JP5722370B2 - Optical display panel continuous manufacturing system and optical display panel continuous manufacturing method - Google Patents

Description

  The present invention relates to an optical display panel continuous manufacturing system and an optical display panel continuous manufacturing method.

  As a method of bonding an optical film to a liquid crystal cell, a long laminated optical film in which an optical film is laminated on a carrier film via an adhesive is wound around the peeling portion with the carrier film inside, and the optical film is wound. There is a method of peeling from a carrier film and bonding the peeled optical film to a liquid crystal cell (see, for example, Patent Documents 1 and 2).

  As an apparatus for realizing the bonding method as described above, for example, an upstream feed roll for supplying a carrier film on which optical films are laminated in order from the upstream to the downstream, a dancer for maintaining the tension of the carrier film A roll, a laminating roll (a pair of laminating rolls) for laminating the optical film to the liquid crystal cell and feeding the liquid crystal cell after laminating, and a downstream feed roll for feeding and feeding the carrier film to the downstream winding roll With. The dancer roll disposed between the upstream feed roll and the peeling portion plays a role of tension adjustment and accumulating for ensuring bonding accuracy.

  In the manufacturing apparatus of Patent Document 1, a pair of feeding pinch rolls 102a and 102b, a dancer roll 104, a tension adjusting weight 106, a winding pinch rolls 9a and 9b, and a winding core 6 are provided. Prepare. The laminated film 2 is supplied from the raw fabric portion 90 by the feeding pinch rolls 102a and 102b. Also, when supplying the laminated film held on the dancer roll (accumulation), the laminated film is supplied from the dancer roll 104 (accumulation) by winding the separate film 4 around the core 6. At this time, the laminated film is not conveyed on the upstream side of the dancer roll.

  In the manufacturing apparatus of Patent Document 2, the feeding means 1, 4, 9, 11, 16, the winding means 17, and the tension adjusting means 12 are interlocked to peel off a normal sheet (a normal product sheet) and a bonding position. It is sent to. At this time, the tension adjusting means 12 is located at the most forward position. The tension adjusting means 12 is interlocked with other feeding means. However, when the normal sheet is pasted, the tension adjusting means 12 is located at the most forward position and does not function as an accumulator. In other words, the tension adjusting device exists only for removing the slack of the carrier film at the time of defective discharge. Since the tension adjusting means does not serve as an accumulator, all the transport rolls are synchronized at the same speed.

  Moreover, as operation | movement of the conventional dancer roll, in patent document 3, when the feeding operation of the laminated material in a laminator apparatus and the feeding operation of the laminated material in a post process are different, the feeding operation of a laminator device and a post process There is provided a feeding operation adjusting device (dancer roller) capable of conveying the laminated material without interlocking the feeding operation of the apparatus. The dancer roller 17 is held so as to be rotatable and movable up and down so that its own weight is supported by the laminated material F1. That is, the dancer moves up and down and is used for speed adjustment.

JP 2004-338408 A JP 2011-150328 A JP 2010-036464 A

  However, in the bonding methods as described in Patent Documents 1 and 2, bubbles may be generated between the optical film and the liquid crystal cell in the initial stage of bonding during the period in which the optical film is bonded to the liquid crystal cell.

  The present invention has been made in view of the above problems, and an object thereof is to provide a continuous manufacturing system of an optical display panel and a continuous manufacturing method of an optical display panel that can suppress bubbles generated in the initial stage of bonding. And

The present invention provides a pair of first nip rolls for feeding a laminated optical film having an optical film having an adhesive and a belt-like carrier film on which the optical film is laminated via the adhesive, and the first The accumulator part having a dancer roll arranged on the downstream side of the nip roll, the peeling part for folding the carrier film inside to peel off the optical film from the carrier film, and the peeling of the optical film by the peeling part A pair of second nip rolls for feeding the carrier film downstream; a winding section for winding the carrier film on a roll disposed downstream of the two nip rolls; an optical cell transport section for transporting an optical cell; The optical film that has been peeled off at the peeling portion while transporting the cell is covered with the adhesive. A continuous manufacturing system of an optical display panel and a bonding unit to form an optical display panel bonded to the optical cell and,
In the continuous manufacturing system of an optical display panel provided with the distortion elimination part which relieve | moderates the distortion which arises in the said lamination | stacking optical film by controlling the inertial force of the said dancer roll while bonding the said optical film to the said optical cell. There is .

  According to this structure, the bubble which generate | occur | produces at the initial stage of bonding can be suppressed.

  The mechanism of the present invention will be described below. As a result of diligent research, the present inventors have greatly influenced the change in the distortion of the laminated optical film (stretching in the longitudinal direction of the laminated optical film) due to the inertial force of the dancer roll, and the resulting speed fluctuation of the laminated optical film. I found out.

  When the laminated optical film is accelerated by the upstream and / or downstream feed rolls at the initial driving stage (from the state in which the laminated optical film is stopped to transport, the initial stage where delivery (conveyance) is started), the laminated optical film is Due to the rotational drag of each of the guide rolls wound around, the laminated optical film transmits the speed while being distorted. Then, the speed is transmitted to the dancer roll, and the dancer roll is accelerated up and down for the first time when a force greater than the gravity of the dancer roll and tension adjusting weight (or the resistance of the hydraulic or pneumatic mechanism) is applied. For example, when the dancer roll is accelerated upward, an inertial force works downward, so that the laminated optical film is further distorted. Thereafter, the distorted laminated optical film relaxes with upward acceleration in order to relax the strain. It takes a short time of about 0.1 to 0.5 seconds from the generation of distortion at the initial stage of driving to the relaxation of distortion. Further, here (during the strain relaxation operation), when the downstream feed roll drive reaches a certain speed, the acceleration of the tension adjustment weight decelerates, so an upward inertia force is generated, combined with film strain relaxation, Promotes speed fluctuations. Thus, it is assumed that (large) speed fluctuations occur due to the influence of the distortion of the laminated optical film due to the inertial force of the dancer roll. And based on this mechanism, the distortion of the laminated optical film is reduced, that is, the speed fluctuation of the laminated optical film can be reduced by controlling the dancer roll so as to suppress the inertial force of the dancer roll. Can be suppressed.

