JP5193407B2 - Transfer film supply method and transfer method - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention provides a transfer film supply method suitable for supplying a transfer film in which a heat-melt type colorant layer is formed on a substrate of a color filter of a liquid crystal display, a transfer method using the supply method, and The present invention relates to a transfer film supply cartridge.
[0002]
[Prior art]
As a method for forming a colored layer on a substrate of a color filter such as a liquid crystal display, a laser transfer method has been proposed (see, for example, JP-A-10-206625 and JP-A-7-104113). In the laser transfer method, a heat melting type colorant is applied to a film-like substrate in advance to form a transfer film, and a laser beam is applied to the transfer film in a state where the transfer film and the color filter substrate are overlapped. In this method, the colorant is transferred to the substrate in a desired pattern by melting the colorant.
[0003]
In the laser transfer method described above, it is necessary to supply a transfer film so as to cover the substrate placed on the stage of the transfer device. In the conventional supply method, a transfer film having a length necessary for one transfer is pulled out from a roll of transfer film, cut from the roll, and the obtained transfer film is transferred onto a stage and transferred onto a substrate. We are developing a transfer film.
[0004]
[Problems to be solved by the invention]
The conventional supply method requires a step of cutting the transfer film in accordance with the substrate size, which increases the number of work steps and increases cost and time. There is a possibility that dust is generated from the cut surface, and the dust adheres to the transfer film or the substrate and adversely affects the transfer.
[0005]
In order to eliminate such inconvenience, by attaching a pair of rolls so that the laser irradiation part is sandwiched in the transfer device, each time transfer is performed, the transfer film is transferred from one roll to the other by a predetermined length, A continuous supply method for continuously supplying a transfer film onto a large number of substrates has been studied. According to such a method, since there is no need to cut the transfer film, the problem of dust generation does not occur.
[0006]
However, in the above-described continuous supply method, the transfer of a pair of rolls with a cantilever structure required to make it possible to exchange a pair of rolls with a transfer film wound between them is required. Device design constraints are increased. It is necessary to expose the transfer film over a distance longer than that of the substrate before and after the laser irradiation portion, and the possibility that foreign matter adheres to the transfer film increases.
[0007]
Therefore, the present invention does not require cutting of the transfer film, requires only a small amount of exposure of the transfer film, and can provide a transfer film supply method that can suppress restrictions on the design of the transfer device resulting from the convenience of supply of the transfer film, and its and to provide a transfer how utilizing supplying method.
[0008]
[Means for Solving the Problems]
The supply method of the present invention is placed on the stage (4) of the transfer device (1) for forming three kinds of colored layers corresponding to the three primary colors of R, G and B on the glass substrate of the color filter of the liquid crystal display. A transfer film (11) having a heat-melting colorant layer formed on a glass substrate (10) to be transferred, and containing a transfer film having a length that can be transferred multiple times A cartridge (12) having a supply section (12a) for collecting the film and a collection section (12b) for collecting the film is prepared, and the transfer film drawn out from the supply section is straightened along the lower end of the cartridge. In addition, a transfer film having a length necessary for one transfer is fed between the supply unit and the collection unit so as to be collected by the collection unit. Said feeding said cartridge in a state in which the transfer film was below the so as to overlap with the glass substrate on stage mounted on the stage driving device for driving the recovery unit, the cleaning device and the transfer film to clean the transfer film One or more cartridges for each of R, G, and B are prepared in an inspection / supply unit equipped with an inspection device that inspects for defects, and the cartridges of the respective colors are alternately staged from the inspection / supply unit. with reloaded to, concurrently while the any one of the cartridge transfer is mounted on the stage is being performed, the driving device, in standby is removed from the stage, it mounted on the stage cartridge length required for the next transfer between the recovery section and the supply section of another color cartridge Is output repeatedly a copy film, and the transfer film feeding, by cleaning the cleaning device, the Rukoto was examined with the test device, to solve the problems described above.
