal direction) formed on the first long release film 12 and the first long release film 12 via the adhesive layer. The first elongated optical film laminate 10 having a first elongated polarizing film (including the adhesive layer thereof) 11 having an axis is wound in a roll.
The second optical film roll R2 has an absorption axis parallel to the feeding direction (longitudinal direction) formed on the second long release film 22 and the second long release film 22 via the adhesive layer. The second long optical film laminate 20 having the two long polarizing films (including the adhesive layer thereof) 21 is wound in a roll.

The first and second long polarizing films 11 and 21 are, for example, a polarizer (about 5 to 80 μm in thickness) and a polarizer protective film (about 1 to 500 μm in thickness generally) on one side or both sides of the polarizer. Degree) is formed without adhesives or adhesives.
As other films constituting the first and second long polarizing films 11 and 21, for example, retardation films (generally 10 to 200 μm in thickness), viewing angle compensation films, brightness enhancement films, surface protection films, etc. It can be mentioned. The thickness of the first and second long polarizing films 11 and 21 may be, for example, in the range of 10 μm to 500 μm.

  The pressure-sensitive adhesive constituting the pressure-sensitive adhesive layer of the first and second long polarizing films 11 and 21 is not particularly limited, and examples thereof include acrylic pressure-sensitive adhesives, silicone-based pressure-sensitive adhesives, and urethane-based pressure-sensitive adhesives. The thickness of the pressure-sensitive adhesive layer is preferably, for example, in the range of 10 to 50 μm. For the first and second release films 12, 22, for example, conventionally known films such as plastic films (for example, polyethylene terephthalate films, polyolefin films and the like) can be used. If necessary, suitable ones according to the prior art may be used, such as those coated with an appropriate release agent such as silicones, long chain alkyls, fluorines and molybdenum sulfide.

(Liquid crystal display panel)
The liquid crystal display panel Y has at least a polarizing film formed on one side or both sides of the liquid crystal cell 4, and a drive circuit is incorporated as necessary. The liquid crystal cell 4 may be of any type such as vertical alignment (VA) type or in-plane switching (IPS) type. The liquid crystal cell 4 has a configuration in which a liquid crystal layer is sealed between a pair of substrates (a first substrate 4a and a second substrate 4b) which are disposed to face each other.

(Continuous manufacturing equipment)
The continuous manufacturing apparatus 100 includes a first release film transfer device 101, a first attaching unit 102, a second release film transfer device 103, and a second attachment unit 104.

The first release film conveyance device 101 performs the first attachment while drawing out the first long release film 12 and the first long polarizing film 11 (the first long optical film laminate 10) from the first optical film roll R1. Transport to the section 102.
In the present embodiment, the first release film conveyance device 101 includes a first cutting unit 31, a first dancer roll 32, a first peeling unit 41, and a first winding unit 61.

The first cutting unit 31 fixes the first long optical film laminate 10 from the first release film 12 side with the first suction unit 31 a, and leaves the first long release film for the first length. The sheet-like polarizing film (including the pressure-sensitive adhesive layer) 11 is cut in the width direction, and the first sheet-like polarizing film 111 is formed on the first long release film 12.
As the 1st cutting part 31, a cutter, a laser apparatus, etc. are mentioned, for example. The first adsorbing portion 31 a may be, for example, an adsorbing plate which has a large number of holes connected to a vacuum pump and can suction air from the holes under negative pressure.

  The first dancer roll 32 has a function of holding the tension of the first long release film 12.

The first peeling section 41 folds the first long mold release film 12 inside at the front end thereof and peels the first sheet-like polarizing film 111 from the first long mold release film 12. The peeled first sheet-like polarizing film 111 is supplied to the first attaching unit 102.
In this embodiment, although the sharp knife edge part is used for the front-end | tip part as the 1st peeling part 41, it is not limited to this.

  The first winding unit 61 winds up the first long release film 12 from which the first sheet-like polarizing film 111 is peeled off. The first winding unit 61 may be configured by an automatic rotation roller.

The first attaching section 102 is a first sheet-like polarized light in which the first elongated release film 12 is peeled off by the first peeling section 41 from the upper side (first surface 4 a) of the liquid crystal cell 4 transported by the transport device 400. The film 111 is attached via the adhesive layer.
In the present embodiment, the first sticking section 102 is configured of a first sticking roller 51a and a first drive roller 51b.

