JPWO2014109306A1 - Method for producing optical member bonded body - Google Patents

Abstract

The manufacturing method of an optical member bonding body heats the 1st process which bonds the 1st optical member sheet | seat larger than the external shape of an optical display component to an optical display component, and makes it a 1st bonding body, An optical member that overlaps the optical display component and the optical display component by shrinking the first optical member sheet so that the outer shape of the first optical member sheet substantially matches the outer shape of the optical display component. And a second step of forming an optical member bonded body including the same.

Description

The present invention relates to a method for producing an optical member bonded body and an optical member bonded body.
This application claims priority based on Japanese Patent Application No. 2013-002831 for which it applied on January 10, 2013, and uses the content here.

  Conventionally, in a production system for an optical display device such as a liquid crystal display, an optical member such as a polarizing plate to be bonded to a liquid crystal panel (optical display component) is formed from a long film into a sheet piece having a size matching the display area of the liquid crystal panel. After being cut out, it is bonded to a liquid crystal panel (for example, see Patent Document 1).

Japanese Unexamined Patent Publication No. 2003-255132

  In the conventional configuration, even if the outer shape of the optical member matches the outer shape of the liquid crystal panel, the optical member shrinks in size and becomes smaller than the display area when heated by a subsequent touch panel attachment process or a heat resistance test. There is a case. In order to suppress dimensional shrinkage, it may be possible to make the adhesive between the liquid crystal panel and the optical member hard and strong, but in this case, warpage occurs in the liquid crystal panel due to stress accompanying thermal shrinkage. Therefore, in the conventional configuration, there is a problem that the frame area around the display area cannot be reduced, and downsizing of the device is hindered.

  An aspect of the present invention has been made in view of such circumstances, and a method for manufacturing an optical member bonded body and an optical member bonding capable of reducing a frame region to expand a display area and downsize an apparatus. The purpose is to provide coalescence.

In order to achieve the above object, the following method was adopted for the method for producing an optical member bonded body and the optical member bonded body according to the aspect of the present invention.
(1) The manufacturing method of the optical member bonding body which concerns on 1 aspect of this invention is a manufacturing method of the optical member bonding body comprised by bonding an optical member to an optical display component, Comprising: The said optical display component WHEREIN: A first step of bonding a first optical member sheet larger than the outer shape of the optical display component to form a first bonded body, heating the first bonded body, shrinking the first optical member sheet, and The optical member including the optical member that overlaps the optical display component and the optical display component by causing the outer shape of the first optical member sheet and the outer shape of the optical display component to substantially coincide with each other. And a second step of making a bonded body.

  (2) In the above aspect (1), in the first step, the optical display component and the first optical member sheet are bonded using an adhesive having a storage elastic modulus of 0.56 Mpa or less at a temperature of 80 ° C. You may stick together.

  (3) In the aspect of the above (1) or (2), in the first step, a second optical member sheet larger than the outer shape of the first optical member sheet is bonded to the optical display component to form a second paste. By combining the second optical member sheet with a laser cut larger than the outer shape of the optical display component along the outer shape of the optical display component, the second bonded body is made into the optical display component and the optical display component. It is good also as said 1st bonding body containing the said 1st optical member sheet | seat which overlaps.

  (4) The optical member bonding body which concerns on the other aspect of this invention is an optical member bonding body comprised by bonding an optical member to an optical display component, Comprising: The aspect from said (1) to (3). It manufactures with the manufacturing method of the optical member bonding body as described in any one of these.

  According to the aspect of the present invention, it is possible to provide a method for manufacturing an optical member bonded body and an optical member bonded body that can reduce the frame area to expand the display area and downsize the device.