[0009]
According to the supply method of the present invention, a transfer film having a required length can be drawn out from the supply portion of the cartridge and stacked on the substrate prior to each transfer, and the used transfer film can be recovered in the recovery portion. it can. Thereby, it is not necessary to cut the transfer film, and the problem of dust generation from the cut surface does not occur. Since the cartridge is mounted on the stage, the amount of exposure of the transfer film is minimal. Since the stage can be moved out of the transfer section (for example, the area immediately below the laser irradiation section) and the cartridge can be mounted and removed at a position where the substrate is replaced, the structure of the transfer film supply mechanism is the transfer section. As a result, the degree of freedom in designing the transfer portion is increased. Further, while any cartridge is mounted on the stage and transfer is being performed, the transfer film is fed out from the waiting cartridge supply unit in preparation for the next transfer. Therefore, there is no possibility that the efficiency of the transfer process is reduced due to the work of drawing out the transfer film. Further, it is possible to prevent the occurrence of transfer failure due to the adhesion of foreign matter to the transfer film. Since the waiting cartridge is cleaned, the efficiency of the transfer process is not impaired. Moreover, it is possible to prevent the occurrence of transfer failure due to transfer film defects. Since the defect inspection is performed on the transfer film of the waiting cartridge, the efficiency of the transfer process is not impaired.
[0014]
When a defect is detected in the transfer film in the inspection, the transfer film may be sent from the supply unit to the recovery unit so that the defective part is out of the range where it overlaps the glass substrate. In this case, the defective part detected on the transfer film is sent to the recovery part, so that the use of the defective part can be reliably prevented.
[0015]
The newly transferred transfer film is cleaned and inspected along with the detection of the defective portion, and the transfer film is repeatedly sent, cleaned and inspected until the defective portion is no longer detected from the range overlapping the glass substrate. You may do it. In this case, a transfer film having no defect can always be supplied to the substrate on the stage.
[0016]
In the supply method of the present invention, rolls (14, 15) are arranged in each of the supply unit and the recovery unit, and the transfer film drawn from the roll of the supply unit is wound around the roll of the recovery unit. Also good. If it does in this way, supply and collection | recovery of a transfer film can be performed with a simple structure, and it can contribute to weight reduction and size reduction of a cartridge.
[0017]
In the transfer method of the present invention, a laser beam is applied from the laser irradiation section (6) of the transfer device (1) to the transfer film (11) supplied on the glass substrate (10) by the transfer film supply method described above. Irradiation is performed to transfer a material to be transferred on the transfer film to the glass substrate. According to this transfer method, transfer can be efficiently performed with high quality by taking advantage of the above-described advantages of the supply method of the present invention.
[0022]
In the above description, in order to facilitate understanding of the present invention, reference numerals in the accompanying drawings are added in parentheses, but the present invention is not limited to the illustrated form.
[0023]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, an embodiment of the present invention will be described with reference to FIGS. 6A and 6B show the overall configuration of the transfer apparatus 1 for forming a colored layer on a glass substrate of a color filter of a liquid crystal display, where FIG. 6A is a front view and FIG. 6B is a right side view. The transfer device 1 includes a bed 2, a portal column 3, and a stage 4. The stage 4 is attached to the bed 2 via a linear guide device 5 and is transferred along a predetermined axial direction in the horizontal plane (direction indicated by an arrow in FIG. 6A) and a transfer position immediately below the column 3. It can move between P2. At the set-up position P1, a set-up operation such as replacement of the substrate 10 is performed.
[0024]
A laser irradiation unit 6 is attached to the column 3. The laser irradiation unit 6 irradiates a laser beam toward the stage 4 sent to the transfer position P2. The laser irradiation unit 6 has a function of scanning a laser beam in a direction orthogonal to the moving direction of the stage 4 in a horizontal plane. The transfer device 1 can irradiate a laser beam at an arbitrary position on the stage 4 by a combination of scanning of the laser beam in the laser irradiation unit 6 and movement of the stage 4. The stage 4 is designed to have a size suitable for mounting a single substrate 10.