  As one embodiment of the present invention, the distortion eliminating portion has a force generated by inertial force of the dancer roll applied per 100 mm width of the carrier film while the optical film is bonded to the optical cell. An inertial force control unit that controls to be 8N or less is provided.

  As one embodiment of the invention, the inertial force control unit suppresses the movement of the dancer roll by examining the acceleration when the dancer roll is movable.

As one embodiment of the invention, the dancer roll is configured to automatically move so as to maintain the tension applied to the laminated optical film,
The distortion eliminating unit includes a dancer roll fixed position control unit that controls the dancer roll not to move from a fixed position while the optical film is bonded to the optical cell.

  Moreover, as the said embodiment, the said dancer roll fixed position control part controls the said dancer roll because the said 1st nip roll and the said bonding part which send out the said laminated optical film move synchronously and at the same speed.

  Moreover, as said embodiment, as for the said dancer roll fixed position control part, a said 1st nip roll and the said bonding part are synchronous and the same speed, Comprising: A said 1st nip roll, the said bonding part, and a said 2nd nip roll, The dancer roll is controlled by moving in synchronization.

  Moreover, as said embodiment, as for the said dancer roll fixed position control part, a said 1st nip roll and the said bonding part are synchronous and the same speed, Comprising: A said 1st nip roll, the said bonding part, and a said 2nd nip roll The dancer roll is controlled by moving at the same speed.

  Moreover, as said embodiment, the said dancer roll fixed position control part controls the said dancer roll because all the said 1st nip rolls, the said bonding part, and the said 2nd nip roll move synchronously and at the same speed.

  As one embodiment of the invention, the dancer roll is a tension adjusting weight type accumulator.

  Examples of the accumulator (accumulator) include a liquid (oil) type, a gas type, a spring type, a prada type, a diaphragm type, and a piston type accumulator. However, the tension adjusting weight type accumulator part is more likely to cause the above problem (generation of distortion) than other mechanisms, and therefore the present invention is highly effective for a manufacturing system using a tension adjusting weight type dancer roll.

As one embodiment of the invention, the dancer roll is configured to move by being controlled to maintain the tension applied to the laminated optical film,
The distortion eliminating unit controls the dancer roll to move according to the result of distortion generated in the laminated optical film detected in advance while the optical film is bonded to the optical cell.

  In this configuration, the dancer roll moves freely and acts to maintain the tension applied to the laminated optical film. And a dancer roll can be moved so that distortion may be canceled using the distortion amount which the distortion elimination part detected beforehand.

  As one embodiment of the invention, the optical film has a thickness of 200 μm or less.

  As the thickness of the optical film is thinner, the generation of bubbles at the time of pasting due to variation in distortion becomes more prominent, so the effect of the present invention is higher.

  As one embodiment of the invention, the optical film includes a polarizing film.

In another aspect of the present invention, a laminated optical film having an optical film having an adhesive and a belt-like carrier film laminated with the optical film via the adhesive is sent downstream by a pair of first nip rolls. A first feeding step, an accumulating step by a dancer roll disposed downstream of the first nip roll, a peeling step of folding the carrier film inside and peeling the optical film from the carrier film, and the peeling step A second feeding step of feeding the carrier film from which the optical film has been peeled downstream by a pair of second nip rolls, and a winding step of winding the carrier film on a roll arranged downstream of the two nip rolls; An optical cell transporting process for transporting the optical cell, and the peeling while transporting the optical cell; A bonding step of forming the optical display panel the optical film is peeled in the process adhered to the optical cell through the pressure-sensitive adhesive, a continuous manufacturing method of an optical display panel comprising,
While the optical film is bonded to the optical cell, it includes a distortion eliminating step of relaxing distortion generated in the laminated optical film by controlling the inertial force of the dancer roll .

  According to this structure, the bubble which generate | occur | produces at the initial stage of bonding can be suppressed.

  As one embodiment of the invention, in the distortion eliminating step, the force due to the inertial force of the dancer roll applied per 100 mm width of the carrier film while the optical film is bonded to the optical cell is 1. Including an inertial force control step of controlling to be 8N or less.

  As one embodiment of the invention, the inertial force control step checks the acceleration when the dancer roll is movable, thereby suppressing the movement of the dancer roll.

As one embodiment of the invention, the dancer roll is configured to automatically move so as to maintain the tension applied to the laminated optical film,
The distortion eliminating step includes a dancer roll fixed position control step for controlling the dancer roll so as not to move from a fixed position while the optical film is bonded to the optical cell.

  Moreover, as the said embodiment, the said dancer roll fixed position control process synchronizes and is the same speed as the feeding operation of the said laminated optical film by a said 1st nip roll, and the bonding operation | movement to the optical cell of the optical film by the said bonding process. To control the dancer roll.

