JP5088280B2 - Color filter manufacturing equipment - Google Patents

Description

  The present invention relates to an apparatus for manufacturing a color filter used for a liquid crystal panel or the like.

  A raw fabric mounting unit for mounting a long base material, an inkjet unit for supplying colored layer ink to the surface of the base material, and a long base material on which a black matrix and a colored layer are formed are wound. 2. Description of the Related Art A color filter manufacturing apparatus including a winding unit for taking is known (for example, Patent Document 1).

JP 2004-117769 A

  In a color filter manufacturing apparatus using an ink jet unit, a film material provided with a plurality of alignment marks around a filter forming region is used in order to eject and apply ink to a predetermined position of the filter forming region. In such a color filter manufacturing apparatus, it is necessary to adjust the position of each filter formation region based on a plurality of alignment marks provided around the filter formation region. Therefore, when using a film material in which a plurality of filter forming regions are arranged in the longitudinal direction at predetermined intervals, the conveyance of the film material is stopped every time the filter forming region moves and the position of the inkjet unit is adjusted. It must be made. Therefore, the movement of the film material becomes intermittent.

  Therefore, the present invention provides a color filter manufacturing apparatus capable of continuously manufacturing a color filter by using a film material in which a plurality of filter forming regions are arranged in the longitudinal direction at predetermined intervals. Objective.

Color filter manufacturing apparatus of the present invention, a plurality of filter forming region is arranged in the longitudinal direction at predetermined intervals, and a pair of encoder timing marks and a pair of counter marks located on a line intersecting the longitudinal direction of the filter A transport means for transporting a plurality of sets of film materials arranged at predetermined intervals in the longitudinal direction so as to avoid the formation region, and ink ejection for spraying and applying ink to the filter formation region; Means, a detecting means for detecting the pair of encoder timing marks and the pair of counter marks from the film material conveyed by the conveying means, and a cumulative count number of the encoder timing marks and the counter marks. and numerical holding means for said encoder timing detected by the detection means It controls the position of the ink injection means as the deviation of the injection position of the ink due to inclination of the film material with respect to the transport direction based on the detection timing of each chromatography click is corrected, and the said detecting means detects Control means for controlling the operation of the ink ejecting means so that ink is ejected to the filter forming region based on a pair of encoder timing marks , and the encoder timing mark and the counter mark can be distinguished from each other. In this way, the film material is provided in a linear shape with different lengths, and the detection means includes both the laser beam irradiated only to the encoder timing mark and both the encoder timing mark and the counter mark. Are separately received, and based on the amount of each laser beam, The transmittance of the film material is calculated, the encoder timing mark and the counter mark are detected based on the transmittance, and the control means is based on the encoder timing mark and the counter mark detected by the detecting means. At least one of counting up the cumulative count held by the numerical value holding means and resetting the cumulative count at a predetermined value is executed (Claim 1).

According to this color filter manufacturing apparatus, a pair of encoder timing marks positioned on a straight line that intersects the longitudinal direction is detected from the conveyed film material, and the ink ejecting means is based on the detection timing for each encoder timing mark. The position of is adjusted. Since the film material is being conveyed in the longitudinal direction, when the inclination occurs in the conveyance direction in the film material, since the change in the positional relationship between the pair of encoder timing mark and the detecting means is generated, the encoder timing in the detection timing Changes occur for each mark . Therefore, by controlling the position of the ink ejecting means based on the detection timing for each encoder timing mark, it is possible to correct the deviation of the ink ejecting position due to the tilt of the film material. Further, according to the color filter manufacturing apparatus, the operation is controlled so that the ink ejecting means ejects ink based on the detected pair of encoder timing marks while conveying the film material. Therefore, for example, if the timing for ejecting ink is set in advance in association with the detection timing of the detected pair of encoder timing marks , the ink can be ejected to an appropriate position in the filter formation region. Since the adjustment of the position of the ink ejecting means and the adjustment of the ejection timing can be performed while transporting the film material, it is not necessary to stop the transport of the film material every time the filter forming region moves. Therefore, a color filter can be continuously manufactured using a film material in which a plurality of filter forming regions are arranged in the longitudinal direction at predetermined intervals. In addition, the encoder timing mark and the counter mark mark are detected according to the transport state of the film material, and the cumulative count number is counted up. For this reason, it is possible to grasp the operating status of the color filter manufacturing apparatus. In addition, since the cumulative count number is reset with an appropriate predetermined value, overflow of the cumulative count number can be prevented.

