JP6356891B1 - Method and apparatus for manufacturing a laminate of an optical display device - Google Patents

Abstract

A method and apparatus for manufacturing a laminate in which optical film sheets having a size corresponding to both sides of a rectangular liquid crystal panel are laminated on both sides of the liquid crystal panel with high precision positioning. A strip-shaped first carrier film that continuously supports a first optical film sheet and a second optical film sheet having a corresponding width or length on both sides of a rectangular liquid crystal panel, and In the production of a laminate for an optical display device to be peeled off and bonded from the second carrier film, only two positions at both ends of the long side of the rectangular first optical film sheet and the second optical film sheet are provided. Detecting and aligning both sides of the liquid crystal panel corresponding to each of the optical film sheets based on the position information of both ends, the first optical film sheet from each of the first carrier film and the second carrier film And the 2nd optical film sheet is peeled and it bonds together on both surfaces of a liquid crystal panel. [Selection] Figure 3

Description

The present invention relates to an optical display device in which an optical film sheet having a polarizing film of a size corresponding to each of both surfaces of a rectangular liquid crystal panel is laminated on both surfaces of the liquid crystal panel so that the absorption axis is in a crossed Nicol relationship. TECHNICAL FIELD The present invention relates to a method and an apparatus for manufacturing a laminate.

In the manufacture of an optical display device, the roll-to-panel (RTP) method is well known as described in Japanese Patent Application Laid-Open No. H10-228707. For example, in the RTP method for manufacturing a liquid crystal optical display device, the optical display device is normally manufactured as follows.

As shown in FIG. 2, first, the width or length of one side of the rectangular liquid crystal panel is formed on the first carrier film included in the strip-shaped first optical film laminate drawn out from R1. A first optical film sheet continuously supported so that a long side having a width or length corresponding to the length faces the width direction of the first carrier film is bonded to the one surface of the liquid crystal panel, And on the 2nd carrier film contained in the beltlike 2nd optical film layered product extended from R2, the long side which has the width or length corresponding to the width or length of the other side of the liquid crystal panel is The second optical film sheet continuously supported so as to face the longitudinal direction of the second carrier film is bonded to the other surface of the liquid crystal panel.

Thereby, the first and second optical film sheets are laminated on both sides of the liquid crystal panel so as to be in a crossed Nicol relationship with each other while being peeled off from each of the first and second carrier films. A laminated optical display is continuously manufactured.

The technical problem required in that case is high-accuracy positioning between the optical film sheet and the liquid crystal panel. It is an optical film sheet that is peeled off from a band-shaped carrier film and sent to a bonding position, and one side or the other side of a rectangular liquid crystal panel that is conveyed to the bonding position in synchronization with the optical film sheet is accurately positioned and laminated. This is to make it happen.

Therefore, in the production of such RTP method, as shown in Patent Document 2, the optical film sheet continuously supported on the carrier film is peeled from the carrier film, sent to the bonding position, and peeled off. When the film sheet is bonded to one surface or the other surface of the liquid crystal panel that is conveyed to the bonding position in synchronization with the film sheet, the one surface or the other surface of the liquid crystal panel is accurately positioned with respect to the optical film sheet. A process is included.

In the production of the RTP method, a peeling means for peeling the optical film sheet continuously supported on the carrier film together with the pressure-sensitive adhesive layer is arranged near the bonding position. The peeling means is preferably a peeling means made of a substantially wedge-shaped peeling body having a top portion facing the bonding position.

The optical film sheet is peeled from the carrier film together with the pressure-sensitive adhesive layer by being transported while being folded back in a direction substantially opposite to the transport direction of the optical film sheet at the top of the substantially wedge-shaped peeled body. Head over. The optical film sheet that has reached the bonding position is bonded to the corresponding bonding surface of the liquid crystal panel that is transported after being adjusted to the bonding position in synchronization therewith.

On the other hand, in recent years, the manufacture of optical display devices has been further reduced in size, thickness, and weight, while the frame portion surrounding the liquid crystal display area has been narrowed, that is, the frame has been narrowed. In the manufacturing process with few troubles, there is a further demand for accurate positioning of the optical film sheet with respect to the liquid crystal panel.

In Patent Document 2, edge detection is performed to adjust the angle of the rectangular panel so that the center line in the feeding direction of the rectangular panel conveyed to the bonding position is parallel to the center line of the optical film sheet that is also sent to the bonding position. An apparatus and a linear movement position detection device that detects the tip position of an optical film sheet at a bonding station, and a method for adjusting the position by parallel movement after the angle adjustment by a deviation amount in parallel positional relationship are disclosed.

In Patent Document 3, before the optical film sheet to be bonded to the panel member at the predetermined sticking position reaches the predetermined sticking position together with the panel member, the tip of the optical film sheet supported by the belt-like carrier film via the adhesive layer Is read in advance by the tip detection means, and is made to coincide with the position where the panel member is pasted and pasted to the panel member while being peeled off from the carrier film.

In Patent Document 4, bonding is performed at a corresponding position of the substrate so that the end surface on the traveling direction side and the cut surface of the film piece peeled off from the release film are parallel to the substrate conveyed to the bonding position. Means are disclosed.

Patent Document 5 discloses an apparatus that reads a corner of a retardation film in conjunction with the stop of the operation of the retardation film corner detection mechanism, in which the panel suction conveyance mechanism is interlocked with the retardation film attaching mechanism, and includes an image recognition camera. .

Patent Document 6 also discloses a first optical film laminate including a first optical film sheet having a width corresponding to the long side of the rectangular substrate and a length corresponding to the short side, and a short side of the rectangular substrate. A method is disclosed in which a second optical film laminate including a second optical film sheet having a length corresponding to a width and a long side is sequentially fed and bonded to both sides of a rectangular substrate.

In any case, the present inventors proceeded diligently to maintain the manufacturing speed of the optical display device by shortening the tact time and reducing the trouble in the manufacturing of the RTP method. The present invention includes an accurate positioning process required for bonding a liquid crystal panel and an optical film sheet, which cannot be assumed from the technology.