As various devices for attaching the second sheet-like polarizing film 211 to the other surface (second surface 4 b) of the liquid crystal cell 4, the various components, devices, and the like described above can be used.
The second release film transport device 103 performs second sticking while drawing out the second long release film 22 and the second long polarizing film 21 (second long optical film laminate 20) from the second optical film roll R2. Transport to the unit 104.
In the present embodiment, the second release film transport device 103 includes a second cutting unit 33, a second dancer roll 34, a second peeling unit 42, and a second winding unit 62.
The second release film transfer device 103 can be configured by the same device as the first release film transfer device 101, and the second attachment unit 104 can be configured by the same device as the first attachment unit 102.
For example, the 2nd cutting part 33 and the 2nd adsorption part 33a can be constituted by the same device as the 1st cutting part 31 and the 2nd adsorption part 31a. The second dancer roll 34 can be configured by the same device as the first dancer roll 32. The second winding unit 62 can be configured by an apparatus similar to the first winding unit 61. The second sticking roller 52a and the second driving roller 52b can be configured by the same mechanism as the first sticking roller 51a and the first driving roller 51b.

(Irradiator)
The continuous inspection apparatus 300 is a liquid crystal display panel in which the first linear light L1 parallel to the width direction d2 of the liquid crystal display panel Y (vertical direction in FIG. 1) which is orthogonal to the transport direction d1 of the liquid crystal display panel Y is A line inspection area E (FIG. 3) of the liquid crystal display panel Y being transported from a direction inclined from the perpendicular to the transport direction at a first angle .theta. ₁ from the perpendicular to one surface of Y (the first surface 4a in FIG. And the first irradiation unit 311 for irradiating the light.

In addition, the continuous inspection apparatus 300 is configured to display the second linear light L2 parallel to the width direction of the liquid crystal display panel Y, which is the orthogonal direction d2 to the transport direction d1 of the liquid crystal display panel Y, from a direction inclined on the downstream side in the transport direction at a second angle theta ₂ from the vertical to the first surface 4a) in 1, a second irradiation unit 312 for irradiating the line inspection area E of the liquid crystal display panel Y being transported Have.

In the present embodiment, the first angle theta ₁ and the second angle theta ₂ are the same value is set to 17 °. Further, in the present embodiment, the first irradiation unit 311 and the second irradiation unit 312 are arranged such that the irradiation direction of the first linear light L1 and the irradiation direction of the second linear light L2 are symmetrical. The first angle θ1 and the second angle θ2 are not limited to 17 °, and may be 5 ° to 30 °, preferably 10 ° to 30 °.

  No particular limitation is imposed on the first and second irradiation units 311 and 312 as long as the first and second linear light beams L1 and L2 having straightness are irradiated. For example, a halogen lamp, a metal halide lamp, an LED line illumination, etc. Can be mentioned. The first and second linear lights L1 and L2 are light extending in a line in the width direction d2 of the carrier device 400, and the lateral directions of the first and second linear lights L1 and L2 (carrier device 400 The width of the liquid crystal display panel Y is shorter than the length in the conveyance direction of the liquid crystal display panel Y). In addition, the first and second irradiation units 311 and 312 may include a lens unit for reducing the width in the short direction of the first and second linear light beams L1 and L2. As a lens part, the round-bar-shaped lens formed along the longitudinal direction of 1st, 2nd linear light L1 and L2 is mentioned, for example. By narrowing and condensing the width of the first and second linear lights L1 and L2 in the width direction, high-intensity light can be irradiated to the liquid crystal display panel surface, and the data processing capacity is suppressed by the image data of a small area. This is preferable in that the operation processing time can be shortened (speed can be increased) and high inspection accuracy can be obtained. The distance between the first and second irradiation units 311 and 312 and the transport device 400 is appropriately adjusted according to the type, size, transport speed, and the like of the liquid crystal display panel Y.

