JP4498462B2 - Method for manufacturing roll stock - Google Patents

Description

  The present invention relates to a method of manufacturing a roll material for cutting to a predetermined length and bonding the surface to the surface of an optical display unit.

  Conventionally, the manufacturing method of a liquid crystal display device is an optical film manufacturer that manufactures a roll of optical film, then cuts it according to the size of the optical display unit to be bonded, appearance inspection, end face processing, etc. After packaging and transporting to a panel processing manufacturer, the panel processing manufacturer inspects the appearance and then bonds it to a cleaned optical display unit (for example, a liquid crystal panel).

  In such a manufacturing process, in particular, end face processing, packaging of single-sheet sheet products, packing disassembly, etc. are necessary because the optical film manufacturer and the panel processing manufacturer exist in different places. ing. However, there is a problem of increased manufacturing costs due to multiple processes, problems such as scratches, dust, and dirt caused by multiple processes and transportation, the necessity of inspection processes associated therewith, and other types of single sheet products There is a problem that it must be stored and managed.

  As a method for solving this problem, the present applicant has proposed a manufacturing method described in Japanese Patent Application Laid-Open No. 2007-140046 (Patent Document 1). The method includes: a supply unit that draws and supplies a belt-like sheet product from a roll around which a belt-like product having an optical film that is a member of an optical display device is wound; and a belt-like sheet product that is drawn by the supply unit. The detection means for detecting the defect, the cutting means for cutting the strip-like sheet-like product based on the detection result of the detection means, and processing into individual sheet-like products, and the sheet-like product cut by the cutting means are pasted. A transfer means for transferring to perform the laminating process; and a laminating process means for laminating the sheet-like product transferred by the transfer means and the optical display unit which is a member of the optical display device. It is arranged on the production line process. The strip-shaped sheet product having the optical film can be directly cut into a desired size, and the cut sheet-shaped product can be bonded to the optical display unit. Therefore, in the past, the belt-like sheet-like product was punched out, the punched sheet-like product was strictly packed, and the product delivered to the panel processing manufacturer was directly packed with the belt-like sheet-like product wrapped around the roll. It is also possible to deliver.

Japanese Patent Laid-Open No. 2007-140046

  However, the manufacturing system of the optical display device disclosed in Patent Document 1 discloses an optical display unit that is separately provided with an apparatus for attaching an optical film to one side of the optical display unit and then attaching the optical film to the other side. Absent. Moreover, when bonding an optical film on both surfaces of an optical display unit, what kind of thing is each used about the direction and width of an optical film is not considered.

  The polarizing plates to be bonded to the upper and lower sides of the optical display unit have different absorption axis directions at the upper and lower sides (vertically intersecting). Therefore, when the upper and lower layers are bonded using the same apparatus, polarized light is polarized by one roll and the other roll. It was necessary to change the direction of the absorption axis of the plate by 90 °. However, when manufacturing a roll material having an absorption axis in the roll width direction, it is generally difficult to accurately control the direction of the absorption axis, and optical characteristics such as optical leakage occur in the optical display device after bonding. There was a problem that became insufficient.

  Therefore, an object of the present invention is to use two rolls that have good axial accuracy for bonding and cut them to a predetermined length and bond them to the optical display unit so that their absorption axes are orthogonal to each other. An object of the present invention is to provide a roll original fabric set that can be manufactured, a method for manufacturing a roll original fabric suitable for manufacturing the same, and a method for manufacturing an optical display device using the roll original fabric set.

The above object can be achieved by the present invention as described below.
That is, the method for producing a roll raw material according to the present invention is a method in which a long sheet-shaped product in which an optical film including a polarizing plate, an adhesive layer, and a release film are laminated in this order is wound from a roll raw material. A method of manufacturing a roll material for attaching an optical film to the surface of a rectangular optical display unit while pulling out a sheet-like product and supplying it after being cut into a predetermined length, the absorption axis of the polarizing plate A slit process for cutting a long original fabric having a longitudinal direction parallel to the longitudinal direction with a width corresponding to the short side or the long side of the optical display unit in parallel to the longitudinal direction, and a long sheet shape obtained by the slit process And a winding step of winding the product into a roll.

  Another method for producing a roll material according to the present invention is a method in which an optical film including a polarizing plate, a pressure-sensitive adhesive layer, and a release film are laminated in this order from a roll material roll wound up with a long sheet product. To draw the long sheet product and paste the optical film on the surface of the rectangular optical display unit while feeding after cutting the optical film and adhesive layer to a predetermined length without cutting the release film A method for producing a roll original fabric, wherein a long original fabric having a longitudinal direction parallel to the absorption axis of the polarizing plate is a width corresponding to the short side or the long side of the optical display unit in parallel to the longitudinal direction. And a winding step of winding the long sheet product obtained in the slit step into a roll.

  In the above, it is preferable that the optical display unit used for bonding is a VA mode or IPS mode liquid crystal panel.

  In the above, in the slit process, it is preferable to cut at a plurality of locations in the width direction with a width corresponding to the short side or the long side of the optical display unit in parallel with the longitudinal direction.

The flowchart which shows the process by the manufacturing system used for this invention The figure for demonstrating an example of the manufacturing system used for this invention The figure for demonstrating an example of the manufacturing system used for this invention The figure for demonstrating the apparatus structure of an example of the manufacturing system used for this invention The figure for demonstrating the apparatus structure of an example of the manufacturing system used for this invention The figure for demonstrating the apparatus structure of an example of the manufacturing system used for this invention The figure for demonstrating the apparatus structure of an example of the manufacturing system used for this invention The figure for demonstrating an example of the laminated structure of a 1st, 2nd optical film The schematic front view which shows an example of the manufacturing apparatus used for the manufacturing method of the roll original fabric of this invention The direction of the absorption axis of the VA mode or IPS mode liquid crystal panel and the polarizing plate bonded to both sides thereof is shown.

  Hereinafter, embodiments of the present invention will be described in detail.

(Roll roll)
As shown in FIG. 3, the roll original fabric set of the present invention is a roll original fabric set for cutting each into a predetermined length and bonding them to both sides of the optical display unit. It consists of a second roll R2.

  In the first roll R1, the long sheet-like product in which the first optical film F11 including the polarizing plate, the adhesive layer, and the release film are laminated in this order is parallel to the absorption axis of the polarizing plate. It is wound in a state in which it is slit with a width corresponding to the short side. The long sheet-like product may be wound alone, but is preferably wound around a core material such as a core tube.