In one aspect of the color filter manufacturing apparatus of the present invention, the pair of encoder timing marks and the pair of counter marks are located on a straight line orthogonal to the longitudinal direction of the film material, and the control means includes the encoder timing The position of the ink ejecting means may be controlled so that the detection timing for each mark is the same. By controlling the position of the ejecting means so that the detection timing for each encoder timing mark is the same, it is compensated that the positional relationship between the film material and the ejecting means is appropriate. The deviation of the injection position can be reliably corrected.

In one aspect of the color filter manufacturing apparatus of the present invention, the film material is provided with an alignment mark on a side of the filter formation region for adjusting a deviation in a direction orthogonal to the transport direction, and the transport Position detecting means for detecting the alignment mark from the film material conveyed by the means, and the control means determines the position of the ink ejecting means based on the alignment mark detected by the position detecting means. You may control (Claim 3 ). In this case, the position of the ink ejecting means can be adjusted corresponding to the deviation in the direction perpendicular to the transport direction generated in the film material while transporting the film material.

  FIG. 1 shows a color filter manufacturing apparatus according to an embodiment of the present invention. As shown in FIG. 1, a manufacturing apparatus 1 includes rollers 3a and 3b as conveying means for conveying a film material 2 as a color filter material, an ink jet apparatus 4 as an ink ejecting means, an imaging apparatus 5, and an optical device. And an automatic detection device 6. The rollers 3a and 3b can be transported while holding the film material 2 therebetween. The film material 2 is conveyed in the direction of arrow 7 by rollers 3a and 3b. The rollers 3a and 3b are controlled by the transport controller 8 in terms of transport speed, direction, and start / stop of transport. Moreover, the film material 2 is supported from the back surface side by the film material stage 9 arrange | positioned at the conveyance path | route.

  FIG. 2 is a plan view of the film material 2. On the film material 2, a plurality of rectangular filter forming regions 11 are arranged at predetermined intervals. A reference pattern 12 is formed in each filter formation region 11. The reference pattern 12 is configured as a so-called black matrix pattern. In the reference pattern 12, a rectangular frame 13 and a plurality of horizontal patterns 14 parallel to the longitudinal direction of the film material 2 are provided in the frame 13.

FIG. 3 is an enlarged view of the film material 2 of FIG. On one end side (upper side in FIG. 2) in the direction perpendicular to the longitudinal direction of the film material 2, a plurality of encoder timing marks 15 are arranged at predetermined intervals according to the transport speed and the ink ejection range. A plurality of counter marks 16 are arranged in the longitudinal direction between the encoder timing marks 15 with a predetermined interval corresponding to the conveyance speed. Both the encoder timing mark 15 and the counter mark 16 extend in a direction perpendicular to the longitudinal direction, and are provided so as to avoid the filter forming region 11. The encoder timing mark 15 is about twice as long as the counter mark 16. On the side of the encoder timing mark 15 and the counter mark 16 (upper side in FIG. 2), a plurality of alignment marks 19 are arranged in the longitudinal direction at intervals such that a plurality of images are picked up by one image pickup by the image pickup device 5. Yes. These encoder timing mark 15, counter mark 16 and alignment mark 19 are also symmetrical with respect to the center line in the direction perpendicular to the longitudinal direction on the other end side (lower side in FIG. 2) in the direction perpendicular to the longitudinal direction. In the position. That is, these marks 15, 16, and 19 are arranged on both sides so as to avoid the filter forming region 11. Details of the functions of these marks 15, 16, and 19 will be described later.