(Imaging unit)
The continuous inspection apparatus 300 measures the line inspection area E irradiated with the first linear light L1 and the second linear light L2 from the other surface of the liquid crystal display panel Y (the second surface 4b in FIG. 1) to the liquid crystal display panel Y. The imaging unit 316 continuously captures an image in a line parallel to the width direction (direction d2 orthogonal to the transport direction d1). One imaging unit 316 is, for example, an optical camera such as one or more CCD cameras arranged in a line, a CMOS sensor camera, or a line sensor camera. One imaging unit 316 is configured to image one line-shaped area corresponding to one line-shaped line inspection area E irradiated with two line-shaped lights, and in the present embodiment, four CCD cameras Are arranged in a straight line.
In the present embodiment, one imaging unit 316 is disposed in a direction perpendicular to the other surface (second surface 4 b) of the liquid crystal display panel Y.
Further, as another embodiment, one imaging unit 316 may be disposed to be inclined at a third angle from the vertical axis with respect to the other surface (second surface 4 b) of the liquid crystal display panel Y. The third angle is, for example, more than 0 ° and not more than 30 ° from the vertical axis.

The continuous inspection apparatus 300 has a slit portion 314 which is disposed on the other surface (second surface 4b) side of the liquid crystal display panel Y and in which an imaging region 314a corresponding to the line inspection region E is defined. The arrangement of each of the first and second irradiation units 311 and 312, the imaging unit 316, and the slit unit 314 is fixed with respect to the transport device 400, and the imaging unit 316 transmits light that passes through the imaging region 314a of the slit unit 314. Light P (transmitted light image) is imaged.
The slit portion 314 is formed such that the distance D1 from the other surface (second surface 2b) of the liquid crystal display panel Y to the slit portion 314 is smaller than the distance D2 from the imaging unit 316 to the slit portion 314 (D ₁ <D ₂ ). Is placed.
In the present embodiment, the slit portion 314 is disposed in the vicinity of the liquid crystal display panel Y (for example, D1 is within ₁₀ mm to 50 mm).

  Further, as another embodiment, the first and second light irradiators 311 and 312 are disposed on the upper side of the transport device 400 according to the state of the liquid crystal display panel Y at the time of inspection, and one imaging unit 316 and slit unit 314 It is also possible to arrange the lower side of the transfer device 400.

  In the present embodiment, when there is a foreign matter between the liquid crystal cell 4 and the first sheet-like polarizing film 111 or the second sheet-like polarizing film 211, as shown in FIG. The light scattered by the foreign matter, which has passed through the imaging region 314a with the interposition of 314, can be selectively imaged. Therefore, one imaging unit 316 can image a foreign object with a clear contrast.

(Transporting device)
The conveying device 400 is a series of conveying devices for conveying the liquid crystal display panel Y in which the first and second sheet-like polarizing films 111 and 211 are attached to both surfaces of the liquid crystal cell 4 and the liquid crystal cell 4. The conveyance device 400 includes, for example, a conveyance roller 70, a suction plate, and the like. In this embodiment, the transport device 400 includes a pivoting mechanism for horizontally rotating the liquid crystal cell 4 to which the first sheet-like polarizing film 111 is attached by 90 °, and a liquid crystal cell to which the first sheet-like polarizing film 111 is attached. A reversing mechanism is provided to flip 4 up and down. In addition, the transport device 400 transports the liquid crystal display panel Y during the inspection by the inspection device 300.

(Inspection flow)
In the present embodiment, based on image data acquired using the imaging unit 316, it is determined whether the liquid crystal display panel Y is a non-defective product or a defective product. To that end, as shown in FIG. 4, the inspection apparatus 300 includes an image processing unit 317, a memory 302, an image counting process / image assembling unit 303, and a good / defect judgment unit 301. This will be described with reference to FIGS.

First, the control unit (not shown) controls the transport device 400 to temporarily stop the liquid crystal display panel Y at the inspection standby position (see FIG. 6A).
Next, the control unit controls the transport device 400 and the inspection device 300 to start transport of the liquid crystal display panel Y (step S1), and starts inspection by the inspection device 300 (step S2).