[0025]
FIG. 1 shows an example in which a transfer film 11 is supplied onto a single substrate 10 placed on the stage 4 of the transfer device 1 by the method of the present invention. In this example, the transfer film 11 is accommodated in a cartridge 12, and the cartridge 12 is mounted on the stage 4 as it is and the transfer film 11 is supplied onto the substrate 10. As shown in FIG. 2, the cartridge 12 has a pair of plate-like frames 13 and 13 arranged in parallel to each other. A supply roll 14 is attached to one end side of the frames 13, 13, and a take-up roll 15 is attached to the other end side of the frame 13. Each of the rolls 14 and 15 can freely rotate around an axis parallel to each other.
[0026]
A space 16 longer than the length of the substrate 10 placed on the stage 4 is secured between the rolls 14 and 15. In order to enable irradiation of the transfer film 11 with a laser beam and transfer of the pattern from the transfer film 11 to the substrate 10, the upper and lower portions of the space 16 are opened. That is, an opening for introducing a laser beam and an opening for bringing the transfer film 11 and the substrate 10 into close contact with each other are provided above and below the cartridge 12.
[0027]
In an initial state before the use of the cartridge 12 is started, a transfer film 11 having a length corresponding to the transfer of a large number (for example, 100 to 400) of substrates 10 is wound around the supply roll 14. As a result, a supply portion 12 a for the transfer film 11 is formed on one end side of the frame 13. The transfer film 11 drawn from the supply roll 14 is stretched straight along the lower end of the cartridge 12, and is wound on the take-up roll 15. As a result, a recovery portion 12b of the transfer film 11 is formed on the other end side of the frame 13. And the feeding part 12c of the transfer film 11 is comprised between the supply part 12a and the collection | recovery part 12b.
[0028]
The length of the transfer film 11 fed to the feeding portion 12 c is longer than that of the substrate 10. Further, the width of the transfer film 11 is larger than the width of the substrate 10. For this reason, the substrate 10 is placed on the stage 4 at the set-up position P1 of the transfer apparatus 1, and the cartridge 12 is placed on the stage 4 from above with the feeding portion 12c facing down, whereby the substrate 10 is placed on the feeding portion 12c. It can be completely covered with the transfer film 11. By moving the stage 4 to the transfer position P2 while the cartridge 12 is mounted and irradiating the transfer film 11 with the laser beam from the laser irradiation unit 6, the transfer material 11 such as the colorant on the transfer film 11 is transferred to the substrate 10 by the substrate 10. Can be transferred to.
[0029]
The total length of the cartridge 12 may be larger or smaller than the total length of the stage 4. However, in order to reduce the load on the stage 4, it is desirable to make the cartridge 12 as small and light as possible.
[0030]
In order to improve the adhesion between the substrate 10 placed on the stage 4 and the transfer film 11 fed to the feeding portion 12 c of the cartridge 12, a familiar roll 18 is provided on the cartridge 12. The familiar roll 18 has a sufficiently small diameter compared to the supply roll 14 and the take-up roll 15. The familiar roll 18 is attached to the frames 13 and 13 so as to be able to reciprocate while rotating between the rolls 14 and 15. For example, a groove extending in the feeding direction of the transfer film 11 is formed in each frame 13, and both ends of the rotation shaft of the familiar roll 18 are fitted to them, thereby allowing the familiar roll 18 to reciprocate and rotate. It can be supported by the frames 13 and 13.
[0031]
As shown in FIG. 1, suction holes 19... 19 are formed in rows on both sides of a substrate 10 (shown in phantom lines in FIG. 1) placed on the stage 4. These suction holes 19 are connected to suction means (not shown). The transfer film 11 can be held on the stage 4 in close contact with the substrate 10 by sucking air from the suction holes 19.
[0032]
Next, with reference to FIGS. 3 to 5, an embodiment in which the above supply method is used for forming a colored layer of a color filter for a liquid crystal display will be described.