  The second roll R2 includes a long sheet-like product in which a second optical film F21 including a polarizing plate, an adhesive layer, and a release film are laminated in this order, and the optical display unit is parallel to the absorption axis of the polarizing plate. It is wound in a state in which it is slit with a width corresponding to the long side. The long sheet-like product may be wound alone, but is preferably wound around a core material such as a core tube.

  In the present invention, “corresponding to the long side or short side of the optical display unit” means the length of the optical film bonded to the long side or short side of the optical display unit (excluding the exposed portion). The length of the long side or the short side of the optical display unit and the width of the optical film do not have to be the same.

  In the present invention, both the first roll R1 and the second roll R2 are slit-processed in parallel with the absorption axis of the polarizing plate constituting the first roll R1 and have the absorption axis in the longitudinal direction of the roll. For this reason, the axial accuracy by bonding is improved, and the optical characteristics of the optical display device after bonding are improved. In particular, when an optical display unit is formed with a VA mode or IPS mode liquid crystal panel used in recent years for large TVs, the absorption axes of the polarizing plates of the first optical film and the second optical film may be orthogonal to each other. Therefore, it is only necessary to feed out the first and second rolls slitted in parallel with the absorption axis and cut them in the width direction, and the production speed can be increased.

  Specifically, the influence of the axial accuracy at the time of bonding on the optical characteristics can be evaluated by the following transmitted light intensity and contrast ratio (CR). That is, from the first roll slitted parallel to the absorption axis of the polarizing plate (Nitto Denko Corporation CAT1463DU) and the second roll slitted at an angle with respect to the absorption axis of the polarizing plate, respectively, the slit direction A square (50 mm × 50 mm) sample was taken out so as to have one parallel side, and the transmittance when two samples were laminated using a spectrophotometer U-4100 manufactured by Hitachi High-Tech was measured. The results are shown in Table 1.

  As shown in the results of Table 1, in the comparative example in which the angle between the absorption axes is shifted from 90 ° as compared with Example 1 in which the angle between the absorption axes is 90 °, the light is only shifted slightly from 90 °. It can be seen that the leakage (transmitted light intensity) becomes significant and the contrast ratio (CR) is greatly reduced.

(Long sheet product)
The optical film constituting the long sheet-shaped product may be one that includes a polarizing plate, and a polarizing plate, or an optical film in which a retardation film, a brightness enhancement film, and a combination of two or more of these films are laminated on the polarizing plate. A film etc. are illustrated. The polarizing plate should just have a polarizer, and may have a polarizer protective film (transparent protective film) on the single side | surface or both surfaces.

  A protective transparent film may be laminated on the surface of these optical films. Further, an adhesive layer is formed on one surface of the optical film so as to be attached to, for example, an optical display unit, and a release film for protecting the adhesive layer is provided. Moreover, a surface protective film is provided on the other surface of the optical film, for example, via an adhesive layer.

  Specifically, each optical film has a structure as shown in FIG. For example, the laminated structure of the first sheet product F1 includes a first optical film F11, a first release film F12, and a surface protection film F13. The first optical film F11 includes a first polarizer F11a, a first film F11b having an adhesive layer (not shown) on one side thereof, and a second film having an adhesive layer (not shown) on the other side. F11c.

  The first and second films F11b and F11c are, for example, polarizer protective films (for example, triacetyl cellulose film, PET film, etc.). The second film F11c is bonded to the optical display unit surface side via the first adhesive F14. A surface treatment can be applied to the first film F11b. Examples of the surface treatment include a hard coat treatment, an antireflection treatment, a treatment for the purpose of prevention of sticking, diffusion or antiglare, and the like. The first release film F12 is provided via the second film F11c and the first pressure-sensitive adhesive layer F14. Moreover, the surface protection film F13 is provided through the 1st film F11b and the adhesive layer F15. Specific configurations of the first and second films F11b and F11c will be described later. Hereinafter, a laminated structure of a polarizer and a polarizer protective film may be referred to as a polarizing plate.

  The laminated structure of the second sheet product F2 is the same as that of the first sheet product, but is not limited to this. The second sheet product F2 includes a second optical film F21, a second release film F22, and a surface protection film F23. The second optical film F21 includes a second polarizer F21a, a third film F21b having an adhesive layer (not shown) on one side thereof, and a fourth film having an adhesive layer (not shown) on the other side. F21c.

  The third and fourth films F21b and F21c are, for example, polarizer protective films (for example, triacetylcellulose film, PET film, etc.). The fourth film F21c is bonded to the optical display unit surface side via the second pressure-sensitive adhesive layer F24. The third film F21b can be subjected to a surface treatment. Examples of the surface treatment include a hard coat treatment, an antireflection treatment, a treatment for the purpose of prevention of sticking, diffusion or antiglare, and the like. The second release film F22 is provided via the fourth film F21c and the second pressure-sensitive adhesive layer F24. Moreover, the surface protection film F23 is provided through the 3rd film F21b and the adhesive layer F25.

  In addition, it is also possible to use the raw material to which defect information was previously attached as a roll original material, and in that case, an in-line inspection process can be made unnecessary. For example, it is possible to perform cutting while avoiding the defects by marking defect information on the original fabric in advance, reading it and reflecting it in the cutting process.

(Production method of roll stock)
The widths of the first roll R1 and the second roll R2 depend on the bonding size of the optical display unit. Specifically, the width of the first roll R1 is determined corresponding to the short side of the optical display unit, and the width of the second roll R2 is determined corresponding to the long side. For this reason, generally, the first roll R1 and the second roll R2 have different widths, and those that have been slit in advance to a predetermined width by slit processing from the roll raw material before slit (long original material). used.

  There are a method of performing slit processing while rewinding a roll raw material before slit, and a method of performing without rewinding, and both can be adopted. Moreover, in this invention, you may perform a slit process before the winding in the production line of a long sheet-like product.

  Therefore, it is preferable to employ the production method of the present invention as a method of producing the roll raw material of the present invention. The method for producing a roll material according to the present invention is a method for producing a material roll that is cut into a predetermined length and bonded to the surface of an optical display unit, and includes an optical film including a polarizing plate and an adhesive layer. A release film is laminated in this order, and a long original fabric having a longitudinal direction parallel to the absorption axis of the polarizing plate corresponds to a short side or a long side of the optical display unit in parallel to the longitudinal direction. The slit process cut | disconnects by the width | variety to perform, and the winding process which winds the elongate sheet-like product obtained at the slit process in roll shape.