Japanese Patent No. 4377964 Japanese Patent No. 4644755 Japanese Patent No. 5458212 JP 2005-037416 A JP 2003-107246 A Japanese Patent No. 5616494

The problem is that the optical film sheet is peeled off and bonded to the rectangular liquid crystal panel from the band-shaped carrier film that supports the optical film sheet having a width or length corresponding to the width or length, thereby optical display. In the method of manufacturing the laminated body of the apparatus, it is to realize highly accurate alignment of the bonding surface of the liquid crystal panel with the optical film sheet while maintaining the tact time.

For this purpose, as shown in Patent Document 3, it is necessary to read the leading end position of the optical film sheet using an imaging device such as a camera and to specify the exact position of the liquid crystal panel to be bonded based on the positional information. is there. In that case, it is unavoidable that all the positions of the four corners of the rectangular optical film sheet are read and the alignment of the liquid crystal panel based on them is complicated.

In order to simplify the bonding of the complicated liquid crystal panel to the optical film sheet, the present invention has been intensively studied, such as whether the positions of the four corners of the optical film sheet can be set in time at the two or three corners. It came to.

The above problem is that the first and second optical film sheets having widths or lengths corresponding to the respective widths or lengths on both surfaces of a rectangular liquid crystal panel are continuously supported in the first and second optical film sheets. And a method of manufacturing a laminated body of an optical display device that is peeled off and bonded from the second carrier film, and detects only both end positions of the long sides of the rectangular first and second optical film sheets, Based on the position information, the bonding surfaces of the liquid crystal panels corresponding to the optical film sheets are aligned, the first and second carrier films are peeled from each of the first and second carrier films, and the liquid crystal panel It is solved by sticking to both sides sequentially or simultaneously.

One embodiment of the present invention provides a method for manufacturing a laminate 6 of an optical display device. It has a width or length corresponding to the width or length of one surface 50 of the rectangular liquid crystal panel 5 as shown in the schematic plan view of FIG. 2 and the schematic view of FIG. The first side having a size corresponding to one surface 50 of the liquid crystal panel 5 that is continuously supported on the first carrier film 30 in a strip shape so that the long side y10 faces the width direction of the first carrier film 30. The optical film sheet 10 is peeled off from the first carrier film 30 and bonded to the one surface 50 of the liquid crystal panel 5 and has a width or length corresponding to the width or length of the other surface 51 of the liquid crystal panel 5. The second side having a size corresponding to the other surface 51 of the liquid crystal panel 5 continuously supported on the belt-like second carrier film 31 so that the long side y11 faces the longitudinal direction of the second carrier film 31. Optical fi The Mushito 11, a method was peeled off from the second carrier film 31 to produce a laminate 6 of the optical display apparatus that bonded to the other surface 51 of the liquid crystal panel 5.

It also stops feeding of the first carrier film 30 when the leading end or the trailing end 101 of the first optical film sheet 10 reaches a predetermined first detection position 70 as shown in FIG. , A step of detecting one end 102 or the other end 103 which are both end positions in the width direction of the front end portion or the rear end portion 101 corresponding to the long side y10 of the first optical film sheet 10; Based on position information 200 consisting of one end 102 and the other end 103, the step of aligning one surface 50 of the liquid crystal panel 5 with the first optical film sheet 10, and the first optical film sheet 10 with the first carrier film The process of peeling from 30 and bonding to the one surface 50 of the liquid crystal panel 5 can be included. 4 includes a device 104 that reads one end 102 and the other end 103 of both ends in the width direction of the rear end portion 101 corresponding to the long side y10 of the first optical film sheet 10 with an imaging device such as a camera. It is an expansion schematic diagram of the pasting station 120.

Further, as shown in FIG. 5, when the leading end 111 of the second optical film sheet 11 reaches a predetermined second detection position 71, the feeding of the second carrier film 31 is stopped, A step of detecting both end positions of the front end 112 and the rear end 113 of the side end portion 111 corresponding to the long side y11 of the optical film sheet 11, and from the front end 112 and the rear end 113 of both end positions of the side end portion 111. Based on the positional information 210, the step of aligning the other surface 51 of the liquid crystal panel 5 with the second optical film sheet 11 and the second optical film sheet 11 are peeled off from the second carrier film 31 to form the liquid crystal panel 5 The process of attaching to the other side 51 of this can also be included. FIG. 5 includes a first device 114 that reads the positions of either the front end 112 and the rear end 113 of the side end 111 corresponding to the long side y11 of the second optical film sheet 11 with an imaging device such as a camera. It is an expansion schematic diagram of the pasting station 220.

In the method of the present invention, the first optical film sheet 10 is made of a first polarizing film, the second optical film sheet 11 is made of a second polarizing film, and the one surface 50 of the liquid crystal panel 5 is placed on the TFT side. The other surface 51 of the liquid crystal panel 5 can be a CF-side surface.

Similarly, in the method of the present invention, the step of detecting one end 102 and the other end 103 at both end positions in the width direction of the first optical film sheet 10 is a step of calculating a deviation angle θ1 between the one end 102 and the other end 103. The step of detecting the front end 112 and the rear end 113 at either end position of either one of the side end portions 111 of the second optical film sheet 11 calculates a deviation angle θ2 between the rear end 113 and the front end 112. A process can be further included.

Similarly, in the method of the present invention, the step of aligning the one surface 50 of the liquid crystal panel 5 and the first optical film sheet 10 by calculating the shift angle θ1 between the both end positions in the width direction of the first optical film sheet 10. Is positioned on one surface 50 of the liquid crystal panel 5 on the first optical film sheet 10 on the basis of the deviation angle θ1, while the deviation angle θ2 between the positions of either one of the side end portions 111 of the second optical film sheet 11. In the step of aligning the other surface 51 of the liquid crystal panel 5 and the second optical film sheet 11 by calculating the above, the other surface 51 of the liquid crystal panel 5 is positioned on the second optical film sheet 11 based on the shift angle θ2. can do.