In this inspection, from the start of the inspection to the end of the inspection, the control unit controls the conveyance device 400 to continue conveying the liquid crystal display panel Y in the conveyance direction d1. Also, during this time, the control unit controls the inspection apparatus 300 so that the first and second irradiation units 311 and 312 irradiate the liquid crystal display panel Y with the first and second linear lights L1 and L2, and the imaging unit 316 The first and second linear lights L1 and L2 of the liquid crystal display panel Y are irradiated, and the transmitted light P that has passed through the imaging region 314a of the slit portion 314 is imaged in a line.
The linear imaging data acquired by the imaging unit 316 is subjected to image processing by the image processing unit 317, and the linear image data subjected to the image processing is stored in the memory 302 (steps S3 and S4; inspection in FIG. 6B). Indicates the state in the middle). In this process, as shown in FIG. 5, the control unit (not shown) controls the transfer device 400 to sequentially transfer the liquid crystal display panel Y to the inspection end position (see FIG. 6C). It will be.

  Next, the image aggregation processing / image assembly unit 303 reads out the line-like image data subjected to the image processing by the image processing unit 317 from the memory 302, performs image aggregation processing, and creates overall image data of the liquid crystal display panel Y Step 5). Next, the entire image data is stored in the memory 302 (step 6).

Next, the good / bad determination unit 301 reads the entire image data from the memory 302, and determines whether the liquid crystal display panel Y is good or defective based on the entire image data (step S7). Here, when the good / defect judgment unit 301 judges the liquid crystal display panel Y to be a good product, the judgment result of the good product is stored in the memory 302 in a form associated with identification information of the liquid crystal display panel Y and the like. (Step S9). The liquid crystal display panel Y is transported by the transport device 400 to the non-defective port.
On the other hand, if the good / defect judgment unit 301 judges the liquid crystal display panel Y to be a defect in step S7, the memory determined in the form of a defective product is associated with identification information of the liquid crystal display panel Y and the like. It is stored in 302 (step S10). The liquid crystal display panel Y is transported by the transport device 400 to the defective product port.

The control unit (not shown) may have a processor and a memory, a program indicating a control procedure may be stored in the memory, and the processor may execute the program, or may be a dedicated circuit or a firmware configuration.
The image processing unit, the image aggregation processing / image assembly unit, and the good / defect judgment unit may have a processor and a memory, a program indicating a processing procedure may be stored in the memory, and the processor may execute the program. Alternatively, it may be configured to be executed by firmware.

(Continuous inspection method of liquid crystal display panel)
In the continuous inspection method of a liquid crystal display panel, an optical film having at least an optical functional film (for example, a polarizing film) is optically inspected continuously in a state in which a liquid crystal display panel provided on both sides or one side is being transported. The said continuous inspection apparatus can be used suitably for the continuous inspection method of a liquid crystal display panel.
The continuous inspection method of a liquid crystal display panel uses a first irradiation unit that emits a first linear light parallel to the width direction of the liquid crystal display panel, which is a direction orthogonal to the transport direction of the liquid crystal display panel. First line-shaped light is applied to the line inspection area of the optical display panel being conveyed from the direction inclined to the upstream side in the conveyance direction at a first angle (θ ₁ ) from the perpendicular to one surface of the first An irradiation process,
A second irradiation unit that emits a second linear light parallel to the width direction of the liquid crystal display panel, which is a direction orthogonal to the transport direction of the liquid crystal display panel, uses a second irradiation unit from the perpendicular to one surface of the liquid crystal display panel A second irradiation step of irradiating the line inspection area of the liquid crystal display panel being conveyed from the direction inclined to the conveyance direction downstream side by two angles (θ ₂ ), the second linear light;
The line inspection area irradiated with the first linear light and the second linear light is continuously formed in a line parallel to the width direction of the optical display panel from the other surface of the liquid crystal display panel in one imaging unit. And an imaging step of imaging.

In the imaging step, the line inspection area may be imaged from the other surface of the liquid crystal display panel via a slit portion in which an imaging area corresponding to the line inspection area is defined.
The imaging unit may be disposed perpendicularly to the other surface of the liquid crystal display panel.
In the first irradiation step and the second irradiation step, the first angle (θ ₁ ) and the second angle (θ ₂ ) have the same value, and the irradiation direction of the first linear light and the irradiation direction of the second linear light are It may be symmetrical.

(Continuous production method of liquid crystal display panel)
In a method for continuously producing a liquid crystal display panel, a first optical film having at least an optical functional film (for example, a polarizing film) is bonded to a first surface of an optical cell, and a second optical having at least an optical functional film (for example, a polarizing film) A manufacturing process for manufacturing a liquid crystal display panel by bonding a film to the second surface of the optical cell, and a process included in the continuous inspection method for the liquid crystal display panel, and a process included in the manufacturing process and the above-mentioned continuous inspection method Is carried out by a series of transport devices for transporting the liquid crystal cell and the liquid crystal display panel.