It is a schematic diagram which shows the manufacturing apparatus of the optical member bonding body which concerns on one Embodiment of this invention. It is a top view of a liquid crystal panel. It is AA sectional drawing of FIG. It is sectional drawing of an optical sheet. It is a figure which shows operation | movement of a cutting device. It is a top view which shows the external shape of the sheet piece with respect to the external shape of a liquid crystal panel. It is a figure which shows an example of the determination method of the bonding position of the sheet piece with respect to a liquid crystal panel. It is a figure which shows an example of the determination method of the bonding position of the sheet piece with respect to a liquid crystal panel. It is a flowchart of the manufacturing method of an optical member bonding body.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings, but the present invention is not limited to the following embodiments.

  In all the following drawings, the dimensions and ratios of the respective constituent elements are appropriately changed in order to make the drawings easy to see. In the following description and drawings, the same or corresponding elements are denoted by the same reference numerals, and redundant description is omitted.

  In the following description, an XYZ orthogonal coordinate system is set as necessary, and the positional relationship of each member will be described with reference to this XYZ orthogonal coordinate system. In the present embodiment, the transport direction of the liquid crystal panel, which is an optical display component, is the X direction, and the direction orthogonal to the X direction (the width direction of the liquid crystal panel) in the plane of the liquid crystal panel is the Y direction, X direction, and Y direction The direction orthogonal to the Z direction is taken as the Z direction.

Hereinafter, the film bonding system 1 which is a manufacturing apparatus of the optical member bonding body which concerns on one Embodiment of this invention is demonstrated with reference to drawings.
Drawing 1 is a figure showing the schematic structure of film pasting system 1 of this embodiment.
The film bonding system 1 bonds a film-shaped optical member such as a polarizing film, an antireflection film, or a light diffusion film to a panel-shaped optical display component such as a liquid crystal panel or an organic EL panel.

  As shown in FIG. 1, the film bonding system 1 of this embodiment is provided as one process of the manufacturing line of liquid crystal panel P. As shown in FIG. Each part of the film bonding system 1 is comprehensively controlled by the control part 40 as an electronic control apparatus.

  FIG. 2 is a plan view of the liquid crystal panel P viewed from the thickness direction of the liquid crystal layer P3 of the liquid crystal panel P. FIG. The liquid crystal panel P includes a first substrate P1 having a rectangular shape in plan view, a second substrate P2 disposed opposite to the first substrate P1, and having a smaller rectangular shape than the first substrate P1, and a first substrate P1. A liquid crystal layer P3 enclosed between the first substrate P1 and the second substrate P2 is provided. The liquid crystal panel P has a rectangular shape along the outer shape of the first substrate P1 in plan view. A region of the liquid crystal panel P that falls inside the outer periphery of the liquid crystal layer P3 in plan view is set as the display region P4.

  3 is a cross-sectional view taken along the line AA in FIG. On the front and back surfaces of the liquid crystal panel P, the first optical sheet F1 and the second optical sheet F2 (refer to FIG. 1; hereinafter, sometimes collectively referred to as the optical sheet FX) having a long belt shape are formed on the first and second surfaces. The optical member F11 and the second optical member F12 (hereinafter, may be collectively referred to as an optical member F1X) are bonded together. In the present embodiment, polarizing films are bonded to both the backlight side and the display surface side of the liquid crystal panel P, respectively. The first optical member F11 is bonded to the surface of the liquid crystal panel P on the backlight side as a polarizing film. The second optical member F12 is bonded to the surface on the display surface side of the liquid crystal panel P as a polarizing film.

The first optical member F11 is formed by heating and shrinking a first sheet piece F1m cut out from a first intermediate sheet piece F1w described later. The second optical member F12 is formed by heating and shrinking a second sheet piece F2m cut out from a second intermediate sheet piece F2w described later.
Hereinafter, the first intermediate sheet piece F1w and the second intermediate sheet piece F2w may be collectively referred to as an intermediate sheet piece FXw. The first sheet piece F1m and the second sheet piece F2m may be collectively referred to as a sheet piece FXm. The intermediate sheet piece FXw corresponds to a second optical member sheet. The sheet piece FXm corresponds to a first optical member sheet.