Similarly, in the method of the present invention, as shown in FIG. 4 and FIG. 5, the first optical film sheet 10 is fed to the first carrier film 30 while the first carrier film 30 is fed back at the top 601 of the first release body 60. A step of peeling from the carrier film 30 and a step of peeling the second optical film sheet 11 from the second carrier film 31 while feeding back the second carrier film 31 at the top 611 of the second peeling body 61. In addition, the step of peeling the first optical film sheet 10 from the first carrier film 30 and bonding the first optical film sheet 10 to the one surface 50 of the liquid crystal panel 5 restarts the feeding of the first carrier film 30 that has stopped feeding, Thereby, the first optical film sheet 10 is bonded to the one surface 50 of the liquid crystal panel 5 while being peeled off from the first carrier film 30. And the step of peeling the second optical film sheet 11 from the second carrier film 31 and bonding it to the other surface 51 of the liquid crystal panel 5 includes feeding the second carrier film 31 that has stopped feeding. The process of resuming and bonding the second optical film sheet 11 to the other surface 51 of the liquid crystal panel 5 while peeling from the second carrier film 31 can be included.

Another embodiment of the present invention provides an apparatus for manufacturing a laminate 6 of an optical display device. It has a width or length corresponding to the width or length of one surface 50 of the rectangular liquid crystal panel 5 as shown in the schematic plan view of FIG. 2 and the schematic view of FIG. The first corresponding to the first surface 50 of the liquid crystal panel 5 that is continuously supported on the first carrier film 30 in a strip shape so that the long side y10 faces the width direction of the first carrier film 30. The optical film sheet 10 is peeled off from the first carrier film 30 and bonded to one surface 50 of the liquid crystal panel 5, and the width or length corresponding to the width or length of the other surface 51 of the liquid crystal panel 5 is set. The second carrier film 31 having a size corresponding to the other surface 51 of the liquid crystal panel 5 continuously supported on the second carrier film 31 having a long side y11 facing the longitudinal direction of the second carrier film 31. 2 optics The Irumushito 11 is an apparatus for manufacturing a laminated body 6 of the optical display device by peeling off from the second carrier film 31 adhered to the other surface 51 of the liquid crystal panel 5.

It also stops feeding of the first carrier film 30 when the leading end or the trailing end 101 of the first optical film sheet 10 reaches a predetermined first detection position 70 as shown in FIG. The first detection means 701 for detecting one end 102 at both ends in the width direction of the front end or rear end 101 corresponding to the long side y10 of the first optical film sheet 10 and the other end 103 at both ends are detected. Based on the second detection means 702 and position information 200 consisting of one end 102 and the other end 103 at both end positions in the width direction, the first surface 50 of the liquid crystal panel 5 and the first optical film sheet 10 are aligned. And the first bonding means 90 that peels the first optical film sheet 10 from the first carrier film 30 and bonds the first optical film sheet 10 to the one surface 50 of the liquid crystal panel 5. It is a non-device 1. 4 includes a device 104 that reads one end 102 and the other end 103 of both ends in the width direction of the rear end portion 101 corresponding to the long side y10 of the first optical film sheet 10 with an imaging device such as a camera. It is an expansion schematic diagram of the pasting station 120.

Further, as shown in FIG. 5, when the leading end 111 of the second optical film sheet 11 reaches a predetermined second detection position 71, the feeding of the second carrier film 31 is stopped, A third detection means 711 for detecting the leading end 112 at either end position of either one of the side end portions 111 corresponding to the long side y11 of the optical film sheet 11, and a fourth detecting means 712 for detecting the rear end 113 at both end positions; A second alignment means 81 for aligning the other surface 51 of the liquid crystal panel 5 and the second optical film sheet 11 based on position information 210 consisting of a front end 112 and a rear end 113 at both end positions of the side end portion 111; The second optical film sheet 11 is a device that includes second bonding means 91 that peels from the second carrier film 31 and bonds the second optical film sheet 11 to the other surface 51 of the liquid crystal panel 5. FIG. 5 includes a second device 114 that reads the positions of either the front end 112 and the rear end 113 of the side end 111 corresponding to the long side y11 of the second optical film sheet 11 with an imaging device such as a camera. It is an expansion schematic diagram of the pasting station 220.

In the apparatus of the present invention, the first optical film sheet 10 is composed of a first polarizing film, the second optical film sheet 11 is composed of a second polarizing film, and the one surface 50 of the liquid crystal panel 5 is disposed on the TFT side. The other surface 50 of the liquid crystal panel 5 can be a CF-side surface.

Similarly, in the apparatus of the present invention, the first detection means 701 and the second detection means 702 that detect both end positions in the width direction of the first optical film sheet 10 are misaligned between the one end 102 and the other end 103 at both end positions. First detection means 703 for calculating θ1 is further included, and third detection means 711 and fourth detection means for detecting the front end 112 and the rear end 113 at either end position of the side end portion 111 of the second optical film sheet 11. The means 712 may further include second calculation means 713 for calculating a deviation angle θ2 between the rear end 113 and the front end 112.

Similarly, in the apparatus of the present invention, the first alignment means 80 calculates the displacement angle θ1 at the both end positions in the width direction of the first optical film sheet 10 and moves the one surface 50 of the liquid crystal panel 5 based on the displacement angle θ1. While the second alignment means 81 is positioned on the first optical film sheet 10, the displacement angle θ2 is calculated by calculating the displacement angle θ2 of either one of the side end portions 111 of the second optical film sheet 11. Accordingly, the other surface 51 of the liquid crystal panel 5 can be positioned with the second optical film sheet 11.

The apparatus of the present invention further includes a first abbreviated first top 601 that peels off the first optical film sheet 10 from the first carrier film 30 while feeding back the first carrier film 30 at the first top 601. A wedge-shaped release body 60 and a second general portion having a second top portion 611 that peels off the second optical film sheet 11 from the second carrier film 31 while feeding back the second carrier film 31 at the second top portion 611. The first bonding means 90 further includes a wedge-shaped peeled body 61, and peels the first optical film sheet 10 from the first carrier film 30 and bonds the first optical film sheet 10 to the one surface 50 of the liquid crystal panel 5. In addition, the feeding of the first carrier film 30 is resumed, and the first optical film sheet 10 is peeled from the first carrier film 30 while one side of the liquid crystal panel 5 is removed. 50, while the second optical film sheet 11 is peeled off from the second carrier film 31 and bonded to the other surface 51 of the liquid crystal panel 5, the second bonding means 91 stops the feeding. The feeding of the carrier film 31 is resumed, and the second optical film sheet 11 can be bonded to the other surface 51 of the liquid crystal panel 5 while being peeled from the second carrier film 31.