  FIG. 9 shows an example of a roll raw fabric production apparatus that can be used in the production method of the present invention. This manufacturing apparatus includes a rewinding mechanism 40 for the roll R0 of the long original fabric 55, a cutting mechanism 50 for the long original fabric 55, and a winding device 60 for the roll original fabrics R1 and R2. In the production line for long sheet-shaped products, the rewinding mechanism 40 is unnecessary when performing the slitting process.

  The rewinding mechanism 40 rewinds the long original fabric 55 from the roll R0 due to the tension generated by the nip roller 57, and includes a nip roller 57 and a roll support portion that rotates and supports the roll R0. The roll support portion may be provided with a braking mechanism, a drive mechanism, a tension control mechanism, and the like.

  The cutting mechanism 50 includes a cutting table 54 provided on the back side of the long original fabric 55 and a laser device 51 provided above the long original fabric 55. The irradiation position of the laser is fixed, and the cutting proceeds by continuous conveyance of the long original fabric 55. Instead of the laser device 51, it is also possible to use a cutting device provided with a cutting blade or the like. In that case, for example, a rotatable circular cutting blade is arranged at a predetermined interval in the direction of the slit, and the slit is continuously formed while passing the long original fabric 55 between the cutting blade and the support roll. Is possible.

  The cutting mechanisms 50 are provided at a plurality of locations in the width direction of the long original fabric 55 (only one is shown in the figure), and can be moved and fixed in the width direction of the long original fabric 55 so that the slit width can be changed. . For example, by providing the cutting mechanism 50 at three locations and setting the two intervals at each irradiation position to a width corresponding to the short side and the long side of the optical display unit, The roll stock R1 and the roll stock R2 can be manufactured simultaneously.

  The winding device 60 is a device for winding the slit rolls R1, R2. One or a plurality of winding devices 60 are provided in accordance with the number of rolls after the slit, and it is preferable to further provide a winding device for winding the end material in the same manner. In the illustrated example, a winding device for winding the end material around the roll R3 is provided.

  The winding device 60 includes, for example, winding portions 61 and 62 for the rolls R1 and R2, and has a rotation drive mechanism that can control the tension. Moreover, the winding parts 61 and 62 have the function to fix roll original fabric R1, R2 or its core material. In the winding device 60, for example, while the speed is controlled by the nip roller 57 provided in front of the winding parts 61 and 62, the long sheet-like product 56 after slitting is wound at a constant speed by the winding parts 61 and 62. can do.

(Optical display unit)
Examples of the optical display unit used in the present invention include a glass substrate unit of a liquid crystal cell and an organic EL light emitting unit. The present invention is effective for an optical display unit having a rectangular outer shape, and for example, one having a long side / short side of 16/9 or 4/3 is used. In addition, as an optical display unit, members, such as an optical film, may be previously laminated and integrated.

(Manufacturing flowchart)
FIG. 1 shows an example of a flowchart of a method for manufacturing an optical display device. FIG. 2 shows a configuration diagram of an example of an optical display device manufacturing system. FIG. 3 shows a plan layout view of an example of a manufacturing system for an optical display device.

  The method for manufacturing an optical display device of the present invention is a method for manufacturing an optical display device in which an optical film including a polarizing plate is bonded to an optical display unit. Although the manufacturing method of this invention includes a 1st cutting bonding process and a 2nd cutting bonding process, any process may be performed previously and both processes may be performed simultaneously or substantially simultaneously.

  In the first cutting and bonding step, the first optical film is bonded to one surface of the optical display unit after being cut into a length corresponding to the long side of the optical display unit using the first roll described above. It is.

  In the second cutting and bonding step, the second optical film is bonded to the other surface of the optical display unit after cutting to a length corresponding to the short side of the optical display unit using the second roll described above. It is.

  More specifically, in the method for manufacturing an optical display device of the present invention, for example, the strip-shaped product is drawn from a roll around which the strip-shaped product having the first optical film is wound, and cut into a predetermined length. While supplying later, the 1st cutting and pasting process which pastes the 1st optical film on the one surface of the above-mentioned optical display unit, and the strip-like sheet-like product from the roll by which the strip-like sheet-like product which has the 2nd optical film was wound up A second cutting and pasting step of pasting the second optical film to the other surface of the optical display unit while being pulled out and supplied after being cut into a predetermined length.

  A 1st cutting bonding process is implemented by the (2) conveyance process- (5) 1st optical film bonding process described below, for example, and the 2nd cutting bonding process is described below (8) conveyance, for example. Process-(11) Implemented by the second optical film bonding process.

  (1) 1st roll original fabric preparation process (FIG. 1, S1). As described above, a long first sheet product is prepared as a first roll.

  Each of the following steps is preferably performed in an isolated structure isolated in a factory, and the cleanliness is preferably maintained. In particular, it is preferable that the cleanliness is maintained in the bonding step of bonding the optical film to the optical display unit.

  (2) Transport process (FIG. 1, S2). The first sheet material F1 is fed out from the first roll stock prepared and installed, and is conveyed downstream. The first conveying device 12 that conveys the first sheet product F1 is configured by, for example, a nip roller pair, a tension roller, a rotation driving device, an accumulating device A, a sensor device, a control device, and the like.

  (3) First inspection step (FIG. 1, S3). The first sheet product F1 is inspected for defects using the first defect inspection device 14. The defect inspection method here includes a method of photographing and processing images with transmitted light and reflected light on both sides of the first sheet product F1, and an inspection polarizing film between the CCD camera and the inspection object. A method of taking an image and processing an image by arranging it so as to be crossed Nicols with the polarization axis of the target polarizing plate (sometimes referred to as 0 degree cross), and a polarizing film for inspection between the CCD camera and the inspection object In addition, it is arranged (sometimes referred to as x degree cross) so as to be at a predetermined angle (for example, a range of greater than 0 degree and within 10 degrees) with the polarization axis of the polarizing plate to be inspected, and image photographing / image processing is performed. A method is mentioned. Note that a known method can be applied to the image processing algorithm. For example, a defect can be detected by density determination by binarization processing.

  In the image capturing / image processing method using transmitted light, foreign matter inside the first sheet product F1 can be detected. In the image photographing / image processing method using the reflected light, the adhered foreign matter on the surface of the first sheet product F1 can be detected. In the image photographing / image processing method using the 0-degree cross, mainly surface foreign matter, dirt, internal foreign matter, etc. can be detected as bright spots. In the image photographing / image processing method using the x-degree cross, a nick can be mainly detected.