  FIG. 4 is a partial cross-sectional view of the optical sheet FX bonded to the liquid crystal panel P. The optical sheet FX includes a film-like optical member main body F1a, an adhesive layer F2a provided on one surface (the upper surface in FIG. 4) of the optical member main body F1a, and one of the optical member main bodies F1a via the adhesive layer F2a. Separator F3a laminated | stacked on the surface so that isolation | separation was possible, and the surface protection film F4a laminated | stacked on the other surface (lower surface in FIG. 4) of optical member main body F1a. The optical member main body F1a functions as a polarizing plate, and is bonded over the entire display area P4 of the liquid crystal panel P and its peripheral area. For convenience of illustration, hatching of each layer in FIG. 4 is omitted.

  The optical member body F1a is bonded to the liquid crystal panel P via the adhesive layer F2a in a state where the separator F3a is separated while leaving the adhesive layer F2a on one surface thereof. Hereinafter, the part remove | excluding the separator F3a from the optical sheet FX is called the bonding sheet | seat F5. The adhesive layer F2a corresponds to an adhesive.

  The separator F3a protects the adhesive layer F2a and the optical member body F1a before being separated from the adhesive layer F2a. The surface protective film F4a is bonded to the liquid crystal panel P together with the optical member body F1a. The surface protective film F4a is disposed on the side opposite to the liquid crystal panel P with respect to the optical member body F1a to protect the optical member body F1a. The surface protective film F4a is separated from the optical member main body F1a at a predetermined timing. The optical sheet FX may not include the surface protective film F4a. The structure which is not isolate | separated from the optical member main body F1a may be sufficient as the surface protection film F4a.

  The optical member body F1a is bonded to the sheet-like polarizer F6, the first film F7 bonded to one surface of the polarizer F6 with an adhesive or the like, and the other surface of the polarizer F6 with an adhesive or the like. And a second film F8. The first film F7 and the second film F8 are protective films that protect the polarizer F6, for example.

  The optical member body F1a may have a single-layer structure including one optical layer. The optical member body F1a may have a stacked structure in which a plurality of optical layers are stacked together. In addition to the polarizer F6, the optical layer may be a retardation film, a brightness enhancement film, or the like. At least one of the first film F7 and the second film F8 may be subjected to a surface treatment capable of obtaining an effect such as a hard coat treatment for protecting the outermost surface of the liquid crystal display element or an antiglare treatment. The optical member body F1a may not include at least one of the first film F7 and the second film F8. For example, when the first film F7 is omitted, the separator F3a may be bonded to one surface of the optical member main body F1a via the adhesive layer F2a.

Next, the film bonding system 1 of this embodiment is demonstrated in detail.
As shown in FIG. 1, the film bonding system 1 of the present embodiment has a downstream side (− in the conveyance direction of the liquid crystal panel P on the left side in the drawing from the upstream side in the conveyance direction (+ X direction side) of the liquid crystal panel P on the right side in the drawing (−). X-direction side), and a drive type roller conveyor 5 that conveys the liquid crystal panel P in a horizontal state is provided.

  The roller conveyor 5 is divided into an upstream conveyor 6 and a downstream conveyor 7 with a reversing device 15 described later as a boundary. On the upstream conveyor 6, the liquid crystal panel P is transported so that the short side of the display area P <b> 4 is along the transport direction. On the other hand, on the downstream conveyor 7, the liquid crystal panel P is transported with the long side of the display area P <b> 4 along the transport direction. An intermediate sheet piece FXw (corresponding to the optical member F1X), which is a sheet piece of the bonding sheet F5 cut out to a predetermined length from the belt-shaped optical sheet FX, is bonded to the front and back surfaces of the liquid crystal panel P.

  The upstream conveyor 6 includes an independent free roller conveyor 24 on the downstream side in the first suction device 11 described later. On the other hand, the downstream conveyor 7 includes an independent free roller conveyor 24 on the downstream side in the second suction device 20 described later.