(Another embodiment)
In the present embodiment, the first sheet-like polarizing film 111 is attached from the upper side of the liquid crystal cell 4, and then the liquid crystal cell 4 to which the first sheet-like polarizing film 111 is attached is reversed (reverse side, 90 if necessary The second sheet-like polarizing film 211 is attached from the upper side of the liquid crystal cell 4 by rotating the liquid crystal cell 4. However, the first sheet-like polarizing film may be attached from the lower side of the liquid crystal cell 4, the liquid crystal cell 4 may be inverted, and the second sheet-like polarizing film may be attached from the lower side of the liquid crystal cell The first sheet-like polarizing film may be attached from the upper side, and the second sheet-like polarizing film may be attached from the lower side of the liquid crystal cell without inverting the liquid crystal cell. And the second sheet-like polarizing film may be attached from the upper side of the liquid crystal cell without inverting the liquid crystal cell. Alternatively, the first sheet-like polarizing film and the second sheet-like polarizing film may be simultaneously attached from the upper side and the lower side of the liquid crystal cell.

Moreover, although the structure which affixes an optical film on both surfaces of an optical cell was illustrated in this embodiment, an optical film may be affixed on the single side | surface of an optical cell, and the continuous test of this invention may be performed after that. 7A and 7B illustrate a configuration in which a polarizing film is attached to one side of a liquid crystal cell and then inspected.
In FIG. 7A, the illumination units 311 and 312, the inspection filter 321, the liquid crystal display panel Y in which the polarizing film 111 is provided on the imaging unit side, the slit unit 314, and the imaging unit 316 are arranged in this order. The inspection filter 321 may be fixed or may be configured to be movable only at the time of inspection.
In FIG. 7B, the illumination units 311 and 312, the liquid crystal display panel Y in which the polarizing film 111 is provided on the illumination unit side, the slit unit 314, the inspection filter 322, and the imaging unit 316 are arranged in this order. The inspection filter 322 may be fixed or may be configured to be movable only at the time of inspection. The inspection filter may be disposed between the liquid crystal display panel Y and the slit portion 314.
The inspection apparatus of FIG. 7A may be disposed downstream of the first attaching unit 102 to perform an inspection. The inspection apparatus of FIG. 7B may be disposed downstream of the 90 ° turning up / down reversing means to perform the inspection.
In FIGS. 7A and 7B, the illumination unit may be disposed above the conveyance device 400, and the imaging unit may be disposed below the conveyance device 400.

  Further, in the present embodiment, the configuration in which the optical film is attached to both sides of the optical cell by the so-called "roll-to-panel method" is exemplified, but the invention is not limited thereto. Optical cells may be attached to both sides of the optical cell, and optical films may be attached to one side of the optical cell by the "roll-to-panel method" and the other side by the "sheet-to-panel method".

  Moreover, in this embodiment, although the optical film roll was used, the structure of a roll-shaped optical film is not limited to this, You may use what is called a "cut optical film roll."

  Moreover, in this embodiment, although the elongate polarizing film drawn | fed out from the optical film roll was cut | disconnected by predetermined spacing, this invention in particular is not restrict | limited to this structure. For example, the long polarizing film drawn from the optical film roll may be subjected to a defect inspection, and cut (so-called skip cut) so as to avoid the defect based on the inspection result. In addition, the defect information or the mark attached to the defect position previously attached to the long polarizing film may be read, and cut so as to avoid the defect based on the defect information or the mark.

  Moreover, in this embodiment, although the elongate polarizing film has an absorption axis parallel to a longitudinal direction, the absorption axis direction of an elongate polarizing film is not limited to this. For example, the first elongated polarizing film may have an absorption axis parallel to its short direction (width direction), and the second elongated polarizing film may have an absorption axis parallel to its longitudinal direction. In this case, the turning mechanism for horizontally rotating the liquid crystal cell to which the first polarizing film is attached can be omitted as appropriate.