  The defect information obtained by the first defect inspection apparatus 14 is linked together with the position information (for example, position coordinates), transmitted to the control apparatus 1, and contributes to a cutting method by the first cutting apparatus 16 described later. be able to.

  (4) 1st cutting process (FIG. 1, S4). The first cutting device 16 cuts the surface protective film F13, the pressure-sensitive adhesive layer F15, the first optical film F11, and the first pressure-sensitive adhesive layer F14 into a predetermined size without cutting the first release film F12. As a result, the first release film F12 can be used as a transport medium for the first optical film F11. That is, in this invention, the 1st optical film F11 and the 2nd optical film are used for the 1st cutting bonding process and the 2nd cutting bonding process by using the release film formed in the optical film through the adhesive layer as a conveyance medium. It is preferable to transport and supply each F21.

  Regarding the cutting length, since the width of the first roll is corresponding to the short side, the optical film is cut with a length corresponding to the long side. In the present embodiment, as shown in FIG. 3, an example is shown in which the width of the first roll original (first sheet product F1) corresponds to the short side of the optical display unit W.

  Examples of the cutting means include a laser device, a cutter, and other known cutting means. Based on the defect information obtained by the first defect inspection apparatus 14, it is configured to cut while avoiding the defect so that the defect is not included in the region bonded to the optical display unit W. Thereby, the yield of the first sheet product F1 is greatly improved. As described above, the method of cutting while avoiding the defects so as not to include the defects in the region bonded to the optical display unit W is called a skip cut. However, the defect information at the time of cutting is an inline defect inspection apparatus. Even what was obtained or what was attached | subjected to the roll original fabric beforehand may be sufficient. The first sheet product F1 including the defect is excluded by a first rejection device 19 described later, and is configured not to be attached to the optical display unit W. That is, in this invention, when supplying the 1st optical film F11 and the 2nd optical film F21, it is preferable to include the fault part elimination process of cut | disconnecting the part which has a fault of an optical film.

  (5) 1st optical film bonding process (FIG. 1, S5). While removing the 1st mold release film F12 using the 1st peeling apparatus 17, the 1st adhesive film is used as the 1st optical film F11 by which the said 1st mold release film F12 was removed using the 1st bonding apparatus 18. Affixed to the optical display unit W via F14. At the time of bonding, as will be described later, the first optical film F11 and the optical display unit W are sandwiched between a pair of rolls (181, 182) and bonded.

  (6-1) Cleaning step (FIG. 1, S6-1). The surface of the optical display unit W is cleaned by, for example, a polishing cleaning device and a water cleaning device. The cleaned optical display unit W is transported to the inspection apparatus by the transport mechanism. The transport mechanism includes, for example, a transport roller, a transport direction switching mechanism, a rotation drive device, a sensor device, and a control device.

  (6-2) Inspection process (FIG. 1, S6-2). The surface of the cleaned optical display unit W is inspected by, for example, an inspection apparatus. The optical display unit W after inspection is conveyed to the 1st bonding apparatus 18 by the conveyance mechanism.

  It is preferable that each of these 1st roll original fabric preparation processes, a 1st inspection process, a 1st cutting process, a 1st optical film bonding process, a washing | cleaning process, and an inspection process is performed by the continuous manufacturing line. In the above series of manufacturing steps, the first optical film F11 was bonded to one surface of the optical display unit W. Below, the manufacturing process which bonds the 2nd optical film F21 on another surface is demonstrated.

  (7) 2nd roll original fabric preparation process (FIG. 1, S11). As described above, the long second sheet product F2 is prepared as a second roll raw material.

  (8) Transporting process (FIG. 1, S12). The second sheet material F2 is fed out from the prepared and installed second roll, and is conveyed downstream. The second conveying device 22 that conveys the second sheet product includes, for example, a nip roller pair, a tension roller, a rotation driving device, an accumulating device A, a sensor device, a control device, and the like.

  (9) Second inspection step (FIG. 1, S13). The second sheet material F2 is inspected for defects using the second defect inspection device 24. The defect inspection method here is the same as the method using the first defect inspection apparatus described above.

  (10) Second cutting step (FIG. 1, S14). The second cutting device 26 cuts the surface protective film F23, the pressure-sensitive adhesive layer F25, the second optical film F21, and the second pressure-sensitive adhesive layer F24 into a predetermined size without cutting the second release film F22. Specifically, since the width of the second roll original fabric corresponds to the long side of the optical display unit, the optical film is cut to a length corresponding to the short side. In the present embodiment, as shown in FIG. 3, an example is shown in which the width of the second roll original (second sheet product F2) corresponds to the long side of the optical display unit W.

  Examples of the cutting means include a laser device, a cutter, and other known cutting means. Based on the defect information obtained by the second defect inspection apparatus 24, the defect is not cut in the region bonded to the optical display unit W, and is cut while avoiding the defect. Thereby, the yield of the second sheet product F2 is greatly improved. The second sheet product F2 including the defect is excluded by a second rejection device 29 described later, and is not attached to the optical display unit W.

  (11) 2nd optical film bonding process (FIG. 1, S15). Next, after the second cutting step, the second optical film from which the second release film F22 has been removed using the second laminating apparatus 28 while removing the second release film F22 using the second peeling apparatus 27. The film F21 is bonded to a surface different from the surface to which the first optical film F11 of the optical display unit W is bonded via the second pressure-sensitive adhesive layer F24. Before the second optical film F21 is bonded to the optical display unit W, the optical display unit W is rotated 90 degrees by the transport direction switching mechanism of the transport mechanism R, and the first optical film F11 and the second optical film F21 are crossed. There may be a Nicole relationship.

  That is, in the present invention, in the turning step of turning the optical display unit W after being bonded in the first cutting and bonding step in the bonding direction in the second cutting and bonding step, or in the second cutting and bonding step. It is preferable to include a turning step of turning the optical display unit W after bonding in the bonding direction in the first cutting and bonding step. In the present invention, the direction of the long side of the first optical film F11 bonded to the optical display unit W after turning and the direction of the long side of the second optical film F21 bonded after cutting are 0 ± 5 °, It is preferable to perform the turning step at an angle that is preferably 0 ± 1 °. For example, when the line direction of the supplied first optical film F11 and the line direction of the supplied second optical film F21 are parallel (including a straight line), the turning angle in the turning step is 85 to 95 °. Is preferred. At the time of bonding, as will be described later, the second optical film F21 and the optical display unit W are sandwiched between rolls and are bonded.