  As shown in FIG. 1, the inkjet device 4 has a head portion 20. An ink jet nozzle 21 that ejects ink onto the film material 2 is provided at the tip of the head portion 20. A tank (not shown) in which ink is stored is connected to the head unit 20, and the ink pumped from the tank is supplied to the head unit 20. The head unit 20 is supported by a stage 22 disposed on the surface side of the film material 2. Although a detailed description of the structure of the stage 22 is omitted, the stage 22 is arranged in a plane parallel to the film material 2 in an X-axis direction parallel to the longitudinal direction of the film material 2 and a Y-axis direction perpendicular to the longitudinal direction. And a rotation direction centered on the center of the head portion 20. The stage 22 is driven by a driving device (not shown), and the driving device is controlled by a stage controller 23. In addition, a head control unit 24 is connected to the head unit 20, and the ink ejection operation is controlled by the head control unit 24.

  The imaging device 5 includes an image recognition illumination 28 that emits light from the back side of the film material 2, and a dichroic mirror 30 that reflects an image of the film material 2 obtained by the illumination of the image recognition illumination 28 in a predetermined direction. The CCD camera 31 captures an image reflected by the dichroic mirror 30. The CCD camera 31 is provided at the same height as the dichroic mirror 30 above the film material stage 9, and an image captured by the CCD camera 31 is sent to the image processing unit 32. The alignment mark 19 shown in FIG. 3 is detected by performing predetermined image processing on the image sent to the image processing unit 32. The imaging device 5 is supported on the stage 22 together with the inkjet device 4, and the image recognition illumination 28, the dichroic mirror 30, and the CCD camera 31 also move as the stage 22 moves. A combination of the imaging device 5 and the image processing unit 32 functions as a position detection unit according to the present invention by cooperation between the imaging device 5 and the image processing unit 32.

  The optical detection device 6 is a device for detecting the encoder timing mark 15 and the counter mark 16 shown in FIG. The optical detection device 6 receives laser light from a laser irradiation device 34 provided below the film material stage 9 and a laser irradiation device 34 disposed on the surface side of the film material 2 and transmitted through the film material 2. It is configured by combining with the laser light receiving device 35. Laser spots A and B shown in FIG. 3 are irradiation positions of laser light by the laser irradiation device 34. The laser irradiation device 34 includes a set of laser diodes that emit laser light only to the encoder timing mark 15 to form a laser spot A, and emit laser light to the counter mark 16 and the encoder timing mark 15. Another set of laser diodes that emit to form a laser spot B are provided. The laser light receiving device 35 includes two sets of photodiodes capable of separately receiving the laser beams from the laser spots A and B. Since the optical detection device 6 is supported by the stage 22, the laser irradiation device 34 and the laser light receiving device 35 also move as the stage 22 moves. Further, each light amount of the laser light detected from the laser spots A and B by the laser light receiving device 35 is sent to the calculation unit 36.

The calculation unit 36 calculates the transmittance of the laser light with respect to the film material 2 based on the light amounts of the laser spots A and B sent from the laser light receiving device 35, and the encoder timing mark 15 and the counter mark 16 based on the transmittance. Detection is performed. As shown in FIG. 3, the encoder timing mark 15 is provided symmetrically with respect to the center line CL on one end side and the other end side in the direction orthogonal to the longitudinal direction of the film material 2. For this reason, when the film material 2 conveyed in the longitudinal direction is conveyed straight without deviating from the conveying direction, it is provided symmetrically with the encoder timing mark 15 on one end side in the direction orthogonal to the longitudinal direction. The encoder timing mark 15 on the other end side is detected at the same time. On the other hand, when the film material 2 is inclined with respect to the transport direction 7, the positional relationship between the optical detection device 6 and the encoder timing mark 15 is shifted, so that a difference occurs in detection timing. Accordingly, the position of the ink jet device 4 is controlled by moving the stage 22 so that the encoder timing marks 15 on the one end side and the other end side can be detected at the same time. The deviation can be corrected .

When the counter mark 16 and the encoder timing mark 15 are detected, the cumulative count number held by the calculation unit 36 is counted up. Therefore, computation unit 36 functions as a numerical value holding means in accordance with the present invention. And the combination of the optical detection apparatus 6 and the calculating part 36 functions as a detection means which concerns on this invention because the optical detection apparatus 6 and the calculating part 36 cooperate.