[0033]
FIG. 3 shows an example in which a colored layer is formed on a color filter substrate of a liquid crystal display with a single transfer device 1. In general, it is necessary to form three types of colored layers respectively corresponding to the three primary colors R, G, and B on the substrate 10 of the color filter. On the other hand, a heat-melting colorant corresponding to any one of the three primary color layers to be formed on the substrate 10 is fixed to the transfer film 11 in advance. In such a case, one or more cartridges 12... 12 are prepared in advance for each color of R, G, B corresponding to one transfer device 1. The prepared cartridge 12 is collected in a predetermined inspection / supply unit 21. Then, among the prepared cartridges 12, any one cartridge 12 used for transfer is supplied from the inspection / supply unit 21 to the stage 4. After the transfer, the cartridge 12 is collected from the transfer device 1 to the inspection / supply unit 21, and another color cartridge 12 is supplied to the transfer device 1. Such a process is repeated for each color to form colored layers of three colors on the substrate 10.
[0034]
FIG. 4 shows processing performed in the inspection / supply unit 21. In the inspection / supply unit 21, a film delivery process (a), a cleaning process (b), and an inspection process (c) are performed on the cartridge 12 that is not used for transfer and is on standby.
[0035]
In the film delivery process, the take-up roll 15 is driven in a predetermined take-up direction (indicated by an arrow in FIG. 4A), so that the supply roll 14 moves from the supply roll 14 to the take-up roll 15 in preparation for the next transfer. The transfer film 11 is sent out for a length necessary for the transfer of the times. As a result, the transfer film 11 before use that is not irradiated with the laser beam is fed out to the feeding portion 12 c of the cartridge 12 supplied to the transfer device 1.
[0036]
In the cleaning process, the transfer film 11 fed to the feeding portion 12c is cleaned. For example, the nozzles 22 and 22 are arranged so as to sandwich the transfer film 11, cleaning gas (for example, carbon dioxide) is sent out from each nozzle 22, and the nozzle 22 is sent along the transfer film 11 to cause foreign matter on the transfer film 11. Is blown away. However, the cleaning process is not limited to a method using gas, and various cleaning methods may be used.
[0037]
In the inspection process, the presence or absence of a defect in the transfer film 11 fed to the feeding portion 12c is inspected. The inspection is performed by, for example, photographing the transfer film 11 of the feeding portion 12c with the inspection camera 23 and analyzing the obtained image to determine the presence or absence of a defect. However, the present invention is not limited to defect inspection using image processing, and various defect detection methods may be used. The term “defect” as used herein refers to various types of concerns that may deteriorate the transfer quality of the colored layer to the substrate 10, such as scratches and unevenness of the colored layer formed on the transfer film 11, and adhesion of foreign matter to the transfer film 11. This is an event.
[0038]
If a defect is detected in the inspection process, the transfer film 11 is sent again. At this time, the transfer amount of the transfer film 11 may be such that the detected defect is removed from the feeding portion 12c. For example, when the position of the defect can be specified in the image processing, the amount of movement of the transfer film 11 required until the defective portion moves from the feeding unit 12c to the collection unit 12b is calculated based on the position, and the calculation is performed. The transfer film 11 may be sent out from the supply unit 12a to the collection unit 12b by the amount of movement. However, the transfer film 11 may always be sent out for a necessary length in one transfer regardless of the position of the defect.
[0039]
After the transfer film 11 is sent again along with the detection of the defect, the cleaning process and the inspection process are performed again. When a defect is detected again in the inspection process, a sending process is further performed. Such a series of processes is repeated until no defect is detected. Thereby, the transfer film 11 having no defect is always fed out to the feeding portion 12 c of the cartridge 12 placed on the stage 4. Accordingly, it is possible to prevent the occurrence of transfer failure due to the defect of the transfer film 11.
[0040]
Each process of the inspection / supply unit 21 described above can be performed in parallel while another cartridge 12 is mounted on the transfer device 1 and transfer is being performed. Therefore, there is no possibility that the transfer efficiency is lowered.