  Moreover, as said embodiment, the said dancer roll fixed position control process WHEREIN: The feeding operation | movement of the said laminated optical film by a said 1st nip roll and the bonding operation | movement to the optical cell of the optical film by the said bonding process are synchronous and the same speed. The feeding operation of the laminated optical film by the first nip roll, the laminating operation to the optical cell of the optical film by the laminating step, and the feeding operation of the carrier film by the second nip roll are synchronized with each other. Control the dancer roll.

  Moreover, as said embodiment, the said dancer roll fixed position control process WHEREIN: The feeding operation | movement of the said laminated optical film by a said 1st nip roll and the bonding operation | movement to the optical cell of the optical film by the said bonding process are synchronous and the same speed. The feeding operation of the laminated optical film by the first nip roll, the laminating operation of the optical film to the optical cell by the laminating step, and the feeding operation of the carrier film by the second nip roll are made the same speed. To control the dancer roll.

  Moreover, as said embodiment, the said dancer roll fixed position control process is the optical operation of the optical film by the feeding operation of the said laminated | multilayer optical film by the said 1st nip roll, the feeding operation of the said carrier film by the said 2nd nip roll, and the said bonding process. The dancer roll is controlled by making all the bonding operations to the cells synchronous and at the same speed.

  As one embodiment of the invention, the dancer roll is a tension adjusting weight type accumulator.

As one embodiment of the invention, the dancer roll is configured to move by being controlled to maintain the tension applied to the laminated optical film,
In the distortion elimination step, the dancer roll is controlled to move in accordance with the result of distortion generated in the laminated optical film detected in advance while the optical film is bonded to the optical cell.

  In the distortion elimination step of the above embodiment, the following is exemplified as a control method for moving the dancer roll according to the result of the distortion. While the optical film is bonded to the optical cell (bonding period), the accumulator is operated with the dancer roll in its own weight state, and the amount of distortion generated in the laminated optical film is detected. The dancer roll is controlled so that the distortion is eliminated. That is, for example, the dancer roll is moved in response to a temporal variation in the amount of distortion that has been detected in advance during test production, thereby eliminating the expansion and contraction of the laminated optical film.

  Moreover, the following is illustrated as another example of the said control method. While the optical film is bonded to the optical cell (bonding period), the accumulator is operated with the dancer roll in its own weight, and the movement of the dancer roll during the bonding (dancer roll during the bonding period) Position, dancer roll speed, acceleration, etc.), and the dancer roll is controlled and moved in the same way as the recorded movement. That is, for example, the movement of the dancer roll under its own weight recorded in advance during test production is reproduced as it is during actual production.

  As one embodiment of the invention, the optical film has a thickness of 200 μm or less.

  As one embodiment of the invention, the optical film includes a polarizing film.

  In the present invention, the optical cell is a VA mode or IPS mode liquid crystal cell or an organic EL cell.

It is the schematic of the continuous manufacturing system of the optical display panel of Embodiment 1. FIG. It is a figure which shows the relationship between the dancer roll displacement of an Example, a film speed, and an infeed speed. It is an enlarged view which shows the relationship between the dancer roll displacement in the initial stage of a drive of FIG. 2A, a film speed, and an infeed speed. It is a figure which shows the relationship between the dancer roll displacement of a comparative example, a film speed, and an infeed speed. FIG. 3B is an enlarged view showing a relationship among a dancer roll displacement, a film speed, and an infeed speed in the initial driving stage of FIG. 3A.

The optical film roll 1 in FIG. 1 has a width corresponding to a pair of opposing sides of an optical cell, and has a strip-shaped optical film having an adhesive, and a strip-shaped laminated with the optical film via the adhesive. A belt-like laminated optical film having a carrier film is wound. As another embodiment, the belt-shaped laminated optical film is wound in a state where a plurality of score lines are formed in the width direction on the belt-shaped optical film.

<Optical film>
Examples of the optical film include a polarizing film. The film body of the polarizing film is, for example, a polarizer (thickness is generally about 1 to 80 μm) and a polarizer protective film (thickness is generally about 1 to 500 μm) attached to one or both sides of the polarizer. Formed without an agent or adhesive. A polarizer usually has an absorption axis in the stretching direction. A polarizing film including a long polarizer having an absorption axis in the longitudinal direction is also referred to as “MD polarizing film”, and a polarizing film including a long polarizer having an absorption axis in the width direction is also referred to as “TD polarizing film”. . Other films constituting the film body include, for example, retardation films such as λ / 4 plates and λ / 2 plates (thickness is generally 10 to 200 μm), viewing angle compensation films, brightness enhancement films, surface protection films, etc. Is mentioned. As for the thickness of a laminated optical film, the range of 10 micrometers-500 micrometers is mentioned, for example.

Examples of the other optical film include a linearly polarized light separating film and a reflective polarizing film having a multilayer structure having a reflection axis and a transmission axis.

  The pressure-sensitive adhesive is not particularly limited, and examples thereof include an acrylic pressure-sensitive adhesive, a silicone pressure-sensitive adhesive, and a urethane pressure-sensitive adhesive. The layer thickness of the pressure-sensitive adhesive is preferably in the range of 10 μm to 50 μm, for example. Examples of the peeling force between the pressure-sensitive adhesive and the carrier film include 0.15 (N / 50 mm width sample), but are not particularly limited thereto. The peeling force is measured according to JIS Z0237.

(Carrier film)
As the carrier film, for example, a conventionally known film such as a plastic film (for example, a polyethylene terephthalate film, a polyolefin film, or the like) can be used. In addition, if necessary, an appropriate material according to the prior art such as a silicone-based, long-chain alkyl-based, fluorine-based or molybdenum sulfide-coated material may be used. The carrier film is generally called a release film (separator film).