Further, in the present embodiment, a liquid crystal cell is illustrated as an optical cell, but the present invention is not limited to this, and the optical cell may be an organic EL cell.
The organic EL cell has a configuration in which an electroluminescent layer is sandwiched between a pair of electrodes. The organic EL cell may be of any type such as top emission type, bottom emission type, double emission type, or the like. The organic EL display panel is obtained by laminating a polarizing film on one side or both sides of an organic EL cell, and a drive circuit is incorporated as needed.

(Example)
The example used the apparatus which concerns on Embodiment 1 (FIGS. 3-6). In the comparative example, an inspection apparatus was used in which the light irradiation unit was disposed in the direction perpendicular to one surface of the liquid crystal display panel, and the imaging unit was disposed in the direction perpendicular to the other surface. As a reference example, an apparatus (FIGS. 4 to 6) according to Japanese Patent Application No. 2011-60335 (Japanese Patent Application Laid-Open No. 2012-194509) was used.
In the embodiment, the light emitting unit is disposed so that the first angle θ1 and the second angle θ2 have the same value of 17 °, and the imaging unit is disposed in the direction perpendicular to the liquid crystal display panel. The slit portion was disposed at a position of 20 mm (distance D1) from the other surface (second surface 2b) of the liquid crystal display panel Y.
In the reference example, the light irradiation unit is disposed in the vertical direction with respect to the liquid crystal display panel, and the imaging unit is disposed at an inclination of 30 ° with respect to the irradiation direction of the linear light.
The inspection was carried out while conveying 200 sheets (n = 200) of liquid crystal display panels whose defects are known in advance. The number of missed liquid crystal display panels was 0 for both the example and the reference example, but was 15 for the comparative example. From this, it has been confirmed that even if the number of imaging units is reduced compared to the prior art, defects can be detected with the same or higher accuracy.

311 first irradiation unit 312 second irradiation unit 314 slit unit 316 one imaging unit

Claims (14)