[0041]
FIG. 5 shows the processing after the cartridge 12 is mounted on the stage 4. After the cartridge 12 is mounted on the stage 4, first, as shown in FIG. 5A, the familiar roll 18 is moved from one end side to the other end side of the substrate 10 to bring the transfer film 11 into close contact with the substrate 10. At this time, if the region where the suction force from the suction hole 19 acts is enlarged from one end side to the other end side of the substrate 10 so as to follow the movement of the familiar roll 18, the transfer film 11 and the substrate 10 are more It is preferable because it can be securely adhered. Further, at the start of movement of the familiar roll 18, the transfer film 11 may be lifted on the end point side, and the transfer film 11 may be lowered toward the substrate 10 as the familiar roll 18 approaches the end point.
[0042]
After the transfer film 11 is brought into close contact with the substrate 10, as shown in FIG. 5B, a laser beam is irradiated from the laser irradiation unit 6 to start the transfer of the colored layer. After the transfer is completed, the cartridge 12 is removed from the stage 4 and another color cartridge 12 is supplied from the inspection / supply unit 21 to the stage 4 and transferred in the same procedure. The three layers of R, G, and B cartridges 12 are alternately mounted on the stage 4 and transferred three times to complete the formation of the colored layer on the single substrate 10.
[0043]
The present invention may be implemented in various forms without being limited to the above-described embodiments. For example, by mounting two or more substrates 10 on the stage 4 and covering them with the transfer film 11 of a single cartridge 12, a colored layer is formed on a plurality of substrates 10 by one transfer. May be.
[0044]
In the above embodiment, three types of transfer films corresponding to the three primary colors of R, G, and B are accommodated in separate cartridges 12, and the transfer is repeated while alternately placing them on the stage 4. The present invention can also be used when a single material to be transferred, for example, a material for forming a black stripe on the substrate 10 is transferred from the transfer film 11 to the substrate 10. In this case, the same type of transfer film may be accommodated in a plurality of cartridges 12 and the cartridges 12 may be alternately mounted on the stage 4.
[0045]
The rolls 14 and 15 when the transfer film 11 is sent from the supply roll 14 to the take-up roll 15 may be driven manually by an operator. However, in mass production, the take-up roll may be driven by a drive source such as a motor. It is desirable to rotate 15. In that case, in order to reduce the load on the stage 4, the driving device is arranged as much as possible outside the cartridge 12, and when mounting the cartridge 12 on the stage 4, the driving device can be separated from the cartridge 12. Is desirable. For example, the shaft end portion of the rotary shaft of the winding roll 15 can be connected to and released from the drive shaft of the drive device installed in the inspection / supply unit 21 via a connecting means such as a shaft coupling or a gear train. You can do it.
[0046]
The cartridge 12 is preferably provided with means for preventing the transfer film 11 fed to the feeding portion 12c from loosening. For example, the supply roll 14 is applied with a rotational force in the direction opposite to the rotation direction when the transfer film 11 is pulled out by using a biasing means such as a coil spring, and the winding roll 15 A braking mechanism that prevents rotation or a reverse rotation prevention mechanism (for example, a ratchet mechanism) that restricts rotation of the transfer film 11 in the direction opposite to the winding direction may be provided.
[0047]
The cartridge 12 of the present invention is not limited to the above embodiment and may be implemented in various configurations. The film supply unit 12a and the recovery unit 12b may each hold a long film by means other than a roll. For example, the collecting unit 12b may be configured to fold and collect a used film.
[0048]
The present invention is not limited to a substrate for a color filter of a liquid crystal display, and can be used when a transfer film is supplied on various substrates.