(A) and (b) are a plurality of first and second optical elements together with a pressure-sensitive adhesive layer on strip-shaped first and second carrier films having a width corresponding to the alignment mark of the long side or the short side of the liquid crystal panel. It is the top view and side view showing an example of the 1st and 2nd optical film laminated body containing a film sheet, (c) is the 1st and 2nd optical film sheet corresponding to both surfaces of a liquid crystal panel bonded together It is the top view and side view showing a liquid crystal panel. The first optical film sheet is peeled off from the first carrier film of the first optical film laminate fed out from one side and bonded to one surface of the liquid crystal panel conveyed from the other side, and then the first optical film The second optical film from the second carrier film of the second optical film laminate that is rotated from the other side of the liquid crystal panel that is turned 90 ° and turned over by the liquid crystal panel having the sheet bonded to one side. It is a top view which represents typically an example of the apparatus which juxtaposed the 1st manufacturing line by a RTP system, and the 2nd manufacturing line which peels and bonds a sheet | seat and manufactures the laminated body of an optical display apparatus. A first production line and a second production shown in FIG. 2 for producing a laminate of an optical display device by the RTP method in which the first or second optical film sheet is bonded to one side or the other side of the liquid crystal panel. It is the schematic diagram which looked at an example of the apparatus which juxtaposed the line from the side. The first optical film shown in FIG. 3 is based on the positional information of both end positions in the width direction of the rear end portion of the first optical film sheet that is sent so that the long side of the first optical film sheet faces the width direction. 1st peeling means, 1st position alignment means, and 1st bonding means which comprise the 1st manufacturing line which manufactures the laminated body of the optical display apparatus by the RTP system which bonds a sheet | seat on the one side of a liquid crystal panel It is an expansion schematic diagram of the 1st bonding station containing. As shown in FIG. 3, the positional information on the positions of both ends of the long side that constitutes one side end of the second optical film sheet that is sent so that the short side of the second optical film sheet faces the width direction. A second peeling means and a second alignment means, which constitute a second production line for producing a laminate of an optical display device based on the RTP method in which the second optical film sheet is bonded to the other surface of the liquid crystal panel, It is an expansion schematic diagram of the 2nd bonding station containing a 2nd bonding means. It is the comparison data of an Example and a comparative example evaluated by _Cp value defined as a process capability index | exponent in the manufacturing process obtained by 10 times of measurements. 4 and FIG. 5, the positional information consisting of one end and the other end of both ends of the long side constituting the width direction of the first optical film sheet to be bonded to one side or the other side of the liquid crystal panel, And the 1st and 1st of the Example bonded together on both surfaces of the liquid crystal panel based on the positional information which consists of the front-end | tip of the both ends of the long side which comprises any one of the side edge parts of a 2nd optical film sheet, and a rear end. Position information composed of one end and the other end of both ends of the long side constituting the width direction of the first optical film sheet to be bonded to the one surface or the other surface of the liquid crystal panel; And the 1st and 1st of the comparative example bonded together on both surfaces of the liquid crystal panel based on the positional information which consists of one end and the other end of the short side which comprises the width direction of a 2nd optical film sheet Of the data comparing the sticking accuracy of the optical film sheet. It is a schematic diagram showing the measuring method of Example (a) and Comparative Example (b) shown in FIG. The first optical film sheet sent in a state where the long side constituting the width direction of the first optical film sheet is shifted by θ1 with respect to the horizontal reference position in the width direction, and the side edges of the second optical film sheet It is a schematic diagram showing the 2nd optical film sheet sent in the state which the long side which comprises any one of a part shifted | deviated by (theta) 2 with respect to the vertical reference position of a longitudinal direction. As shown in FIG. 4, the rear end portion of the first optical film sheet that is fed so that the long side of the first optical film sheet faces in the width direction is replaced with the front end portion of the first optical film sheet. It is an expansion schematic diagram of the 1st bonding station which comprises the 1st manufacturing line which manufactures the laminated body of the optical display apparatus by the RTP system made to be based on the positional information on both ends position of.

First, the process capability index _Cp value representing the example of FIG. 6 that characterizes the present invention and comparative example data will be described. The process capability index _Cp value is a well-known value as one index for quantitatively evaluating the process capability of a certain process in the quality control field of industrial products. Usually defined as:
C _p = (USL−LSL) / (6 × δ)
However, USL is the upper standard value, LSL is the lower standard value, and δ is the estimated value of the population standard deviation. These values are assumed to have a normal distribution of characteristic values in the population.

The process capability index _Cp value is usually defined to indicate that a larger number has a desirable capability, and a value near 0 is too large to be subject to quality control as a product. Represents. Preferably, C _p > 1.33. In the case of C _p > 1.67, the approval standard is reached, which is more preferable. In the case of C _p <1.33, the manufactured product group is not evaluated as reaching the standard standard and does not meet the initial target quality, and therefore does not satisfy the product shipment standard.

The present invention is a manufacturing method and apparatus that realizes the pasting accuracy for achieving quantitative evaluation of such quality control while shortening the tact time of the manufacturing process.

The method and apparatus for manufacturing the laminate 6 of the optical display device according to the present invention are as follows. 1A and 1B show that each of the first optical film sheet 10 and the second optical film sheet 11 including a polarizing film bonded to one surface 50 and the other surface 51 of the rectangular liquid crystal panel 5 is provided. The top view showing an example of 1st optical film laminated body R1 and 2nd optical film laminated body R2 laminated | stacked through the adhesive layer 3 on the 1st carrier film 30 and the 2nd carrier film 31, and It is a side view. FIG. 1C is a plan view showing the liquid crystal panel 5 in which the first optical film sheet 10 and the second optical film sheet 11 are bonded to each other on both sides of the rectangular liquid crystal panel 5 so as to have a crossed Nicols relationship. It is a figure and a side view.