(Liquid crystal cell, liquid crystal display panel)
Examples of the optical cell include a liquid crystal cell and an organic EL cell. The liquid crystal cell has a structure in which a liquid crystal layer is sealed between a pair of substrates (a first substrate (viewing side surface) Pa and a second substrate (back surface) Pb) disposed to face each other. Although any type of liquid crystal cell can be used, it is preferable to use a vertical alignment (VA) mode or in-plane switching (IPS) mode liquid crystal cell in order to achieve high contrast. A liquid crystal display panel has a polarizing film bonded to one or both sides of a liquid crystal cell, and a drive circuit is incorporated as necessary.

(Organic EL cell, organic EL display panel)
The organic EL cell has a configuration in which an electroluminescent layer is sandwiched between a pair of electrodes. As the organic EL cell, for example, an arbitrary type such as a top emission method, a bottom emission method, a double emission method, or the like can be used. The organic EL display panel has a polarizing film bonded to one or both sides of an organic EL cell, and a drive circuit is incorporated as necessary.

<Embodiment 1>
FIG. 1 is a schematic diagram of an optical display panel continuous manufacturing system. Hereinafter, the continuous manufacturing system of the optical display panel according to the present embodiment will be specifically described with reference to FIG.

  In the present embodiment, a rectangular liquid crystal cell is used as an optical cell, and a rectangular liquid crystal display panel is used as an example of an optical display panel. As the optical film roll, the one shown in FIG. 1 is used. That is, as the optical film roll 1, a band-shaped polarizing film 11 (corresponding to an optical film) having an absorption axis in the longitudinal direction is laminated on a carrier film 12, and has a width corresponding to the long side of the liquid crystal cell P. A film in which the belt-shaped laminated optical film 10 is wound is used. Furthermore, in this embodiment, the strip | belt-shaped polarizing film 11 has the strip | belt-shaped film main body 11a and the adhesive 11b, and is comprised.

  As shown in FIG. 1, the continuous manufacturing system for a liquid crystal display panel according to this embodiment includes a series of transport units X that transport the liquid crystal cell P and the liquid crystal display panel LD, an optical film supply unit 101, and a bonding unit 81. including.

(Optical cell transfer unit)
The transport unit X transports the liquid crystal cell P and the liquid crystal display panel LD. The conveyance unit X includes a plurality of conveyance rollers X1, a suction plate, and the like.

(Optical film supply unit)
The optical film supply unit 101 feeds a strip-shaped laminated optical film 10 having a width corresponding to the long side of the liquid crystal cell P from the optical film roll 1, and a length corresponding to the short side of the liquid crystal cell P. The polarizing film 111 obtained by cutting in the width direction is supplied to the bonding part 81. In this embodiment, the optical film supply unit 101 includes a feeding unit 1a, a cutting unit 21, an infeed roll unit 31, an accumulating unit 41, a peeling unit 51, an outfeed roll unit 61, a winding unit 71, and a plurality of conveying rollers. Parts 101a, 101b, and 101c.

  The feeding unit 1 a has a feeding shaft on which the optical film roll 1 is installed, and feeds the belt-shaped laminated optical film 10 from the optical film roll 1.

  The cutting unit 21 includes a cutting unit 21a and a suction unit 21b, and half-cuts the belt-shaped laminated optical film 10 in the width direction with a length corresponding to the short side of the liquid crystal cell P (cuts the carrier film 12). Without cutting the strip-shaped polarizing film 11 in the width direction). In the present embodiment, the cutting unit 21 uses the cutting unit 21a to adsorb and fix the band-shaped laminated optical film 10 from the carrier film 12 side using the adsorbing unit 21b, and the band-shaped polarizing film 11 (the film main body 11a and the adhesive film). The agent 11b) is cut in the width direction, and a polarizing film 111 having a size corresponding to the liquid crystal cell P is formed on the carrier film 12. The cutting means 21a includes a cutter, a laser device, a combination thereof, and the like.

  The infeed roll unit 31 includes a pair of opposed first nip rolls 31 a and 31 b for sandwiching the laminated optical film 10 and feeding it to the downstream accumulator unit 41. At least one of the pair of nip rolls 31a and 31b includes a driving roller. The in-feed roll unit 31 may have a plurality of pairs of opposed rolls. The drive roller is a mechanism that rotates in conjunction with a motor (not shown).

The accumulation part 41 is arrange | positioned downstream of the infeed roll part 31, and has the tension | tensile_strength weight part 41a and the dancer roll 41b. The accumulator 41 has a function of maintaining the tension of the belt-shaped laminated optical film 10.

  The peeling part 51 peels the polarizing film 111 from the carrier film 12 by folding the band-shaped laminated optical film 10 with the carrier film 12 inside. Examples of the peeling part 51 include a wedge-shaped member and a roller.

  The outfeed roll unit 61 includes a pair of opposing second nip rolls 61 a and 61 b for sending the carrier film 12 from which the polarizing film 111 has been peeled off by the peeling unit 51 to the downstream winding unit 71. At least one of the pair of nip rolls 61a and 61b is constituted by a drive roller. The outfeed roll unit 61 may include a plurality of pairs of opposed rolls. The drive roller is a mechanism that rotates in conjunction with a motor (not shown).

  The winding unit 71 is disposed on the downstream side of the outfeed unit 61, and winds the carrier film 12 from which the polarizing film 111 has been peeled off on a winding roll 71a. The winding unit 71 is a mechanism that rotates in conjunction with a motor (not shown).