  The film bonding system 1 of this embodiment is the 1st adsorption | suction apparatus 11, the 1st dust collector 12, the 1st bonding apparatus 13, the 1st cutting device 31, the inversion apparatus 15, the 2nd dust collector 16, 2nd. A bonding device 17, a second cutting device 32, a heating device 50 and a control unit 40 are provided.

  The first suction device 11 sucks and transports the liquid crystal panel P to the upstream conveyor 6 and performs alignment (positioning) of the liquid crystal panel P. The first suction device 11 includes a panel holding unit 11a, an alignment camera 11b, and a rail R.

  The panel holding part 11a holds the liquid crystal panel P in contact with the downstream stopper S by the upstream conveyor 6 so as to be movable in the vertical direction and the horizontal direction, and aligns the liquid crystal panel P. The panel holding part 11a sucks and holds the upper surface of the liquid crystal panel P in contact with the stopper S by vacuum suction. The panel holding part 11a moves on the rail R in a state where the liquid crystal panel P is sucked and held, and transports the liquid crystal panel P. When the conveyance is finished, the panel holding unit 11 a releases the suction holding and delivers the liquid crystal panel P to the free roller conveyor 24.

In the alignment camera 11b, the panel holding unit 11a holds the liquid crystal panel P in contact with the stopper S, and images the alignment mark, tip shape, and the like of the liquid crystal panel P in the raised state. Imaging data from the alignment camera 11b is transmitted to the control unit 40, and based on this imaging data, the panel holding unit 11a operates to align the liquid crystal panel P with the free roller conveyor 24 at the transport destination. In other words, the liquid crystal panel P is transported to the free roller conveyor 24 in consideration of the transport direction with respect to the free roller conveyor 24, the direction orthogonal to the transport direction, and the deviation in the turning direction around the vertical axis of the liquid crystal panel P. .
The liquid crystal panel P conveyed on the rail R by the panel holding portion 11a is nipped by the pressure roll 23 together with the intermediate sheet piece FXw while being sucked by the suction pad 26.

  The 1st dust collector 12 is provided in the conveyance upstream of the liquid crystal panel P of the pinching roll 23 which is the bonding position of the 1st bonding apparatus 13. FIG. The first dust collector 12 removes static electricity and collects dust in order to remove dust around the liquid crystal panel P before being introduced to the bonding position, particularly dust on the lower surface side.

  The 1st bonding apparatus 13 is provided in the panel conveyance downstream rather than the 1st adsorption | suction apparatus 11. FIG. The 1st bonding apparatus 13 bonds the bonding sheet | seat F5 (equivalent to 1st intermediate sheet piece F1w) cut into the predetermined size with respect to the lower surface of liquid crystal panel P introduce | transduced into the bonding position.

  The first bonding device 13 includes a transport device 22 and a pinching roll 23.

  The transport device 22 transports the optical sheet FX along the longitudinal direction of the optical sheet FX while unwinding the optical sheet FX from the original roll R1 around which the optical sheet FX is wound. The conveying apparatus 22 conveys the bonding sheet | seat F5 by using separator F3a as a carrier. The conveyance device 22 includes a roll holding portion 22a, a plurality of guide rollers 22b, a cutting device 22c, a knife edge 22d, and a winding portion 22e.

The roll holding unit 22a holds the original roll R1 around which the belt-shaped optical sheet FX is wound and feeds the optical sheet FX along the longitudinal direction of the optical sheet FX.
The plurality of guide rollers 22b wind the optical sheet FX so as to guide the optical sheet FX unwound from the original roll R1 along a predetermined conveyance path.
The cutting device 22c performs a half cut on the optical sheet FX on the conveyance path.
The knife edge 22d feeds the bonding sheet F5 to the bonding position while winding the optical sheet FX subjected to the half cut at an acute angle to separate the bonding sheet F5 from the separator F3a.
The winding unit 22e holds a separator roll R2 that winds the separator F3a that has become independent through the knife edge 22d.