A continuous inspection method of an optical display panel, which continuously optically inspects in a state where an optical film having at least an optical functional film is provided on both sides or one side of the optical display panel.
Using a first irradiation unit that emits a first linear light parallel to the width direction of the optical display panel, which is a direction perpendicular to the transport direction of the optical display panel, from perpendicular to one surface of the optical display panel A first irradiation step of irradiating the line inspection area of the optical display panel being conveyed from the direction inclined to the upstream side in the conveyance direction at the first angle (θ ₁ );
Using a second irradiation unit that emits a second linear light parallel to the width direction of the optical display panel, which is orthogonal to the transport direction of the optical display panel, from perpendicular to one surface of the optical display panel A second irradiation step of irradiating the line inspection area of the optical display panel being conveyed from the direction inclined to the conveyance direction downstream side by the second angle (θ ₂ );
The line inspection area irradiated with the first linear light and the second linear light is formed into a line parallel to the width direction of the optical display panel from the other surface of the optical display panel in one imaging unit. And an imaging step of imaging continuously;
Continuous inspection method of optical display panel including.   The optical display according to claim 1, wherein the imaging step images the line inspection area from the other surface of the optical display panel via a slit portion in which an imaging area corresponding to the line inspection area is defined. Method of continuous inspection of panels.   The method according to claim 1, wherein the imaging unit is disposed in a direction perpendicular to the other surface of the optical display panel. In the first irradiation step and the second irradiation step, the first angle (θ ₁ ) and the second angle (θ ₂ ) have the same value, and the irradiation direction of the first linear light and the second linear shape The continuous inspection method of the optical display panel according to any one of claims 1 to 3, wherein the irradiation direction of light is symmetrical.   The optical film has an optical axis corresponding to the optical axis of the optical functional film included in the optical film when optically inspecting continuously in a state where the optical display panel provided on one side is being conveyed The inspection filter is disposed between the first and second irradiation units and the one imaging unit at a predetermined distance from the other surface different from one surface of the optical display panel on which the optical film is provided. The continuous inspection method of the optical display panel according to any one of claims 1 to 4, wherein imaging is performed. A continuous inspection apparatus for an optical display panel which continuously optically inspects in a state where an optical film having at least an optical functional film is provided on both sides or one side of the optical display panel.
A first linear light parallel to the width direction of the optical display panel, which is a direction perpendicular to the transport direction of the optical display panel, at a first angle (θ ₁ ) from perpendicular to one surface of the optical display panel A first irradiation unit configured to irradiate the line inspection area of the optical display panel being conveyed from the direction inclined to the upstream side in the conveyance direction;
The second linear light parallel to the width direction of the optical display panel, which is a direction perpendicular to the transport direction of the optical display panel, is perpendicular to one surface of the optical display panel at a second angle (θ ₂ ) A second irradiation unit configured to irradiate the line inspection area of the optical display panel being conveyed from the direction inclined to the downstream side in the conveyance direction;
The line inspection area irradiated with the first linear light and the second linear light is continuously imaged in a line parallel to the width direction of the optical display panel from the other surface of the optical display panel. The first imaging unit,
Continuous inspection apparatus for an optical display panel. The optical display panel further includes a slit portion disposed on the other surface side of the optical display panel and defining an imaging area corresponding to the line inspection area.
The continuous inspection apparatus for an optical display panel according to claim 6, wherein the imaging unit performs imaging with the slit unit interposed.   The continuous inspection apparatus of the optical display panel according to claim 6, wherein the imaging unit is disposed in a direction perpendicular to the other surface of the optical display panel. The first angle (θ ₁ ) and the second angle (θ ₂ ) have the same value, and the irradiation direction of the first linear light and the irradiation direction of the second linear light are symmetrical. The continuous inspection apparatus of the optical display panel of any one of Claims 6-8 by which one irradiation part and said 2nd irradiation part are arrange | positioned.   In the case where the optical display panel provided with the optical film on one side is being optically inspected in a continuous state, it is between the first and second irradiation units and the one imaging unit. And a predetermined distance different from the other surface of the optical display panel on which the optical film is provided and a predetermined distance from the optical axis of the optical functional film included in the optical film. The continuous inspection apparatus for an optical display panel according to any one of claims 6 to 9, further comprising an inspection filter. Manufacturing an optical display panel by bonding a first optical film having at least an optical functional film to a first surface of an optical cell, and bonding a second optical film having at least an optical functional film to a second surface of the optical cell Process,
A step included in the method of continuously inspecting an optical display panel according to any one of claims 1 to 5;
A continuous manufacturing method of an optical display panel, wherein the manufacturing process and the process included in the continuous inspection method are performed by a series of conveying devices which convey the optical cell and the optical display panel. The manufacturing process is
A sheet-like first optical film obtained by cutting the first long optical film while leaving the long first release film while feeding the first long optical film from the first optical film roll is conveyed Sticking to the first surface of the optical cell, or sticking a sheet-like first optical film to the first surface of the optical cell,
And / or a sheet-like second optical film obtained by cutting the second long optical film while leaving the second long release film while feeding the second long optical film from the second optical film roll, The sheet is pasted on the second surface of the optical cell to be conveyed such that the optical axis of the first optical film and the optical axis of the second optical film form a predetermined angular arrangement, or a sheet-like second The optical display according to claim 11, wherein an optical film is attached to the second surface of the optical cell such that an optical axis of the first optical film and an optical axis of the second optical film form a predetermined angular arrangement. Method of continuous production of panels. Manufacturing an optical display panel by bonding a first optical film having at least an optical functional film to a first surface of an optical cell, and bonding a second optical film having at least an optical functional film to a second surface of the optical cell A device,
A continuous inspection apparatus for an optical display panel according to any one of claims 6 to 10.
A continuous manufacturing system of an optical display panel, wherein the manufacturing apparatus and the continuous inspection apparatus are arranged in a series of conveying apparatuses which convey the optical cell and the optical display panel. The manufacturing apparatus is
A sheet-like first optical film obtained by cutting the first long optical film while leaving the long first release film while feeding the first long optical film from the first optical film roll is conveyed Sticking to the first surface of the optical cell, or sticking a sheet-like first optical film to the first surface of the optical cell,
And / or a sheet-like second optical film obtained by cutting the second long optical film while leaving the second long release film while feeding the second long optical film from the second optical film roll, The sheet is pasted on the second surface of the optical cell to be conveyed such that the optical axis of the first optical film and the optical axis of the second optical film form a predetermined angular arrangement, or a sheet-like second The optical display according to claim 13, wherein an optical film is attached to the second surface of the optical cell such that an optical axis of the first optical film and an optical axis of the second optical film form a predetermined angular arrangement. Continuous production system of panels.

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