(Pasting part)
The bonding unit 81 was supplied by the optical film supply unit 101 (peeled by the peeling unit 51) while transporting the liquid crystal cell P transported by the transport unit X with its short side direction parallel to the transport direction. The polarizing film 111 is bonded to the surface Pb in the ceiling direction of the liquid crystal cell P through the adhesive 11b along the supply direction of the polarizing film 111 (the short side direction of the liquid crystal cell P) from the long side of the liquid crystal cell P. Note that the bonding unit 81 includes a pair of bonding rollers 81a and 81b, and at least one of the bonding rollers 81a and 81b includes a driving roller. The drive roller is a mechanism that rotates in conjunction with a motor (not shown).

(Distortion elimination part)
The distortion eliminating unit 91 acts to relieve the distortion generated in the laminated optical film 10 while the polarizing film 111 is bonded to the liquid crystal cell P. Specifically, the distortion eliminating unit 91 includes an inertial force control unit 91a, and the inertial force control unit 91a is applied per 100 mm width of the carrier film 12 while the polarizing film 111 is bonded to the liquid crystal cell P. The force by the inertial force of the dancer roll 41b is controlled to be 1.8N or less. As a control method therefor, for example, the inertial force control unit 91a checks the acceleration when the dancer roll is moved, thereby suppressing the movement of the dancer roll 41b.

<Another control method>
As another control method, the dancer roll 41 b is configured to automatically move so as to maintain the tension applied to the laminated optical film 10. The distortion eliminating unit 91 includes a dancer roll fixed position control unit 91b. The dancer roll fixed position control unit 91b moves the dancer roll 41b from the fixed position while the polarizing film 111 is bonded to the liquid crystal cell P. Control to not. Specifically, the dancer roll fixed position control unit 91b stops the dancer roll 41b at a fixed position by moving the infeed roll unit 31 and the bonding unit 81 that feed the laminated film in synchronization and at the same speed.

  In addition, as another control method, the dancer roll fixed position control unit 91b is further controlled to synchronize and speed the infeed roll unit 31 and the bonding unit 81 for feeding the laminated film as described above. The dancer roll 41b is controlled by moving the feed roll unit 61 in synchronization. The dancer roll fixed position control unit 91b controls the rotation timing of the motor interlocked with each of the infeed roll unit 31, the outfeed roll unit 61, and the bonding unit 81, and performs control so as to be synchronized.

  In addition, as another control method, the dancer roll fixed position control unit 91b is further wound in addition to the infeed roll unit 31 and the bonding unit 81 for feeding the laminated film synchronously and at the same speed as described above. The dancer roll 41b is controlled by moving the catch portion 71 at the same speed. The dancer roll fixed position control unit 91b controls each motor so that the rotation speeds of the motors linked to the infeed roll unit 31, the outfeed roll unit 61, and the bonding unit 81 are the same.

  As another control method, the dancer roll fixed position control unit 91b is movable while the in-feed roll unit 31, the out-feed roll unit 61, and the bonding unit 81 that send out the laminated optical film 10 are synchronized and at the same speed. Thus, the dancer roll 41b is controlled. The dancer roll fixed position control unit 91b controls and synchronizes the rotation timings of the motors linked to the infeed roll unit 31, the outfeed roll unit 61, and the bonding unit 81, and the rotation speed is the same. Control each motor.

  As another control method, the dancer roll 41b is configured to move by being controlled so as to maintain the tension applied to the laminated optical film 10. And the distortion elimination part 91 is controlled so that the dancer roll 41b is moved according to the result of the distortion which arises in the laminated | multilayer optical film 10 detected beforehand, while bonding the polarizing film 111 to the liquid crystal cell P. FIG. To do. Using the amount of strain (distribution of strain during the period from strain generation to strain relaxation in the initial stage of driving) detected in advance (measured in advance such as during trial manufacture or previous actual manufacturing) The dancer roll can be moved to eliminate distortion. For example, the dancer roll is moved in a direction in which the distortion is eliminated in response to the temporal variation of the distortion amount detected in advance. If the laminated optical film stretches in the longitudinal direction, the dancer roll is moved to reduce the stretched amount of the laminated optical film, or the dancer roll is moved to reduce the stretch of the laminated optical film when the laminated optical film begins to stretch. Can be made. Alternatively, a sensor that detects the vertical position of the dancer roll may be used to feed back and control each feed roll based on the detection data.

  The operation timing of each of the above units and devices is calculated by, for example, a method in which a sensor is arranged at a predetermined position and detected, or calculated by detecting the rotating member of the transfer unit or transfer mechanism with a rotary encoder or the like. Is done. The distortion eliminating unit 91 and various control units (not shown) may be realized by the cooperation of a software program and hardware resources such as a CPU and a memory. In this case, the program software, processing procedure, various settings, etc. A memory is stored in advance. Further, it can be configured by a dedicated circuit or firmware.

(Modification of Embodiment 1)
In the first embodiment, it has been described that the polarizing film is bonded to the one surface Pa of the liquid crystal cell P by the bonding unit 81, but the present invention is not limited thereto. The present invention can be used, for example, when an optical film is bonded to the other surface Pb of the liquid crystal cell P, or when the optical film is bonded to both surfaces of the liquid crystal cell P. Moreover, although the bonding part 81 bonded the polarizing film from the upper side of the liquid crystal cell P, it is not limited to this, You may bond from the lower side of a liquid crystal cell. In addition, the bonding unit 81 transports the polarizing film 111 from the long side of the liquid crystal cell P (the direction of the liquid crystal cell P) while transporting the liquid crystal cell P with the short side direction parallel to the transport direction. Although the liquid crystal cell P is transported with the long side direction parallel to the transport direction, the polarizing film 111 is supplied from the short side of the liquid crystal cell P in the supply direction of the polarizing film 111. You may bond together (long side direction of the liquid crystal cell P).