  (12) Inspection step of optical display device (FIG. 1, S16). The inspection device inspects an optical display device having an optical film attached to both sides. Examples of the inspection method include a method of taking an image and processing an image using reflected light on both sides of the optical display device. As another method, a method of installing a polarizing film for inspection between the CCD camera and the inspection object is also exemplified. Note that a known method can be applied to the image processing algorithm. For example, a defect can be detected by density determination by binarization processing.

  (13) Non-defective product determination of the optical display device is made based on the defect information obtained by the inspection device. The optical display device determined to be non-defective is conveyed to the next mounting process. If a defective product is determined, a rework process is performed, a new optical film is applied, and then inspected.If a good product is determined, the process proceeds to a mounting process. Discarded.

  In the above series of manufacturing steps, the optical display device can be preferably manufactured by executing the bonding step of the first optical film F11 and the second optical film F21 bonding step in a continuous production line. In particular, by carrying out the above steps inside an isolation structure isolated from the factory, the optical film can be bonded to the optical display unit in an environment in which cleanliness is ensured, and a high-quality optical display device is manufactured. Can do.

(Another embodiment of skip cut)
Further, another embodiment of the first cutting step and the second cutting step will be described below. This embodiment is particularly effective when the first inspection process and the second inspection process are not provided. At one end in the width direction of the first and second rolls, defect information (defect coordinates, defect type, size, etc.) of the first and second sheet-like products in a predetermined pitch unit (for example, 1000 mm). It may be attached as code information (for example, QR code, barcode). In such a case, before the cutting, the code information is read and analyzed, and cut into a predetermined size in the first and second cutting steps so as to avoid the defective portion. Further, a part including defects is excluded or configured to be bonded to a member that is not an optical display unit, and a non-defective sheet-shaped product cut to a predetermined size is configured to be bonded to the optical display unit. . Thereby, the yield of an optical film is improved significantly.

(Overall configuration of manufacturing system)
Next, the overall configuration of the manufacturing system used in the present invention will be described. The manufacturing system used in the present invention is an optical display device manufacturing system in which an optical film having optical anisotropy is bonded to an optical display unit. Preferably, an optical film including a polarizing plate is bonded to the optical display unit. It is a manufacturing system of an optical display device. The manufacturing system used for this invention is equipped with the 1st cutting bonding apparatus which performs a 1st cutting bonding process, and the 2nd cutting bonding apparatus which performs a 2nd cutting bonding process.

  In this embodiment, as shown in FIG. 3, the supply apparatus M1 of the optical display unit W, the supply apparatus M2 of the first optical film F11, the first bonding apparatus M3 for bonding the first optical film F11, and the bonding The example provided with the conveyance supply apparatus M4 which conveys and supplies the optical display unit W after matching, the supply apparatus M5 of the 2nd optical film F21, and the 2nd bonding apparatus M6 which bonds the 2nd optical film F21. Indicates. In this example, the first cutting and bonding apparatus includes a supply device M2 for the first optical film F11 and a first bonding apparatus M3 for bonding the first optical film F11. 2 The supply apparatus M5 of the optical film F21 and the 2nd bonding apparatus M6 which bonds the 2nd optical film F21 are included.

  In this embodiment, as shown in FIG. 3, the supply device M2 of the first optical film F11, the first bonding device M3, the transport supply device M4, the supply device M5 of the second optical film F21, and the second While the bonding apparatus M6 is arranged in a straight line, the supply apparatus M1 is arranged so that the optical display unit W is supplied from a direction perpendicular to the panel flow direction of the first bonding apparatus M3. An example is shown.

(Configuration of each part of the manufacturing system)
Below, an example of a structure of each part of the manufacturing system used for this invention is demonstrated. FIG. 4 is a diagram illustrating the first transport device 12, the first pre-inspection peeling device 13, the first defect inspection device 14, the first release film sticking device 15, and the first cutting device 16.

  FIG. 5 is a diagram illustrating the first peeling device 17, the first sticking device 18, and the first exclusion device 19. FIG. 6 is a diagram illustrating the second transport device 22, the second pre-inspection peeling device 23, the second defect inspection device 24, the second release film sticking device 25, and the second cutting device 26. FIG. 7 is a view showing the second peeling device 27, the second sticking device 28, and the second exclusion device 29.

  The manufacturing system used in the present invention includes an optical display unit supply device M1 for supplying an optical display unit W. In the present embodiment, an example in which the optical display unit supply device M1 includes a polishing cleaning device, a water cleaning device, and a drying device is shown. In the present invention, it is also possible to configure the optical display unit supply device M1 only by the transport mechanism R.

  The manufacturing system used in the present invention is a first optical film that is supplied after the belt-like sheet-shaped product F1 is drawn from a roll around which the belt-shaped sheet-like product having the first optical film F11 is wound, cut into a predetermined length. A supply device M2 is provided. In the present embodiment, the first optical film supply device M2, as shown in FIG. 4, is a first transport device 12, a first pre-inspection peeling device 13, a first defect inspection device 14, and a first release film bonding. The example provided with the apparatus 15 and the 1st cutting device 16 is shown. In the present invention, by providing the first pre-inspection peeling device 13, the first defect inspection device 14, and the first release film laminating device 15, the first optical film can be inspected with high precision. It can be omitted.

  In the present invention, the first optical film supply device M2 cuts an optical film having a width corresponding to the short side to a length corresponding to the long side, corresponding to the long side and the short side of the optical display unit. Or an optical film having a width corresponding to the long side is cut by a length corresponding to the short side. In the present embodiment, an example is shown in which the first optical film supply device M2 is configured to cut an optical film having a width corresponding to the short side of the optical display unit with a length corresponding to the long side.

  The first roll of the long first sheet product F1 is installed on a roller gantry that is linked to a motor or the like so as to rotate freely or at a constant rotational speed. The rotation speed is set by the control device 1 and the drive is controlled.

  The first conveying device 12 is a conveying mechanism that conveys the first sheet product F1 to the downstream side. The first transport device 12 is controlled by the control device 1.

  The first pre-inspection peeling device 13 has a configuration in which the release film H11 is peeled from the conveyed first sheet product F1 and wound on a roll 132. The winding speed around the roll 132 is controlled by the control device 1. The peeling mechanism 131 has a knife edge portion with a sharp tip. The release film H11 is wound around the knife edge portion and reversely transferred, whereby the release film H11 is peeled off and the release film H11 is removed. It is comprised so that the 1st sheet material F1 after peeling may be conveyed in a conveyance direction.