[0049]
【Effect of the invention】
As described above, according to the supply method of the present invention, a transfer film having a required length can be drawn out from the supply portion of the cartridge and superimposed on the substrate before each transfer, and the used transfer film can be It can be collected in the collection unit. Thereby, it is not necessary to cut the transfer film, and the problem of dust generation from the cut surface does not occur. Since the cartridge is mounted on the stage, the amount of exposure of the transfer film is minimal. Since the stage can be moved out of the transfer section (for example, the area immediately below the laser irradiation section) and the cartridge can be mounted and removed at a position where the substrate is replaced, the structure of the transfer film supply mechanism is the transfer section. As a result, the degree of freedom in designing the transfer portion is increased. In particular, if a plurality of cartridges are prepared, and they are alternately placed on the stage, the transfer film used for the next transfer, the transfer film cleaning, and the inspection are performed on the waiting cartridge. It is advantageous that various preparations necessary for the transfer process can be performed without impairing the efficiency of the transfer process. Further, according to the transfer method and the cartridge of the present invention, it is possible to realize a transfer process with high efficiency and high quality by using the supply method of the present invention.
[Brief description of the drawings]
FIG. 1 is a perspective view showing an embodiment in which a transfer film is supplied onto a single substrate placed on a stage of a transfer device by the method of the present invention.
FIG. 2 is a diagram illustrating a state where a cartridge placed on a stage is viewed from above.
FIG. 3 is a diagram illustrating a relationship between a transfer device and a cartridge inspection / supply unit.
FIG. 4 is a diagram illustrating various processes performed on a cartridge that is waiting in an inspection / supply unit.
FIG. 5 is a view showing processing after the cartridge is placed on the stage of the transfer device.
FIG. 6 is a diagram illustrating an example of a transfer device.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Transfer apparatus 4 Stage 6 Laser irradiation part 10 Substrate 11 Transfer film 12 Cartridge 12a Supply part 12b Collection part 12c Feeding part 13 Frame 14 Supply roll 15 Take-up roll 16 Space 18 Familiar roll 19 Adsorption hole 21 Inspection / supply part 22 Nozzle 23 Inspection camera

Claims (5)

Heat melting type coloring on a glass substrate to be transferred, which is placed on a stage of a transfer device that forms three types of colored layers corresponding to the three primary colors R, G, and B on a glass substrate of a color filter of a liquid crystal display. A method of supplying a transfer film on which an agent layer is formed , comprising a cartridge having a supply unit for storing a transfer film having a length that can be transferred multiple times and a recovery unit for collecting the film. The transfer film pulled out from the supply unit is stretched straight along the lower end of the cartridge and then collected by the collection unit so that the transfer film is transferred once between the supply unit and the collection unit. with feeding the transfer film length required for, and the transfer film transfer film feeding that is feeding said to overlap with the glass substrate on the stage below Mounting the cartridge of state to the stage,
One or more for each color of R, G, and B in a driving device that drives the collection unit, a cleaning device that cleans the transfer film, and an inspection / supply unit that inspects the presence or absence of defects in the transfer film. the cartridge was prepared, with reloaded into the stage alternately each color cartridge from the inspection and supply unit, in parallel while the transfer is being performed to any one of the cartridge is mounted on the stage, the Transfer to the drive unit in a standby state after being removed from the stage and between the supply unit and the recovery unit of a cartridge of a different color from the cartridge mounted on the stage. It is decremental the film and the transfer film feeding, by cleaning the cleaning device, the inspection of the inspection system Supply method of a transfer film characterized in Rukoto. When a defect is detected in the transfer film in the inspection, the transfer film is sent from the supply unit to the recovery unit so that the defective part is out of a range overlapping with the glass substrate. Item 2. A transfer film supply method according to Item 1. The newly transferred transfer film is cleaned and inspected along with the detection of the defective portion, and the transfer film is repeatedly sent, cleaned and inspected until the defective portion is no longer detected from the range overlapping the glass substrate. The method for supplying a transfer film according to claim 2. The roll of each of the said supply part and the said collection | recovery part is arrange | positioned, The transfer film withdraw | derived from the roll of the said supply part was wound up on the roll of the said collection | recovery part, Any one of Claims 1-3 characterized by the above-mentioned. the method of supplying the transfer film according to one paragraph or. Be on the transfer film from the laser irradiation portion of the transfer device to a transfer film is supplied onto the glass substrate by the method of supplying the transfer film by irradiating a laser beam as claimed in any one of claims 1 to 4 A transfer method comprising transferring a transfer substance onto the glass substrate.

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