  In Embodiment 1, as the optical film roll, a roll-shaped laminated optical film obtained by laminating a band-shaped optical film on a carrier film is used, but the configuration of the optical film roll is not limited to this. For example, by appropriately using a belt-shaped laminated optical film formed by laminating a band-shaped optical film in which a plurality of score lines are formed in the width direction on a carrier film (a cut optical film roll). Also good. In addition, a cutting part becomes unnecessary in the optical film supply part which supplies an optical film from the optical film roll with a notch.

  In the first embodiment, the cutting unit cuts the band-shaped optical film in the width direction and forms the optical film having a size corresponding to the optical cell on the carrier film. However, from the viewpoint of improving the yield, the band-shaped optical film is formed. The band-shaped optical film is cut in the width direction (skip cut) so as to avoid the defective part of the optical film of the optical film of the size corresponding to the optical cell on the carrier film (the non-defective optical that is bonded to the optical cell) In addition to forming a film, an optical film including a defect portion may be formed in a size smaller than the optical cell (more preferably in a size as small as possible).

<Manufacturing method>
The continuous manufacturing method of the optical display panel of this embodiment is a pair of first laminated optical films having an optical film having an adhesive and a belt-like carrier film laminated with the optical film via the adhesive. A first feeding step for feeding downstream by a nip roll; an accumulating step by a dancer roll disposed downstream of the first nip roll; and a peeling step for folding the carrier film inside and peeling the optical film from the carrier film And a second delivery step of feeding the carrier film from which the optical film has been peeled off by the peeling step to the downstream with a pair of second nip rolls, and winding the carrier film on a roll disposed downstream of the 2 nip rolls A winding process, an optical cell transport process for transporting the optical cell, and
A bonding step of forming the optical display panel by bonding the optical film peeled in the peeling step while transporting the optical cell to the optical cell via the adhesive. And the distortion elimination process which relieve | moderates the distortion which arose in the said laminated | multilayer optical film, while bonding the said optical film to the said optical cell is included.

  The distortion elimination step is controlled so that the force due to the inertial force of the dancer roll applied per 100 mm width of the carrier film is 1.8 N or less while the optical film is bonded to the optical cell. Including an inertial force control step. The inertial force control step may suppress the movement of the dancer roll by examining the acceleration when the dancer roll is movable.

  As another embodiment, the dancer roll is configured to automatically move so as to maintain the tension applied to the laminated optical film. And the said distortion elimination process includes the dancer roll fixed position control process controlled so that the said dancer roll is not moved from a fixed position, while bonding the said optical film to the said optical cell.

  As another embodiment, in the dancer roll fixed position control step, the feeding operation of the laminated optical film by the first nip roll and the bonding operation of the optical film to the optical cell by the bonding step are synchronized and at the same speed. The dancer roll is controlled so that

  As another embodiment, in the dancer roll fixed position control step, the feeding operation of the laminated optical film by the first nip roll and the bonding operation of the optical film to the optical cell by the bonding step are synchronized and at the same speed. The feeding operation of the laminated optical film by the first nip roll, the laminating operation to the optical cell of the optical film by the laminating step, and the feeding operation of the carrier film by the second nip roll are synchronized with each other. Control the dancer roll.

  As another embodiment, in the dancer roll fixed position control step, the feeding operation of the laminated optical film by the first nip roll and the bonding operation of the optical film to the optical cell by the bonding step are synchronized and at the same speed. The feeding operation of the laminated optical film by the first nip roll, the laminating operation of the optical film to the optical cell by the laminating step, and the feeding operation of the carrier film by the second nip roll are made the same speed. To control the dancer roll.

  Moreover, as said embodiment, the said dancer roll fixed position control process is the optical operation of the optical film by the feeding operation of the said laminated | multilayer optical film by the said 1st nip roll, the feeding operation of the said carrier film by the said 2nd nip roll, and the said bonding process. The dancer roll is controlled by making all the bonding operations to the cells synchronous and at the same speed.

  As another embodiment, the dancer roll is configured to move by being controlled so as to maintain the tension applied to the laminated optical film. The distortion eliminating step is controlled to move the dancer roll according to a result of distortion generated in the laminated optical film detected in advance while the optical film is bonded to the optical cell. To do.

<Embodiment 2>
The second embodiment has the same function as that of the first embodiment, and a configuration unique to the second embodiment will be described below.

  The distortion eliminating unit 91 of the second embodiment controls the dancer roll 41b to move while applying a brake so as to reduce or eliminate (substantially eliminate) the swing generated when the dancer roll 41b moves. Thereby, bubble generation at the initial stage of bonding can be suppressed.

<Example>
The following Examples 1-6 were performed using the continuous manufacturing system of FIG. A polarizing film (VEGQ1724DU manufactured by Nitto Denko Corporation) was bonded to a liquid crystal cell (40 inch size) using the manufacturing system shown in FIG.