  The first defect inspection device 14 performs defect inspection after the release film H11 is peeled off. The first defect inspection device 14 detects the defect by analyzing the image data captured by the CCD camera, and further calculates its position coordinates. The position coordinates of this defect are provided for the skip cut by the first cutting device 16 described later.

  The 1st release film bonding apparatus 15 bonds the release film H12 to the 1st optical film F11 via the 1st adhesive layer F14 after a 1st fault test | inspection. As shown in FIG. 4, the release film H12 is unwound from the roll 151 of the release film H12, and the release film H12 and the first optical film F11 are sandwiched by one or a plurality of roller pairs 152. At 152, a predetermined pressure is applied to bond together. The rotation speed, pressure control, and conveyance control of the roller pair 152 are controlled by the control device 1.

  The first cutting device 16 does not cut the release film H12 after laminating the release film H12, but the first optical film F11, the surface protective film 15, the first pressure-sensitive adhesive layer F14, and the pressure-sensitive adhesive layer F15. Is cut into a predetermined size. The first cutting device 16 is, for example, a laser device. Based on the position coordinates of the defect detected in the first defect inspection process, the first cutting device 16 cuts to a predetermined size so as to avoid the defect portion. That is, the cut product including the defective portion is rejected as a defective product by the first rejecting device 19 in a subsequent process. Alternatively, the first cutting device 16 may continuously cut into a predetermined size while ignoring the existence of the defect. In this case, it can be configured such that the portion is removed without being bonded in the bonding process described later. Control in this case also depends on the function of the control device 1.

  In the manufacturing system used in the present invention, the first optical film F11 supplied from the first optical film supply device M2 is bonded to one surface of the optical display unit W supplied from the optical display unit supply device M1. A bonding device 18 (M3) is provided. In this embodiment, the 1st bonding apparatus 18 (M3) is further provided with the 1st peeling apparatus 17 and the 1st exclusion apparatus 19 while being comprised by the pressing roller 181 and the guide roller 182 as shown in FIG. An example is shown. The first exclusion device 19 and the first cutting device 16 constitute a defect elimination mechanism that cuts and eliminates a defect portion of the optical film. However, such an exclusion mechanism may be omitted. .

  The 1st bonding apparatus 18 is 1st sheet product F1 (1st optical film F11) from which the release film H12 was peeled by the 1st peeling apparatus 17 after the said cutting process via the 1st adhesive layer F14. Affixed to the optical display unit W. The conveyance path of the first sheet product F1 is above the conveyance path of the optical display unit W.

  As shown in FIG. 5, when bonding, the first optical film F <b> 11 is bonded to the surface of the optical display unit W while being pressed by the pressing roller 181 and the guide roller 182. The control device 1 controls the pressing pressure and driving operation of the pressing roller 181 and the guide roller 182.

  The peeling mechanism 171 of the first peeling device 17 has a knife edge portion having a sharp tip, and the release film H12 is wrapped around the knife edge portion and reversely transferred to peel the release film H12. The first sheet product F1 (first optical film F11) after the release film H12 is peeled off is sent out to the optical display unit W surface. The peeled release film H12 is wound around a roll 172. The winding control of the roll 172 is controlled by the control device 1.

  That is, the supply device M2 for the first optical film in the present invention supplies the first optical film F11 to the first bonding device M3 using the release film formed on the optical film via the adhesive layer as the transport medium. It has a transport mechanism.

  The laminating mechanism is composed of a pressing roller 181 and a guide roller 182 disposed opposite thereto. The guide roller 182 is composed of a rubber roller that is rotationally driven by a motor, and is arranged so as to be movable up and down. In addition, a pressing roller 181 made of a metal roller that is rotationally driven by a motor is disposed directly above it. When the optical display unit W is fed to the bonding position, the pressing roller 181 is raised to a position higher than the upper surface so as to open a roller interval. Note that both the guide roller 182 and the pressing roller 181 may be rubber rollers or metal rollers. As described above, the optical display unit W is cleaned by various cleaning devices and is transported by the transport mechanism R. The transport control of the transport mechanism R is also controlled by the control device 1.

  The first rejection apparatus 19 that excludes the first sheet product F1 including the defect will be described. When the first sheet material F1 including the defect is conveyed to the bonding position, the guide roller 182 moves vertically downward. Next, the roller 192 around which the removal film 191 is stretched moves to a fixed position of the guide roller 182. By moving the pressing roller 181 vertically downward, the first sheet product F1 including the defect is pressed against the removal film 191, and the first sheet product F1 is attached to the removal film 191 and includes the defect together with the removal film 191. The first sheet product F1 is wound around the roller 193. Although the film 191 for removal can stick the 1st sheet product F1 containing a fault using the adhesive force of the 1st adhesive layer F14 of the 1st sheet product F1, an adhesive tape is used as the film 191 for removal. Can also be used.

  The optical display unit W manufactured as described above is transported downstream, and the second optical film F21 (second sheet product F2) is bonded thereto. In the following, the description of the same device configuration will be briefly described.

  Although the manufacturing system used for this invention is equipped with the conveyance supply apparatus M4 which conveys and supplies the optical display unit W after bonding of the 1st optical film F11, this conveyance supply apparatus M4 is the 1st bonding apparatus 18. It is preferable to have a turning mechanism 20 that turns the optical display unit W after bonding in the bonding direction in the second bonding apparatus 28.

  For example, when the second optical film F21 is bonded to the first optical film F11 in a 90 ° relationship (cross Nicole relationship), the optical display unit W is moved by the transport direction switching mechanism (the turning mechanism 20) of the transport mechanism R. The second optical film F21 is bonded after being rotated by 90 °. In the method of laminating the second sheet product F2 described below, each step is processed in a state where the second sheet product F2 is inverted (with the release film on the upper surface), and the second optical film F21 is processed. Are bonded together from the lower side of the optical display unit W.

  The manufacturing system used in the present invention is a second optical film that is supplied after the belt-like sheet-like product F2 is drawn from a roll around which the belt-like sheet-like product having the second optical film F21 is wound and cut into a predetermined length. A supply device M5 is provided. In the present embodiment, the second optical film supply device M5 is, as shown in FIG. 6, a second transport device 22, a second pre-inspection peeling device 23, a second defect inspection device 24, and a second release film bonding. The example provided with the apparatus 25 and the 2nd cutting device 26 is shown. In the present invention, the second optical film can be inspected with high accuracy by including the second pre-inspection peeling device 23, the second defect inspection device 24, and the second release film laminating device 25. It can be omitted.