As shown in FIG. 2 and FIG. 3, in the first production line 110, the first optical film laminate R1 is fed out from one side, and the rectangular liquid crystal panel 5 from the other side has the long side A at the front end surface. Be transported. As shown in FIG. 1A, the width or length of the one surface 50 of the liquid crystal panel 5 corresponds to the width of the first surface 50 of the liquid crystal panel 5 on the strip-shaped first carrier film 30 constituting the first optical film laminate R1 that is fed out. The first optical film sheet 10 having a width or length has the long side y10 facing the width direction of the first carrier film 30 or the short side x10 facing the longitudinal direction of the first carrier film 30. So that it is continuously supported.

The first optical film sheet 10 is wound around the first carrier film 30 at the first bonding station 120 by folding back the first carrier film 30 at the first top portion 601 of the first substantially wedge-shaped peeled body 60. It peels from the film 30 and is sent to the 1st bonding position 100. FIG. From the other side of the first production line 110, the liquid crystal panel 5 is conveyed toward the first bonding position 100 with the long side A at the front end surface.

The liquid crystal panel 5 is conveyed to the first bonding position 100 by the first positioning means 80 made of, for example, a suction conveyance device, while the long side A is conveyed to the front end surface. One end 102 and the other end 103, which are both end positions of the rear end portion 101 of the long and short y10 constituting the width direction of the optical film sheet 10, are detected, and θ1 with respect to a horizontal reference position set in an imaging device described later. When it is confirmed that there is a misalignment, the orientation control of the liquid crystal panel 5 is performed in consideration of the misalignment amount θ1, whereby the one surface 50 of the liquid crystal panel 5 and the first optical film sheet 10 are positioned with high accuracy. It is bonded by the first bonding means 90 while being aligned.

In the second production line 210 shown in FIGS. 2 and 3, the second optical film laminate R2 is fed out from one side, and the rectangular liquid crystal panel 5 conveys the short side B from the other side to the tip surface. Is done. As shown in FIG. 1B, the width or length of the other surface 51 of the liquid crystal panel 5 is formed on the belt-like second carrier film 31 constituting the second optical film laminate R2 that is fed out. The second optical film sheet 11 having a width or a length is such that the long side y11 faces the longitudinal direction of the second carrier film 31 or the short side x11 faces the width direction of the first carrier film 30. So that it is continuously supported.

The second optical film sheet 11 is wound around the second carrier film 31 at the second bonding station 220 by folding back the second carrier film 31 at the second top portion 611 of the second substantially wedge-shaped peeled body 61. It peels from the film 31 and is sent to the 2nd bonding position 200. FIG. From the other side of the second production line 210, the liquid crystal panel 5 in which the first optical film sheet 10 is bonded to the one surface 50 of the liquid crystal panel 5 is turned 90 ° and inverted, so that the liquid crystal panel 5 has a short side B. Is conveyed toward the second bonding position 200 on the tip surface.

The liquid crystal panel 5 is conveyed to the second bonding position 200 by the second alignment means 81 made of, for example, an adsorption conveyance device, while the short side B is conveyed to the front end surface, while the second optical position is detected at the second detection position 71. The leading end 112 and the trailing end 113 which are both end positions of the long side y11 constituting one of the side end portions of the film sheet 11 are detected, and a deviation of θ2 with respect to a vertical reference position set in an imaging apparatus described later. When it is confirmed that there is a gap, the attitude control of the liquid crystal panel 5 is performed in consideration of the deviation amount θ2, so that the other surface 51 of the liquid crystal panel 5 and the second optical film sheet 11 are aligned with high accuracy. It is bonded by the second bonding means 91 while being done.

The technical problem of the present invention is that in the method and manufacturing of the laminated body 6 of the optical display device, it is possible to realize how highly accurate bonding can be achieved without reducing the stoppage of the manufacturing line due to failure and reducing the manufacturing speed. The problem is whether to do it. Various proposals for accurately positioning and bonding an optical film sheet supported on a carrier film constituting an optical film laminate to a rectangular member such as a liquid crystal panel while peeling from the carrier film are disclosed in Patent Documents 1 to 3, for example. Have been described. In the following, the technical features of the present invention will be clarified while comparing with the techniques proposed so far.

As shown in FIGS. 2 and 3, the method of the present invention is the first manufacturing line 110 when the leading end 1010 of the first optical film sheet 10 reaches the predetermined first detection position 70. Detecting the one end 102 and the other end 103, which are both end positions of the long side y10 constituting the width direction of the leading end portion 1010 of the first optical film sheet 10, and stopping the feeding of one carrier film 30 Based on the position information 104 in the width direction, the step of aligning the one surface 50 of the liquid crystal panel 5 with the first optical film sheet 10 by the first alignment unit 80 and the first peeling unit 60 The process includes peeling the optical film sheet 10 from the first carrier film 30 and bonding the optical film sheet 10 to the one surface 50 of the liquid crystal panel 5 by the first bonding means 90.

In the first production line 110, when the leading end portion 1010 of the first optical film sheet 10 reaches a predetermined first detection position 70, the width direction of the leading end portion 1010 is changed as shown in FIG. When it is confirmed that there is a deviation of θ1 with respect to the horizontal reference position set by the first detection means 701 and the second detection means 702, the liquid crystal panel 5 performs posture control in consideration of the deviation amount θ1. It is something that can be done.

In the method of the present invention, in the second production line 210, the liquid crystal panel 5 in which the first optical film sheet 10 is bonded to the one surface 50 formed in the first production line 110 is rotated by 90 ° and inverted. The leading end portion 1110 of the second optical film sheet 11 is subjected to a predetermined second detection with respect to the other surface 51 of the liquid crystal panel 5 conveyed with the short side B as the leading end surface toward the second bonding position 200. When the position 71 is reached, the feeding of the second carrier film 31 is stopped, and the leading ends 112 that are both end positions of the long side y11 that constitutes one of the side end portions 111 in the longitudinal direction of the second optical film sheet 11. And the step of detecting the rear end 113, and the second alignment means 81 to move the other surface 51 of the liquid crystal panel 5 to the second optical film sheet 11 based on the detected position information 114 in the longitudinal direction. A step of placing, a step of peeling the second optical film sheet 11 from the second carrier film 31 by the first peeling means 61, and affixing the second optical film sheet 11 to the other surface 51 of the liquid crystal panel 5 by the second bonding means 91 Is included.