  The roll holding unit 22a positioned at the start point of the transport device 22 and the winding unit 22e positioned at the end point of the transport device 22 are driven in synchronization with each other, for example. Thereby, the winding unit 22e winds up the separator F3a that has passed through the knife edge 22d while the roll holding unit 22a feeds the optical sheet FX in the conveyance direction of the optical sheet FX. Hereinafter, the upstream side in the transport direction of the optical sheet FX (separator F3a) in the transport device 22 is referred to as a sheet transport upstream side, and the downstream side in the transport direction is referred to as a sheet transport downstream side.

  Each guide roller 22b changes the traveling direction of the optical sheet FX being conveyed along the conveyance path, and at least a part of the plurality of guide rollers 22b is movable so as to adjust the tension of the optical sheet FX being conveyed. .

  A dancer roller (not shown) may be disposed between the roll holding unit 22a and the cutting device 22c. The dancer roller absorbs the feeding amount of the optical sheet FX conveyed from the roll holding unit 22a while the optical sheet FX is cut by the cutting device 22c.

FIG. 5 is a diagram illustrating the operation of the cutting device 22c of the present embodiment.
As shown in FIG. 5, when the optical sheet FX is fed out by a predetermined length, the cutting device 22c applies a part in the thickness direction of the optical sheet FX over the entire width in the width direction orthogonal to the longitudinal direction of the optical sheet FX. Make a half-cut to cut. The cutting device 22c of the present embodiment is provided so as to be able to advance and retreat toward the optical sheet FX from the side opposite to the separator F3a with respect to the optical sheet FX.

  The cutting device 22c adjusts the advancing / retreating position of the cutting blade so that the optical sheet FX (separator F3a) is not broken by the tension acting during conveyance of the optical sheet FX (so that a predetermined thickness remains in the separator F3a), Half-cut to the vicinity of the interface between the adhesive layer F2a and the separator F3a. In addition, you may use the laser apparatus replaced with a cutting blade.

  In the optical sheet FX after the half cut, the optical member main body F1a and the surface protection film F4a are cut in the thickness direction of the optical sheet FX, so that cut lines L1 and L2 extending over the entire width in the width direction of the optical sheet FX are formed. It is formed. The cut lines L1 and L2 are formed so as to be aligned in the longitudinal direction of the belt-shaped optical sheet FX. For example, in the case of the bonding process which conveys the liquid crystal panel P of the same size, the plurality of cut lines L1 and L2 are formed at equal intervals in the longitudinal direction of the optical sheet FX. The optical sheet FX is divided into a plurality of sections in the longitudinal direction by a plurality of cut lines L1, L2. The sections between the pair of cut lines L1 and L2 adjacent in the longitudinal direction in the optical sheet FX correspond to one intermediate sheet piece FXw in the bonding sheet F5, respectively.

FIG. 6 is a plan view showing the outer shape of the intermediate sheet piece FXw and the outer shape of the sheet piece FXm with respect to the outer shape of the liquid crystal panel P.
As shown in FIG. 6, the intermediate sheet piece FXw is a sheet piece of the optical sheet FX having a size larger than the outer shape of the liquid crystal panel P (specifically, a size larger than the outer shape of the sheet piece FXm).

  Returning to FIG. 1, the knife edge 22 d is arranged below the upstream conveyor 6 and extends at least over the entire width of the optical sheet FX in the width direction of the optical sheet FX. The knife edge 22d winds the optical sheet FX so as to be in sliding contact with the separator F3a side of the optical sheet FX after the half cut.

  The knife edge 22d has a first surface that is inclined downward when viewed from the width direction of the optical sheet FX (the width direction of the upstream conveyor 6), a first surface and a first surface that are viewed from the width direction of the optical sheet FX. It has the 2nd surface arrange | positioned above a 1st surface so that two surfaces may form an acute angle, and the front-end | tip part where a 1st surface and a 2nd surface cross.