  In the present invention, the second optical film supply device M5 cuts an optical film having a width corresponding to the short side to a length corresponding to the long side, corresponding to the long side and the short side of the optical display unit W. The optical film having a width corresponding to the long side is cut by a length corresponding to the short side. In this embodiment, the 2nd optical film supply apparatus M5 shows the example comprised so that the optical film F21 of the width | variety corresponding to the long side of the optical display unit W may be cut | disconnected by the length corresponding to a short side. .

  As shown in FIG. 6, the second roll of the long second sheet product F2 is installed on a roller gantry that is linked to a motor or the like so as to rotate freely or at a constant rotational speed. The rotation speed is set by the control device 1 and the drive is controlled.

  The second conveying device 22 is a conveying mechanism that conveys the second sheet product F2 to the downstream side. The second transport device 22 is controlled by the control device 1.

  The second pre-inspection peeling device 23 is configured to peel the release film H <b> 21 from the conveyed second sheet product F <b> 2 and wind it on a roll 232. The winding speed around the roll 232 is controlled by the control device 1. The peeling mechanism 231 has a knife edge portion with a sharp tip. The release film H21 is wrapped around the knife edge portion and transferred in reverse, thereby peeling the release film H21 and removing the release film H21. It is comprised so that the 2nd sheet material F2 after peeling may be conveyed in a conveyance direction.

  The second defect inspection device 24 performs defect inspection after the release film H21 is peeled off. The second defect inspection device 24 analyzes the image data picked up by the CCD camera, detects the defect, and calculates its position coordinates. The position coordinates of this defect are provided for the skip cut by the second cutting device 26 described later.

  The manufacturing system used for this invention is the 2nd bonding apparatus which bonds the 2nd optical film F21 supplied from the supply apparatus M5 of the 2nd optical film on the other surface of the optical display unit W supplied from the conveyance supply apparatus M4. 28 (M6). In the present embodiment, as shown in FIG. 7, the second bonding device 28 (M6) includes a pressing roller 281 and a guide roller 282, and further includes a second peeling device 27 and a second excluding device 29. An example is shown. The second exclusion device 29, together with the second cutting device 26, constitutes a defect portion elimination mechanism that cuts and eliminates the defective portion of the optical film. However, such an exclusion mechanism may be omitted. .

  The 2nd release film bonding apparatus 25 bonds the release film H22 to the 2nd optical film F21 via the 2nd adhesive layer F24 after a 2nd fault test | inspection. As shown in FIG. 6, the release film H22 is unwound from the roll 251 of the release film H22, and the release film H22 and the second optical film F21 are sandwiched by one or a plurality of roller pairs 252, and the pair of rollers At 252, a predetermined pressure is applied to perform bonding. The rotation speed, pressure control, and conveyance control of the roller pair 252 are controlled by the control device 1.

  The second cutting device 26, after bonding the release film H22, without cutting the release film H22, the second optical film F21, the surface protective film 25, the second pressure-sensitive adhesive layer F24, the pressure-sensitive adhesive layer F25. Is cut into a predetermined size. The second cutting device 26 is, for example, a laser device. Based on the position coordinates of the defect detected in the second defect inspection process, the second cutting device 26 cuts to a predetermined size so as to avoid the defect portion. That is, the cut product including the defective portion is rejected as a defective product by the second rejection device 29 in a later process. Or the 2nd cutting device 26 may ignore the presence of a fault, and may cut continuously to a predetermined size. In this case, it can be configured such that the portion is removed without being bonded in the bonding process described later. Control in this case also depends on the function of the control device 1.

  The 2nd bonding apparatus 28 optically transmits 2nd sheet product F2 (2nd optical film F21) from which the release film H22 was peeled by the 2nd peeling apparatus 27 through the 2nd adhesive layer F24 after a cutting process. Affix to the display unit W. As shown in FIG. 7, when bonding, the second optical film F <b> 21 is bonded to the surface of the optical display unit W while being pressed by the pressing roller 281 and the guide roller 282. The control device 1 controls the pressing pressure and driving operation of the pressing roller 281 and the guide roller 282.

  The peeling mechanism 271 of the second peeling device 27 has a knife edge portion with a sharp tip, and the release film H22 is wound around the knife edge portion and reversely transferred to peel the release film H22. The second sheet product F2 (second optical film) after the release film H22 is peeled off is sent to the optical display unit W surface. The peeled release mold H22 is wound around a roll 272. The winding control of the roll 272 is controlled by the control device 1.

  That is, the 2nd optical film supply apparatus M5 in this invention supplies the 2nd optical film F21 to the 2nd bonding apparatus M6 by using the release film formed in the optical film via the adhesive layer as a conveyance medium. It has a transport mechanism.

  The laminating mechanism is composed of a pressing roller 281 and a guide roller 282 arranged to face it. The guide roller 282 is composed of a rubber roller that is rotationally driven by a motor, and is arranged so as to be movable up and down. In addition, a pressing roller 281 made of a metal roller that is rotationally driven by a motor is disposed directly below it. When the optical display unit W is sent to the bonding position, the pressing roller 281 is moved to a lower position so as to open a roller interval. Note that both the guide roller 282 and the pressing roller 281 may be rubber rollers or metal rollers.

  The 2nd rejection apparatus 29 which excludes the 2nd sheet material F2 containing a fault is demonstrated. When the second sheet product F2 including the defect is conveyed to the bonding position, the guide roller 282 moves vertically upward. Next, the roller 292 around which the removal film 291 is stretched moves to a fixed position of the guide roller 282. By moving the pressing roller 281 vertically upward, the second sheet product F2 including the defect is pressed against the removal film 291 and the second sheet product F2 is attached to the removal film 291 and includes the defect together with the removal film 291. The second sheet product F2 is wound around the roller 293.

  The optical display device on which the first and second sheet products are bonded is conveyed to an inspection device. The inspection device performs an inspection on both sides of the optical display device that has been conveyed. The light source vertically irradiates the upper surface of the optical display device with a half mirror, and the reflected light image is captured as image data with a CCD camera. The light source and the CCD camera perform an inspection of the opposite surface. The light source irradiates the surface of the optical display device at a predetermined angle, and the reflected light image is captured as image data by a CCD camera. The light source and the CCD camera perform an inspection of the opposite surface. The defect is subjected to image processing analysis from these image data, and a non-defective product is determined.