  In Examples 1 to 6 and Comparative Examples 1 to 3, the thickness of the laminated optical film, the film feeding (conveying) speed of each of the infeed roll part, the outfeed roll part and the bonding part (hereinafter referred to as “infeed speed”, Called "outfeed speed", "bonding speed"), timing with other components (synchronous or asynchronous), maximum inertial force of dancer roll (N), dancer roll action (non-moving (stop), movable), The dancer roll control method (tension adjustment weight type, control based on the amount of strain detected in advance) was changed as shown in Table 1. The maximum inertia force was obtained from the product of acceleration and mass (the mass of the dancer roll and tension adjusting weight) obtained from the displacement speed of the dancer roll. Bubble generation after pasting was evaluated. For the bubble evaluation, 500 sheets were attached and observed visually, and the rate at which bubbles were generated was calculated.

  In Example 1, the infeed speed, the outfeed speed, and the bonding speed were all synchronized and the same speed, and the dancer roll was controlled so as not to move (immobilize), so that the speed fluctuation of the laminated optical film was small. Therefore, no bubble generation was observed. In FIG. 2A, the infeed speed (same as the outfeed speed or the pasting speed) during the pasting period, which is the period during which the polarizing film is pasted on the liquid crystal cell in Example 1, the laminated optical film speed, the dancer roll Indicates displacement. FIG. 2B is an enlarged view of the initial stage of driving in FIG. 2A.

  In Example 2, the infeed speed was made slower than the outfeed speed or the bonding speed. Therefore, a part of the laminated optical film housed in the dancer roll is discharged (supplied downstream), so that the dancer roll is in a movable state. However, since the acceleration was small and no large speed fluctuation occurred, the results were better than those of Comparative Examples 1 to 3.

  In Example 3, the outfeed roll moved later than the infeed roll and the bonding roll, and was asynchronous. Therefore, since the outfeed moves from the middle of the infeed and the bonding roll moving, and the peeling of the polarizing film from the carrier film begins, it is estimated that, for example, chattering (fine vibrations) has occurred at the start of peeling. Although the result was better than those of Examples 1 to 3, some bubbles were generated.

  In Example 4, the outfeed speed was slower than the infeed speed and the bonding speed. Therefore, peeling does not occur along the peeling part (in a state where the carrier film is wound inside), and the reflex part (reversing part) of the carrier film protrudes from the leading edge of the peeling part and floats from the leading edge of the peeling part In this state, the polarizing film continued to peel from the carrier film and was unstable. In Examples 3 and 4, the outfeed roll moves after the infeed roll and the bonding roll (moves at a lower speed), but the polarizing film is sandwiched between the pair of bonding rolls before being driven. If the feed roll and the bonding roll move synchronously, the tension adjusting weight will not move.

  Example 5 was the same conditions as Example 1 except that the thickness of the laminated optical film was 250 μm, and no generation of bubbles was observed.

  In Example 6, control based on the amount of distortion detected in advance was performed. The infeed speed was slightly slower than the outfeed speed and the pasting speed. However, it was faster than Example 2. Since a part of the laminated optical film housed in the dancer roll was discharged (supplied downstream) as in Example 2, the dancer roll was movable. However, since the dancer roll was driven by itself, there was almost no inertial force and no large speed fluctuation occurred, so no bubbles were observed.

  Comparative Example 1 was the same as Example 1 except that the infeed speed was 0 and asynchronous. Therefore, the acceleration of the dancer roll was large, and the film speed fluctuated greatly accordingly. As a result, many bubbles were observed. FIG. 3A shows the infeed speed, the bonding speed, and the displacement of the dancer roll during the bonding period in which the polarizing film is bonded to the liquid crystal cell in Comparative Example 1. FIG. 3B is an enlarged view of the initial stage of driving in FIG. 3A. Compared with FIGS. 2A and 2B, it can be clearly seen that the laminated optical film speed varies greatly.

  Comparative Example 2 was under the same conditions as in Example 2 except that the infeed speed was slower than in Example 2. Therefore, the speed difference between the bonding speed and the infeed speed was increased, the laminated optical film stored in the dancer roll was discharged (supplied downstream), and the dancer roll moved with a large acceleration. Since the acceleration was large and the film speed fluctuation was large, the bubble generation rate was high.

  Comparative Example 3 had the same conditions as Comparative Example 1 except that the thickness of the laminated optical film was 250 μm. Even when the thickness increased, the laminated optical film housed in the dancer roll was discharged (supplied downstream), and the dancer roll moved with a large acceleration. Since the acceleration was large and the film speed fluctuation was large, the bubble generation rate was high. However, the result was better than Comparative Example 1. That is, the thinner the laminated optical film is, the lower the rigidity and the greater the elasticity, and thus the greater the influence on the speed fluctuation. However, the present invention has a more remarkable effect in the laminated optical film with a small thickness. It can be done.

DESCRIPTION OF SYMBOLS 1 Optical film roll 21 Cutting | disconnection part 31 Infeed roll part 31a, 31b 1st pair of nip roll 41 Accumulation part 51 Separation part 61 Outfeed roll part 61a, 61b 2nd pair of nip roll 71 Winding part 71a Winding roll 81 Bonding part P Liquid crystal cell LD Liquid crystal display panel X Conveyance part (optical cell conveyance part)

Claims (20)