  In the first bonding apparatus 13, the knife edge 22d winds the first optical sheet F1 around the tip of the knife edge 22d so that the first optical sheet F1 is folded at an acute angle. The first optical sheet F1 separates the sheet piece (first intermediate sheet piece F1w) of the bonding sheet F5 from the separator F3a when folded at an acute angle at the tip of the knife edge 22d. The tip end of the knife edge 22d is arranged close to the panel conveyance upstream side of the pinching roll 23. The first intermediate sheet piece F1w separated from the separator F3a by the knife edge 22d overlaps the lower surface of the liquid crystal panel P in the state of being adsorbed by the first adsorbing device 11, and between the pair of bonding rollers 23a of the pinching roll 23. be introduced. The first intermediate sheet piece F1w is a sheet piece of the first optical sheet F1 having a size larger than the outer shape of the liquid crystal panel P (specifically, a size larger than the outer shape of the first sheet piece F1m).

  On the other hand, the separator F3a separated from the bonding sheet F5 is directed to the winding portion 22e by the knife edge 22d. The winding unit 22e winds up and collects the separator F3a separated from the bonding sheet F5.

  The pinching roll 23 bonds the first intermediate sheet piece F1w separated from the first optical sheet F1 by the conveying device 22 to the lower surface of the liquid crystal panel P conveyed by the upstream conveyor 6.

  The pinching roll 23 has a pair of bonding rollers 23a and 23a arranged in parallel with each other in the axial direction (the upper bonding roller 23a is movable in the vertical direction). A predetermined gap is formed between the pair of bonding rollers 23 a and 23 a, and the inside of this gap is the bonding position of the first bonding apparatus 13.

  In the gap, the liquid crystal panel P and the first intermediate sheet piece F1w are overlapped and introduced. The liquid crystal panel P and the first intermediate sheet piece F1w are sent to the downstream side of the upstream conveyor 6 while being sandwiched between the pair of bonding rollers 23a. In this embodiment, 1st optical member bonding body PA1 is formed when the 1st intermediate sheet piece F1w is bonded by the pinching roll 23 on the surface by the side of the backlight of liquid crystal panel P. As shown in FIG. 1st optical member bonding body PA1 is corresponded to a 2nd bonding body.

  The 1st cutting device 31 is provided in the panel conveyance downstream rather than the 1st bonding apparatus 13. FIG. The first cutting device 31 laser-cuts the first intermediate sheet piece F1w bonded to the liquid crystal panel P to be larger than the outer shape of the liquid crystal panel P along the outer shape of the liquid crystal panel P. Thereby, let 1st optical member bonding body PA1 be 2nd optical member bonding body PA2 containing 1st sheet piece F1m which overlaps with liquid crystal panel P and its liquid crystal panel P (refer FIG. 6). 2nd optical member bonding body PA2 is corresponded to a 1st bonding body.

  The 1st sheet piece F1m is bonded by the surface of the backlight side of liquid crystal panel P by the 1st cutting device 31 cutting off the excess part of the 1st intermediate sheet piece F1w from 1st optical member bonding body PA1. 2nd optical member bonding body PA2 to be formed is formed. The surplus part cut off from the first intermediate sheet piece F1w is peeled off and collected from the liquid crystal panel P by a peeling device (not shown).

  The reversing device 15 reverses the front and back of the second optical member bonding body PA2 with the display surface side of the liquid crystal panel P as the upper surface so that the backlight side of the liquid crystal panel P is the upper surface, and the liquid crystal panel for the second bonding device 17 Align P.

  The reversing device 15 has the same alignment function as the panel holding unit 11a of the first suction device 11. The reversing device 15 is provided with an alignment camera 15 c similar to the alignment camera 11 b of the first suction device 11.

  The reversing device 15 is positioned in the component width direction of the second optical member bonding body PA2 with respect to the second bonding device 17 based on the inspection data in the optical axis direction stored in the control unit 40 and the imaging data of the alignment camera 15c. Position in the rotational direction. 2nd optical member bonding body PA2 is introduce | transduced into the bonding position of the 2nd bonding apparatus 17 after this positioning.