  The operation timing of each device is calculated by, for example, a method of detecting by arranging a sensor at a predetermined position, or calculated by detecting a rotating member of the transfer device or the transfer mechanism R with a rotary encoder or the like. . The control device 1 may be realized by a cooperative action of a software program and hardware resources such as a CPU and a memory. In this case, a memory is stored in advance for the program software, processing procedure, various settings, and the like. Further, it can be configured by a dedicated circuit or firmware.

  The roll original fabric set according to the present invention can be preferably used for forming an image display device (corresponding to an optical display device) such as a liquid crystal display device, an organic EL display device, and a PDP.

  The roll roll set according to the present invention can be preferably used for forming various devices such as a liquid crystal display device. The liquid crystal display device can be formed according to the conventional method. That is, the liquid crystal display device is generally formed by appropriately assembling components such as a liquid crystal cell (corresponding to an optical display unit), an optical film, and an illumination system as necessary, and incorporating a drive circuit. In this invention, there is no limitation in particular except the point which uses the roll original fabric set by this invention, According to the former, it can apply. The present invention is also effective when the liquid crystal cell is a VA mode or IPS mode liquid crystal panel. FIG. 10 shows the direction of the absorption axis of the VA mode or IPS mode liquid crystal panel and the polarizing plate bonded to both sides thereof. As shown in this figure, in the VA mode or the IPS mode, the absorption axis A11 of the first polarizing plate is parallel to the long side of the optical display unit W that is a liquid crystal panel, and It is important that the absorption axes A21 of the two polarizing plates are parallel.

  An appropriate liquid crystal display device such as a liquid crystal display device in which an optical film is disposed on both sides of the liquid crystal cell or a backlight or a reflector used in an illumination system can be formed. In that case, the roll original fabric set by this invention can be installed in the both sides of a liquid crystal cell. When providing an optical film on both sides, they may be the same or different. Further, when forming a liquid crystal display device, for example, a single layer or a suitable part such as a diffusing plate, an antiglare layer, an antireflection film, a protective plate, a prism array, a lens array sheet, a light diffusing plate, a backlight, etc. Two or more layers can be arranged.

  The roll original fabric set according to the present invention can be preferably used for forming various devices such as a liquid crystal display device. The liquid crystal display device may be formed as a transmission type or a reflection type in which the roll original fabric set according to the present invention is arranged on both sides of the liquid crystal cell, or an appropriate structure according to the conventional type of a transmission / reflection type. it can. Accordingly, the liquid crystal cell forming the liquid crystal display device is arbitrary, and for example, a liquid crystal cell of an appropriate type such as an active matrix driving type typified by a thin film transistor type may be used.

  Moreover, when providing a polarizing plate and an optical member in the both sides of a liquid crystal cell, they may be the same thing and may differ. Furthermore, when forming the liquid crystal display device, for example, appropriate components such as a prism array sheet, a lens array sheet, a light diffusing plate, and a backlight can be arranged in one or more layers at appropriate positions.

(Another embodiment of the manufacturing system)
Arrangement | positioning of each apparatus of the manufacturing system used for this invention may be any, for example, the supply apparatus M1 of the optical display unit W, the supply apparatus M2 of the 1st optical film F11, and the 1st bonding apparatus M3 are linear form. The second optical film F21 supply device M5 and the second bonding device M6 are arranged in parallel to this, and between the first bonding device M3 and the second bonding device M6, You may arrange | position so that the conveyance supply apparatus M4 may be provided.

  In addition, in this invention, when not providing the turning mechanism of the optical display unit W, the supply apparatus M2 of the 1st optical film F11 and the 1st bonding apparatus M3 are the supply apparatus M5 of the 2nd optical film F21, and 2nd. It is preferable to arrange | position perpendicular | vertical with respect to the bonding apparatus M6.

F1 1st sheet product F2 2nd sheet product F11 1st optical film F11a 1st polarizer F11b 1st film F11c 2nd film F12 1st release film F13 Surface protection film F14 1st adhesive layer F21 2nd optical film F21a Second polarizer F21b Third film F21c Fourth film F22 Second release film F23 Surface protective film F24 Second pressure-sensitive adhesive layer M1 Optical display unit supply device M2 First optical film supply device M3 First bonding device M4 Conveyance supply device M5 Second optical film supply device M6 Second bonding device 1 Control device 12 First conveyance device 13 First pre-inspection peeling device 14 First defect inspection device 15 First release film bonding device 16 First Cutting device 17 First peeling device 18 First bonding device 19 First rejection device 20 Turning mechanism 22 Second transport device 23 Second Pre-examination peeling device 24 Second defect inspection device 25 Second release film laminating device 26 Second cutting device 27 Second peeling device 28 Second laminating device 29 Second excluding device 50 Cutting mechanism 51 Laser device R0 Nagahara Reverse roll R1 First roll R2 Second roll R Conveying mechanism W Optical display unit

Claims (4)

The long sheet-like product is drawn from the roll roll on which the long sheet-like product in which the optical film including the polarizing plate, the pressure-sensitive adhesive layer, and the release film are laminated in this order is wound, and is cut into a predetermined length. A method for producing a roll material for laminating an optical film on the surface of a rectangular optical display unit,
A slit raw material having a longitudinal direction having a longitudinal direction parallel to the absorption axis of the polarizing plate is cut in a width corresponding to the short side or the long side of the optical display unit in parallel with the longitudinal direction, and the slit step. A roll raw material manufacturing method including a winding step of winding the long sheet-shaped product thus formed into a roll. Pull out the long sheet-shaped product from the roll roll on which the long sheet-shaped product in which the optical film including the polarizing plate, the pressure-sensitive adhesive layer, and the release film are laminated in this order is wound, and cut the release film. Without supplying the optical film and the pressure-sensitive adhesive layer after cutting into a predetermined length, a method for producing a roll material for laminating an optical film on the surface of a rectangular optical display unit,
A slit raw material having a longitudinal direction having a longitudinal direction parallel to the absorption axis of the polarizing plate is cut in a width corresponding to the short side or the long side of the optical display unit in parallel with the longitudinal direction, and the slit step. A roll raw material manufacturing method including a winding step of winding the long sheet-shaped product thus formed into a roll.   The method for manufacturing a roll material according to claim 1 or 2, wherein the optical display unit used for bonding is a VA mode or IPS mode liquid crystal panel.   In the said slit process, in multiple places of the width direction, it cut | disconnects by the width | variety corresponding to the short side or the long side of the said optical display unit in parallel with the longitudinal direction. Production method.

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