Also in the second production line 210, when the leading end portion 1110 of the second optical film sheet 11 reaches a predetermined second detection position 71, as shown in FIG. When it is confirmed that there is a deviation of θ2 with respect to the vertical reference position set by the third detection means 711 and the fourth detection means 712, the liquid crystal panel 5 controls the posture in consideration of the deviation amount θ2. It is something that can be done.

The apparatus of the present invention stops the feeding of the first carrier film 30 when the leading end portion 101 of the first optical film sheet 10 reaches a predetermined first detection position 70, and the first optical film sheet 10 Based on first detection means 701 for detecting one end 102 at both end positions of the long side y10 constituting the width direction of the tip 101, second detection means 702 for detecting the other end 103, and both end position information 104 in the width direction. First alignment means 80 for aligning the one surface 50 of the liquid crystal panel 5 and the first optical film sheet 10, and a first for peeling the first optical film sheet 10 from the first carrier film 30. The peeling means 60 and the 1st bonding means 90 which bonds the peeled 1st optical film sheet 10 to the one surface 50 of the liquid crystal panel 5 are included.

Furthermore, the apparatus of the present invention stops the feeding of the second carrier film 31 when the leading end portion 1110 of the second optical film sheet 11 reaches a predetermined second detection position 71, and the second optical film sheet 11. The third detection means 711 for detecting the tip 112 at one end position of the long side y11 constituting the side end portion 111 in the longitudinal direction, the fourth detection means 712 for detecting the rear end 113, and both ends of the side end portion 111 Based on the position information 114, the second alignment means 81 for aligning the other surface 51 of the liquid crystal panel 5 and the second optical film sheet 11, and the second optical film sheet 11 from the second carrier film 31. It includes second peeling means 61 that peels off, and second bonding means 91 that bonds the peeled second optical film sheet 11 to the other surface 51 of the liquid crystal panel 5. That.

As shown in FIGS. 1A and 1B, the pair of strip-like optical film laminates R1 and R2 attached to the method and apparatus of the present invention has a long side A or a short side of the rectangular liquid crystal panel 5. It has a width corresponding to side B. In the 1st conveyance line 110, the liquid crystal panel 5 is conveyed to the front end surface toward the 1st bonding position 100 at the long side A. FIG. Accordingly, the first optical film sheet 10 bonded to the one surface 50 of the liquid crystal panel 5 has a long side y10 corresponding to, for example, an alignment mark on the long side A of the liquid crystal panel 5, so that the first carrier film It is continuously supported on 30 to face the width direction, and is sent to the first bonding position 100 while being peeled off from the first carrier film 30. At that time, one end 102 and the other end 103 in the width direction constituting the front end surface of the first optical film sheet 10 to be peeled are detected by two detection means, for example, a CCD camera, specifically, the first imaging. The deviation angle θ1 with respect to the horizontal reference position set in the device 701 and the second imaging device 702 is calculated as position data in the width direction, and the attitude of the conveyed liquid crystal panel 5 is controlled so as to correct the deviation angle θ1. .

On the other hand, the liquid crystal panel 5 is transported along the second transport line 210 toward the second bonding position 200 with the short side B on the front end surface. Therefore, the second optical film sheet 11 to be bonded to the other surface 51 of the liquid crystal panel 5 has a long side y11 corresponding to, for example, an alignment mark on the long side A of the liquid crystal panel 5, so that the second carrier film It is supported continuously so as to face the longitudinal direction on 31, and is sent to the second bonding position 200 while being peeled off from the second carrier film 31. At that time, in order to obtain the same sticking accuracy as that of the first transport line 110, the tip of the long side y11 constituting one of the side end portions 111 of the tip end portion 1110 of the peeled second optical film sheet 11 is used. 112 and the rear end 113 are, for example, two detection means composed of a CCD camera, specifically, a deviation angle θ2 with respect to the vertical reference position set in the third imaging device 711 and the fourth imaging device 712 is set as position data in the longitudinal direction. The attitude of the liquid crystal panel 5 calculated and conveyed is controlled so as to correct the deviation angle θ2.

As described above, according to the present invention, the first and second optical film sheets are bonded to both surfaces of the liquid crystal panel 5 immediately before being bonded to both surfaces of the liquid crystal panel 5. The long side y10 and the long side y11 constituting the width direction and the longitudinal direction constituting the front end portions of the first optical film sheet 10 and the second optical film sheet 11 having different widths corresponding to the lengths are read at only two places. On the other hand, the deviation angle θ1 with respect to the horizontal reference position and the deviation angle θ2 with respect to the vertical reference position on the other side are calculated, and the orientation of the liquid crystal panel 5 is controlled based on these, thereby bonding the both sides of the liquid crystal panel 5 with high adhesion accuracy. Is realized.

The feature of the present invention is that, as shown in FIG. 7, the long side y10 constituting the leading end portion 1010 of the first optical film sheet 10 and the long side constituting the leading end portion 1110 of the second optical film sheet 11. Similarly to the example (a) in which y11 is detected, the long side y10 constituting the tip portion 1010 of the first optical film sheet 10 and the tip portion 1110 of the second optical film sheet 11 are constituted. It becomes clear from the data of the process capability index _Cp value compared with the comparative example (b) in which only the short side x11 is detected.

As shown in the table of FIG. 6, all of the methods and apparatuses for manufacturing a conventional optical display device laminate by the RTP method for detecting and aligning the tip position only at two locations are comparative examples (b). Has been done on the basis of. From the data of the example of FIG. 6, C _p when the one surface 50 of the liquid crystal panel 5 is aligned and pasted to the long side y10 constituting the width direction of the first optical film sheet 10 is pasted. C _p > 1.67 at the beginning and at the end of pasting, and C _p > 1.33 on the driving side as well. C _p when contrast combined stick by aligning the other surface 51 of the liquid crystal panel 5 to the short side x10 constituting the width direction of the second optical film 11, below the 1.00 average C _p <1.33 at the beginning and at the end of pasting, and C _p <1.00 when the driving side reaches the operation side, and the laminate of the conventional optical display device In the manufacturing method and apparatus, the liquid crystal panel 5 and the optical film sheet cannot be aligned based on detection data including only two portions of the short side x10 constituting the width direction.