  Since the 2nd adsorption | suction apparatus 20 is equipped with the structure similar to the 1st adsorption | suction apparatus 11, it attaches | subjects and demonstrates the same code | symbol to the same part. The 2nd adsorption | suction apparatus 20 adsorbs 2nd optical member bonding body PA2, conveys it to the downstream conveyor 7, and performs alignment (positioning) of 2nd optical member bonding body PA2. The second suction device 20 includes a panel holding unit 11a, an alignment camera 11b, and a rail R.

  The panel holding part 11a holds the second optical member bonding body PA2 in contact with the downstream stopper S by the downstream conveyor 7 so as to be movable in the vertical direction and the horizontal direction and aligns the second optical member bonding body PA2. Do. The panel holding | maintenance part 11a adsorbs and hold | maintains the upper surface of 2nd optical member bonding body PA2 contact | abutted to the stopper S by vacuum suction. The panel holding | maintenance part 11a moves on the rail R in the state which adsorbed and hold | maintained 2nd optical member bonding body PA2, and conveys 2nd optical member bonding body PA2. When this conveyance is finished, the panel holding unit 11a releases the suction holding and transfers the second optical member bonding body PA2 to the free roller conveyor 24.

  In the alignment camera 11b, the panel holding unit 11a holds the second optical member bonding body PA2 in contact with the stopper S, and images the alignment mark, the tip shape, and the like of the second optical member bonding body PA2 in the raised state. Imaging data from the alignment camera 11b is transmitted to the control unit 40, and based on this imaging data, the panel holding unit 11a is operated to align the second optical member bonding body PA2 with respect to the free roller conveyor 24 at the transport destination. That is, 2nd optical member bonding body PA2 is in the state which considered the gap in the turning direction around the perpendicular direction of the conveyance direction to the free roller conveyor 24, the direction orthogonal to the conveyance direction, and the 2nd optical member bonding body PA2. It is conveyed to the free roller conveyor 24.

  The 2nd dust collector 16 is arrange | positioned in the conveyance direction upstream of the liquid crystal panel P of the pinching roll 23 which is the bonding position of the 2nd bonding apparatus 17. FIG. The second dust collecting device 16 performs static electricity removal and dust collection in order to remove dust around the second optical member bonding body PA2 before being introduced to the bonding position, particularly dust on the lower surface side.

The 2nd bonding apparatus 17 is provided in the panel conveyance downstream rather than the 2nd dust collector 16. FIG. The 2nd bonding apparatus 17 is bonding of the bonding sheet | seat F5 (equivalent to 2nd intermediate sheet piece F2w) cut into the predetermined size with respect to the lower surface of 2nd optical member bonding body PA2 introduced into the bonding position. I do.
The 2nd bonding apparatus 17 is provided with the conveying apparatus 22 and the pinching roll 23 similar to the 1st bonding apparatus 13. FIG.

  In the gap between the pair of bonding rollers 23a of the pinching roll 23 (the bonding position of the second bonding device 17), the second optical member bonding body PA2 and the second intermediate sheet piece F2w are overlapped and introduced. . The second intermediate sheet piece F2w is a sheet piece of the second optical sheet F2 having a size larger than the outer shape of the liquid crystal panel P (specifically, a size larger than the outer shape of the second sheet piece F2m).

  2nd optical member bonding body PA2 and 2nd intermediate sheet piece F2w are sent out to the panel conveyance downstream of the downstream conveyor 7, being pinched by a pair of bonding roller 23a. In the present embodiment, a second intermediate is applied to the display surface side surface of the liquid crystal panel P (the surface opposite to the surface on which the first sheet piece F1m of the second optical member bonding body PA2 is bonded) by the pinching roll 23. The third optical member bonding body PA3 is formed by bonding the sheet piece F2w. 3rd optical member bonding body PA3 is corresponded to a 2nd bonding body.