  The main control unit 40 is connected to the transport controller 8, the stage controller 23, the head control unit 24, the image processing unit 32, and the calculation unit 36, and is configured as a computer that executes control of these operations according to a predetermined program. FIG. 4 is a flowchart showing an example of the position control routine of the stage 22 executed by the main control unit 40.

  In the control routine of FIG. 4, an instruction is issued to the calculation unit 36 to detect the pair of encoder timing marks 15 based on the amount of light detected by the optical detection device 6 from the film material 2 conveyed in step S1. In the subsequent step S2, it is determined from the detected pair of encoder timing marks 15 whether the detection timings of the encoder timing marks 15 are the same. If the determination in step S2 is affirmative, the subsequent steps are skipped and the current routine is terminated. If the determination is negative, the process proceeds to step S3. In step S3, the position of the stage 22 is adjusted so that the detection timing for each encoder timing mark 15 is the same, and the current routine is terminated.

  When the main control unit 40 executes the control routine of FIG. 4, the pair of encoder timing marks 15 is detected from the film material 2 in the conveyed state, and the detection timing for each encoder timing mark 15 is the same. The position of the part 20 is adjusted.

  In parallel with the control of FIG. 4, the main control unit 40 performs ink ejection control by the inkjet device 4. When a pair of encoder timing marks 15 is detected from the film material 2 in the conveyed state, the main control unit 40 instructs the head control unit 24 to eject ink from the inkjet nozzles 21 of the head unit 20. It is. Since the encoder timing mark 15 is provided at a predetermined interval according to the conveyance speed of the film material 2 and the ink ejection range, the detection timing of the encoder timing mark 15 and the ink ejection timing are associated in advance. The appropriate timing at which the head unit 20 ejects ink can be adjusted. The adjustment of the ink ejection timing and the control routine of FIG. 4 are both performed while the film material 2 is being conveyed. For this reason, since it is not necessary to stop conveyance of the film material 2 every time the filter formation area 11 moves, the film material 2 in which the plurality of filter formation areas 11 are arranged in the longitudinal direction with a predetermined interval is used. The color filter can be continuously manufactured. The main control unit 40 functions as a control unit according to the present invention by executing the control routine of FIG. 4 and controlling the ink jet apparatus 4 based on the encoder timing mark 15.

  FIG. 5 is a flowchart illustrating an example of a count control routine executed by the main control unit 40. In the control routine of FIG. 5, an instruction is issued to the calculation unit 36 to detect the pair of counter marks 16 and the encoder timing mark 15 from the film material 2 conveyed in step S11. At 36, the accumulated count is increased. In step S12, it is determined whether the cumulative count after counting up is equal to or greater than a predetermined value. If the determination in step S12 is negative, the current routine is terminated. On the other hand, if the determination in step S12 is affirmative, the process proceeds to step S13, the cumulative count is reset, and the current routine is terminated. The main control unit 40 repeatedly executes the routines of FIGS. 4 and 5 at a predetermined cycle.

  When the main control unit 40 executes the routine of FIG. 5, the cumulative count number is incremented according to the conveyance state of the film material 2. Thereby, the operating condition of the color filter manufacturing apparatus 1 can be grasped. In addition, since the cumulative count number is reset with an appropriate predetermined value, overflow of the count number can be prevented.

  The position control shown in FIG. 4 is a control corresponding to the inclination of the film material 2, but in parallel with the control of FIG. 4, the stage 22 in the Y-axis direction described above based on the alignment mark 19 shown in FIG. The position control is also performed. That is, the main control unit 40 detects the alignment mark 19 from the film material being conveyed, and determines whether or not the detected alignment mark 19 is at a predetermined position in the Y-axis direction. The alignment mark 19 is detected using the CCD camera 31. If this determination is negative, the position of the stage 22 is adjusted so that the alignment mark 19 is at a predetermined position. Thereby, the position of the head part 20 can be adjusted corresponding to the shift | offset | difference of the direction orthogonal to the conveyance direction which arose in the film material 2. FIG.