By the way, Patent Document 1 and Patent Document 2 disclose an edge detection device for detecting the leading edge of an optical film sheet and a detection device for an alignment mark of a liquid crystal panel, which are equivalent to both sides of a liquid crystal panel realized by the present invention. The idea of realizing high sticking accuracy is not disclosed at all.

According to Patent Document 3, both end positions in the width direction of the optical film sheet that is peeled off from the carrier film immediately before the bonding position are detected by two imaging devices including, for example, CCD cameras, and the optical film is based on the detected data. It is disclosed that the front end position of the corresponding panel member is read on the other side while the front end position of the sheet is adjusted, and the panel member is attached to the peeled optical film sheet while adjusting the position. However, in Patent Document 3, as in Patent Document 1 and Patent Document 2, only the long sides constituting the tips of the first and second optical film sheets having different widths are read, and the horizontal reference position and the vertical reference are read. There is no disclosure of the idea of calculating the respective displacement angles with respect to the position and controlling the attitude of the liquid crystal panel based on them. According to Patent Document 3, when detecting both end positions of the short side constituting the leading end surface of the optical film sheet, it is impossible to realize high sticking accuracy as in the present invention. It is clear from

As apparent from FIGS. 6 and 7, the orientation of the liquid crystal panel 5 is controlled by controlling the attitude of the liquid crystal panel 5 only by the two-point position information only in the width direction including the position data by the short sides disclosed in Patent Documents 1 to 3. Even if the first and second optical film sheets are bonded to both sides, the same sticking accuracy cannot be realized.

Patent Document 4 discloses a detection means for detecting a leading end of a corresponding film piece of an optical film sheet before being bonded to a substrate in a method and apparatus for manufacturing a laminate of an optical display device by the RTP method. However, the idea of bonding the first optical film sheet and the second optical film sheet having different widths on both surfaces of the liquid crystal panel is not disclosed at all. Patent Document 5 only describes a process of reading both end positions of the front end portion of the optical film sheet, and a first optical film sheet and a second optical film sheet having different widths are pasted on both surfaces of the liquid crystal panel. There is no description at the same time, and it is merely a detecting means for detecting both end positions in the width direction constituting the leading end portion of the optical film sheet described in Patent Document 3.

As described above, the laminated body 6 of the optical display device manufactured by the RTP method is used when the first optical film sheet 10 and the second optical film sheet 11 are attached to the one surface 50 and the other surface 51 of the liquid crystal panel 5. In addition, only the both ends of the long sides y10 and y11 constituting the tips of the first optical film sheet 10 and the second optical film sheet 11 having different widths are read, and the liquid crystal is based on the information on the positions of the two ends. By controlling the attitude of the panel 5, the pasting accuracy of the first optical film sheet 10 and the second optical film sheet 11 on both surfaces of the liquid crystal panel 5 is realized. Therefore, the present invention realizes the pasting accuracy equivalent to the position information of only two locations without relying on the position information of three or more points in order to realize high pasting accuracy, and on the manufacturing process. Without a large number of detection means for enhancing the establishment of a failure, a high application accuracy can be achieved by a minimum detection means.

Although the present invention has been described with reference to the embodiments and drawings, the present invention is not limited thereto, and the technical idea of the present invention and the following description will be described by a person having ordinary knowledge in the technical field belonging to the present invention. It goes without saying that various modifications and variations can be made within the scope of the claims.

R1: 1st optical film laminated body R2: 2nd optical film laminated body 10: 1st optical film sheet y10: Long side 1010 of the width direction which comprises the 1st optical film sheet front-end | tip: 1st optical film Sheet end 102: One end 103 in the width direction of the first optical film sheet: The other end 104 in the width direction of the first optical film sheet 104: Both end position information 11 in the width direction of the first optical film sheet 11: First Second optical film film y11: Long side in the longitudinal direction constituting the front end of the second optical film sheet 1110: Front end portion of the second optical film sheet 111: Side end portion constituting the front end portion of the second optical film sheet 112: Front end 113 constituting the side end portion in the longitudinal direction of the second optical film sheet 113: Rear end 114 constituting the side end portion in the longitudinal direction of the second optical film sheet: 2 of the optical film sheet longitudinal ends position information 30: the first carrier film 31: second carrier film 5: liquid crystal panel 6: laminate 50: one surface (TFT side) of the liquid crystal panel
51: The other surface (CF side surface) of the liquid crystal panel
60: 1st peeling means 601: 1st top part 61: 2nd peeling means 611: 2nd top part 70: 1st detection position 701: 1st detection means or 1st imaging device 702: 2nd detection means or 2nd Imaging device 71: second detection position 711: third detection means or third imaging device 712: fourth detection means or fourth imaging device 80: first alignment means 81: second alignment means 90: first Bonding means 91: second bonding means 100: first bonding position 110: first manufacturing line 120: first bonding station 200: second bonding position 210: second manufacturing line 220: 1st bonding station

Claims (12)