A pair of first nip rolls for feeding a laminated optical film having an optical film having an adhesive and a band-shaped carrier film on which the optical film is laminated via the adhesive, downstream of the first nip roll An accumulator part having a dancer roll disposed on the substrate, a peeling part for folding the carrier film inside to peel off the optical film from the carrier film, and the carrier film from which the optical film has been peeled off by the peeling part. A pair of second nip rolls that are sent downstream; a winding unit that winds the carrier film around a roll disposed downstream of the two nip rolls;
An optical cell transport unit for transporting the optical cell;
A continuous production of an optical display panel comprising: an optical display panel formed by laminating the optical film peeled at the peeling portion while transporting the optical cell to the optical cell via the adhesive. A system,
A continuous manufacturing system of an optical display panel comprising a distortion eliminating section that relaxes distortion generated in the laminated optical film by controlling an inertial force of the dancer roll while the optical film is bonded to the optical cell.   The distortion eliminating unit controls the force due to the inertial force of the dancer roll, which is applied per 100 mm width of the carrier film, to 1.8 N or less while the optical film is bonded to the optical cell. The continuous manufacturing system for an optical display panel according to claim 1, further comprising an inertial force control unit.   The continuous display system for an optical display panel according to claim 2, wherein the inertial force control unit suppresses the movement of the dancer roll by examining acceleration when the dancer roll is movable. The dancer roll is configured to automatically move so as to maintain the tension applied to the laminated optical film,
The distortion eliminating unit includes a dancer roll fixed position control unit that controls the dancer roll not to move from a fixed position while the optical film is bonded to the optical cell .
The dancer roll fixed position control unit controls the dancer roll so that the first nip roll for feeding the laminated optical film and the bonding unit move synchronously and at the same speed. The continuous manufacturing system of the optical display panel as described in the item. 5. The continuous optical display panel according to claim 4 , wherein the dancer roll fixed position control unit controls the dancer roll by moving the first nip roll, the bonding unit, and the second nip roll in synchronization with each other. Manufacturing system. The optical display panel according to claim 4 or 5 , wherein the dancer roll fixed position control unit controls the dancer roll by moving the first nip roll, the bonding unit, and the second nip roll at the same speed. Continuous manufacturing system. The continuous production system for an optical display panel according to any one of claims 4 to 6 , wherein the dancer roll is a tension-type weight accumulator. The dancer roll is configured to move by being controlled to maintain the tension applied to the laminated optical film,
The distortion eliminating unit controls the dancer roll to move according to a result of distortion generated in the laminated optical film detected in advance while the optical film is bonded to the optical cell. Item 3. The continuous production system for an optical display panel according to Item 1 or 2. The optical film continuous manufacturing system of an optical display panel according to any one of claims 1 to 8, the thickness is 200μm following. The continuous manufacturing system of the optical display panel of any one of Claims 1-9 in which the said optical film contains a polarizing film. A first delivery step of sending a laminated optical film having an optical film having an adhesive and a band-shaped carrier film laminated with the optical film via the adhesive to a downstream by a pair of first nip rolls; The optical film was peeled off by an accumulating step by a dancer roll disposed on the downstream side of one nip roll, a peeling step in which the carrier film was turned inside to peel off the optical film from the carrier film, and the peeling step. A second feeding step of feeding the carrier film downstream with a pair of second nip rolls, and a winding step of winding the carrier film on a roll disposed downstream of the two nip rolls;
An optical cell transporting process for transporting the optical cell;
A bonding step of forming an optical display panel by bonding the optical film peeled in the peeling step while transporting the optical cell to the optical cell via the pressure-sensitive adhesive. A method,
A continuous manufacturing method of an optical display panel including a distortion eliminating step of relaxing distortion generated in the laminated optical film by controlling an inertial force of the dancer roll while the optical film is bonded to the optical cell. The distortion elimination step is controlled so that the force due to the inertial force of the dancer roll applied per 100 mm width of the carrier film is 1.8 N or less while the optical film is bonded to the optical cell. The method for continuously producing an optical display panel according to claim 11 , comprising an inertial force control step. The continuous manufacturing method of the optical display panel according to claim 12 , wherein the inertial force control step suppresses the movement of the dancer roll by examining acceleration when the dancer roll is movable. The dancer roll is configured to automatically move so as to maintain the tension applied to the laminated optical film,
The distortion eliminating step, while bonding the optical film to the optical cell, seen including a dancer roller position controlling process of controlling the dancer rolls so as not to move from the home position,
In the dancer roll fixed position control step, the dancer roll is configured such that the feeding operation of the laminated optical film by the first nip roll and the bonding operation of the optical film to the optical cell by the bonding step are synchronized and at the same speed. The continuous manufacturing method of the optical display panel of any one of Claims 11-13 which controls these . The dancer roll fixed position control step includes a feeding operation of the laminated optical film by the first nip roll, a laminating operation of the optical film to the optical cell by the laminating step, and a feeding operation of the carrier film by the second nip roll. The continuous manufacturing method of the optical display panel according to claim 14 , wherein the dancer roll is controlled by synchronizing. The dancer roll fixed position control step includes a feeding operation of the laminated optical film by the first nip roll, a laminating operation of the optical film to the optical cell by the laminating step, and a feeding operation of the carrier film by the second nip roll. The continuous manufacturing method of the optical display panel according to claim 14 or 15 , wherein the dancer roll is controlled by setting the same speed. The method for continuously producing an optical display panel according to any one of claims 14 to 16 , wherein the dancer roll is an accumulator portion of a tension adjustment weight type. The dancer roll is configured to move by being controlled to maintain the tension applied to the laminated optical film,
The distortion eliminating step controls the dancer roll to move according to a result of distortion generated in the laminated optical film detected in advance while the optical film is bonded to the optical cell. Item 13. A method for continuously producing an optical display panel according to Item 11 or 12 . The method for continuously producing an optical display panel according to claim 11 , wherein the optical film has a thickness of 200 μm or less. The continuous manufacturing method of the optical display panel of any one of Claims 11-19 in which the said optical film contains a polarizing film.

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