  The present invention is not limited to the above-described embodiment, and can be implemented in various forms within the scope of the gist of the present invention. In the above embodiment, the pair of encoder timing marks are located on a straight line orthogonal to the longitudinal direction of the film material, but the present invention is not limited to this, and a pair of encoders located on a straight line intersecting the longitudinal direction A timing mark may be provided. For this reason, the pair of encoder timing marks may not be provided with the filter formation region interposed therebetween, and may be provided, for example, between the filter formation regions. The encoder timing mark is formed in a straight line extending in a direction orthogonal to the longitudinal direction, but is not limited to this shape, and may be any shape as long as it can be detected by an optical detection device. The counter mark may be omitted, or the encoder timing mark may be used as the counter mark.

  Further, the alignment mark may have any shape as long as the position adjustment in the Y-axis direction can be performed. There is no restriction on the position where the alignment mark is provided. In addition, it is merely an example that a plurality of alignment marks are provided at predetermined intervals with respect to the transport direction. Therefore, the alignment marks can be linearly extending continuously in the longitudinal direction on the side of the filter forming region.

  Further, the optical detection device 6 as the detection means can adopt various configurations as long as the encoder timing mark and the counter mark can be detected. In the above embodiment, the imaging unit 6 and the image processing unit 32 as the position detection unit and the optical detection device 6 as the detection unit are provided separately. However, the imaging unit 6 and the image processing as the position detection unit are provided. The unit 32 may also be used as detection means.

FIG. 5 illustrates a color filter manufacturing apparatus according to one embodiment of the present invention. The top view of a film material. The enlarged view of the filter formation area | region in FIG. 3 is a flowchart showing an example of a stage position control routine executed by a main control unit according to the present invention. The flowchart which shows an example of the count control routine which the main control part which concerns on this invention performs.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Color filter manufacturing apparatus 2 Film material 3a, 3b Roller (conveyance means)
4 Inkjet device (ink ejecting means)
DESCRIPTION OF SYMBOLS 5 Optical detection apparatus 6 Imaging apparatus 11 Filter formation area 15 Encoder timing mark (detection part)
32 Image processing unit 36 Calculation unit 40 Main control unit (control means)

Claims (3)

A plurality of filter formation areas are arranged in the longitudinal direction at predetermined intervals, and a pair of encoder timing marks and a pair of counter marks that are positioned on a straight line that intersects the longitudinal direction are long so as to avoid the filter formation areas. Transport means for transporting a plurality of sets of film materials arranged along the longitudinal direction at predetermined intervals in the direction;
Ink ejecting means for ejecting and applying ink to the filter forming region;
Detecting means for detecting the pair of encoder timing marks and the pair of counter marks from the film material conveyed by the conveying means;
Numerical value holding means for holding a cumulative count number of the encoder timing mark and the counter mark;
Controlling the position of the ink ejecting means based on the detection timing of each encoder timing mark detected by the detecting means so that the deviation of the ink ejecting position due to the inclination of the film material with respect to the transport direction is corrected; and Control means for controlling the operation of the ink ejecting means so that ink is ejected to the filter formation region based on the pair of encoder timing marks detected by the detecting means ,
The encoder timing mark and the counter mark are provided on the film material in a linear shape with different lengths so that they can be distinguished from each other,
The detection means separately receives the laser beam irradiated only to the encoder timing mark and the laser beam irradiated to both the encoder timing mark and the counter mark, and based on the light quantity of each laser beam Calculate the transmittance of the film material, detect the encoder timing mark and the counter mark based on the transmittance,
The control means is at least one of counting up the cumulative count held by the numerical value holding means and resetting the cumulative count at a predetermined value based on the encoder timing mark and the counter mark detected by the detection means An apparatus for producing a color filter, wherein one of the two is executed . The pair of encoder timing marks and the pair of counter marks are located on a straight line orthogonal to the longitudinal direction of the film material,
The color filter manufacturing apparatus according to claim 1, wherein the control unit controls the position of the ink ejecting unit so that the detection timing for each encoder timing mark is the same. In the film material, an alignment mark for adjusting a shift in a direction orthogonal to the transport direction is provided on the side of the filter forming region,
Further comprising position detection means for detecting the alignment mark from the film material conveyed by the conveying means;
Said control means, apparatus for producing a color filter according to claim 1 or 2 for controlling the position of the ink ejection unit based on the alignment mark said position detecting means has detected.

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