Continuously on a strip-shaped first carrier film having a width or length corresponding to the width or length of one side of the rectangular liquid crystal panel so that the long side faces the width direction of the first carrier film. A first optical film sheet having a size corresponding to one surface of the supported liquid crystal panel is peeled off from the first carrier film and bonded to one surface of the liquid crystal panel, and the other liquid crystal panel The liquid crystal panel, which has a width or length corresponding to the width or length of the direction and is continuously supported on a belt-like second carrier film so that the long side faces the longitudinal direction of the second carrier film A laminate for an optical display device, wherein a second optical film sheet having a size corresponding to the other surface of the liquid crystal panel is peeled from the second carrier film and bonded to the other surface of the liquid crystal panel. A method of forming,
When the leading edge or the trailing edge of the first optical film sheet reaches a predetermined first detection position, the feeding of the first carrier film is stopped, and the long side of the first optical film sheet is stopped. Detecting one end and the other end of both end positions in the width direction of the corresponding front end or rear end,
A step of aligning the one surface of the liquid crystal panel and the first optical film sheet on the basis of positional information consisting of the one end and the other end of the both end positions in the width direction;
Peeling the first optical film sheet from the first carrier film and bonding it to one surface of the liquid crystal panel;
When the leading end of the second optical film sheet reaches a predetermined second detection position, the feeding of the second carrier film is stopped, and the side end corresponding to the long side of the second optical film sheet A step of detecting the front end and the rear end of either end position of any of the parts;
A step of aligning the second surface of the liquid crystal panel and the second optical film sheet based on positional information including the rear end and the front end of the both end positions of the side end portion;
Peeling the second optical film sheet from the second carrier film and bonding it to the other surface of the liquid crystal panel;
Including methods.
The method according to claim 1, wherein the first optical film sheet comprises a first polarizing film, and the second optical film sheet comprises a second polarizing film.
3. The method according to claim 1, wherein one surface of the liquid crystal panel is a surface on the TFT side, and the other surface of the liquid crystal panel is a surface on the CF side.
The step of detecting one end and the other end of both end positions in the width direction of the first optical film sheet further includes a step of calculating a deviation angle θ1 between the one end and the other end of the both end positions, and the second optical film sheet. The step of detecting the leading end and the trailing end of either one of the side end portions of the film sheet further includes a step of calculating a deviation angle θ2 between the trailing end and the leading end of the both end positions. 4. The method according to any one of 3.
The step of aligning the one surface of the liquid crystal panel and the first optical film sheet includes positioning one surface of the liquid crystal panel on the first optical film sheet based on the misalignment angle θ1, 5. The method according to claim 4, wherein in the step of aligning the direction and the second optical film sheet, the other surface of the liquid crystal panel is positioned on the second optical film sheet based on the displacement angle θ <b> 2.
Peeling the first optical film sheet from the first carrier film while feeding back the first carrier film at the top of the first peeler; and removing the second carrier film from the second peeler Further including peeling the second optical film sheet from the second carrier film while feeding back at the top,
The step of peeling the first optical film sheet from the first carrier film and bonding the first optical film sheet to one surface of the liquid crystal panel resumes the feeding of the first carrier film stopped feeding, Including a step of attaching an optical film sheet to one surface of the liquid crystal panel while peeling the optical film sheet from the first carrier film,
The step of peeling the second optical film sheet from the second carrier film and bonding it to the other surface of the liquid crystal panel resumes the feeding of the second carrier film that has stopped feeding, The method according to claim 1, further comprising a step of bonding an optical film sheet to the other surface of the liquid crystal panel while peeling the optical film sheet from the second carrier film.
Continuously on a strip-shaped first carrier film having a width or length corresponding to the width or length of one side of the rectangular liquid crystal panel so that the long side faces the width direction of the first carrier film. A first optical film sheet having a size corresponding to one surface of the supported liquid crystal panel is peeled off from the first carrier film and bonded to one surface of the liquid crystal panel, and the other liquid crystal panel The liquid crystal panel, which has a width or length corresponding to the width or length of the direction and is continuously supported on a belt-like second carrier film so that the long side faces the longitudinal direction of the second carrier film A laminate for an optical display device, wherein a second optical film sheet having a size corresponding to the other surface of the liquid crystal panel is peeled from the second carrier film and bonded to the other surface of the liquid crystal panel. A concrete to equipment,
When the leading edge or the trailing edge of the first optical film sheet reaches a predetermined first detection position, the feeding of the first carrier film is stopped, and the long side of the first optical film sheet is stopped. A first detection means for detecting one end of both end positions in the width direction of the corresponding front end or rear end, and a second detection means for detecting the other end;
First alignment means for aligning one surface of the liquid crystal panel and the first optical film sheet based on position information consisting of the one end and the other end of the both end positions in the width direction;
A first laminating means for separating the first optical film sheet from the first carrier film and laminating it on one surface of the liquid crystal panel;
When the leading end of the second optical film sheet reaches a predetermined second detection position, the feeding of the second carrier film is stopped, and the side end corresponding to the long side of the second optical film sheet Third detection means for detecting the tip of either end position of any one of the parts, and fourth detection means for detecting the rear end of the both end positions;
Second alignment means for aligning the other surface of the liquid crystal panel and the second optical film sheet based on positional information consisting of the rear end and the front end of the both end positions of the side end portion;
And a second laminating means for separating the second optical film sheet from the second carrier film and laminating it on the other surface of the liquid crystal panel.
The apparatus according to claim 7, wherein the first optical film sheet is made of a first polarizing film, and the second optical film sheet is made of a second polarizing film.
The device according to claim 7, wherein one surface of the liquid crystal panel is a TFT side surface, and the other surface of the liquid crystal panel is a CF side surface.
The first detection means and the second detection means for detecting both end positions in the width direction of the first optical film sheet calculate a deviation angle θ1 between the one end and the other end of the both end positions. The third detection means and the fourth detection means for detecting the leading edge and the trailing edge of the both end positions of any one of the side edges of the second optical film sheet, The apparatus according to any one of claims 7 to 9, further comprising second calculation means for calculating a deviation angle θ2 between a rear end and the front end.
The first alignment means aligns one surface of the liquid crystal panel and the first optical film sheet based on the displacement angle θ1, and the second alignment means aligns the first surface based on the displacement angle θ2. The apparatus according to claim 10, wherein the second surface of the liquid crystal panel and the second optical film sheet are aligned.
The apparatus includes: a first peeling body having the first top portion for peeling the first optical film sheet from the first carrier film while feeding back the first carrier film at the first top portion; A second release body having the second top portion for peeling the second optical film sheet from the second carrier film while feeding back the carrier film of 2 at the second top portion,
The first bonding means for peeling the first optical film sheet from the first carrier film and bonding the first optical film sheet to one surface of the liquid crystal panel resumes the feeding of the first carrier film that has stopped feeding. And bonding the first optical film sheet to one side of the liquid crystal panel while peeling the first optical film sheet from the first carrier film,
The second bonding means that peels the second optical film sheet from the second carrier film and bonds the second optical film sheet to the other surface of the liquid crystal panel resumes the feeding of the second carrier film that has stopped feeding. The apparatus according to claim 7, wherein the second optical film sheet is bonded to the other surface of the liquid crystal panel while being peeled from the second carrier film.

Images