  The 2nd cutting device 32 is provided in the panel conveyance downstream rather than the 2nd bonding apparatus 17. FIG. The second cutting device 32 laser-cuts the second intermediate sheet piece F2w bonded to the liquid crystal panel P to be larger than the outer shape of the liquid crystal panel P along the outer shape of the liquid crystal panel P. Thereby, let 3rd optical member bonding body PA3 be 4th optical member bonding body PA4 containing 1st sheet piece F1m and 2nd sheet piece F2m which overlap with liquid crystal panel P and its liquid crystal panel P (refer FIG. 6). 4th optical member bonding body PA4 is corresponded to a 1st bonding body.

  The second sheet piece F2m is bonded to the surface on the display surface side of the liquid crystal panel P by separating the excess part of the second intermediate sheet piece F2w from the third optical member bonding body PA3 by the second cutting device 32, and The 4th optical member bonding body PA4 comprised by bonding the 1st sheet piece F1m to the surface at the side of the backlight of liquid crystal panel P is formed. The surplus part cut off from the second intermediate sheet piece F2w is peeled off and collected from the liquid crystal panel P by a peeling device (not shown).

The first cutting device 31 and the second cutting device 32 are, for example, CO ₂ laser cutters. The first cutting device 31 and the second cutting device 32 have an intermediate sheet piece FXw bonded to the liquid crystal panel P larger than the outer shape of the liquid crystal panel P along the outer shape of the liquid crystal panel P (specifically, the sheet piece FXm). Cut to endless shape.

  The heating device 50 is provided on the downstream side of the panel conveyance with respect to the second cutting device 32. The heating device 50 heats the fourth optical member bonding body PA4 and contracts each of the first sheet piece F1m and the second sheet piece F2m to obtain the outer shape of the first sheet piece F1m and the outer shape of the second sheet piece F2m. Each substantially matches the outer shape of the liquid crystal panel P.

  Here, “substantially match” means that the outer shapes of the first sheet piece F1m, the outer shape of the second sheet piece F2m, and the outer shape of the liquid crystal panel P are within a range in which a large positional deviation does not occur. It means that it may be slightly different. For example, when the outer shape of the first sheet piece F1m, the outer shape of the second sheet piece F2m, and the outer shape of the liquid crystal panel P are rectangular, the length V1 of one side of the first sheet piece F1m and the length Vp of one side of the liquid crystal panel P Ratio V1 / Vp is in the range of 0.999 / 1 or more and 1.001 / 1 or less, and the ratio of the length V2 of one side of the second sheet piece F2m to the length Vp of one side of the liquid crystal panel P If V2 / Vp is in the range of 0.999 / 1 or more and 1.001 / 1 or less, it can be said that the lengths of the respective sides substantially match. If it is such a range, the position shift between the external shape of the 1st sheet piece F1m, the external shape of the 2nd sheet piece F2m, and the external shape of liquid crystal panel P can fully be suppressed.

Usually, the polarizing plate shrinks by about 0.1% to 0.8% depending on the environment. If the adhesive that bonds the liquid crystal panel and the polarizing plate is made strong so as not to contract the polarizing plate, the liquid crystal panel warps as the polarizing plate contracts. Therefore, in this embodiment, a liquid crystal panel and a polarizing plate are bonded using a flexible adhesive, which will be described later, and processing is performed with a larger size considering the contraction of the polarizing plate.
The shrinkage occurs throughout the polarizing plate. The trace of using a flexible adhesive is examined by checking the adhesive remaining on the edge of the liquid crystal panel after the contraction of the polarizing plate when the polarizing plate becomes smaller than the outer shape of the liquid crystal panel due to the contraction. be able to.

  Thereby, let 4th optical member bonding body PA4 be 5th optical member bonding body PA5 containing 1st optical member F11 and 2nd optical member F12 which overlap with liquid crystal panel P and its liquid crystal panel P. As shown in FIG. 5th optical member bonding body PA5 is corresponded to an optical member bonding body.

  When each of the first sheet piece F1m and the second sheet piece F2m is contracted by the heating device 50, the second optical member F12 is bonded to the surface on the display surface side of the liquid crystal panel P, and the liquid crystal panel P The 5th optical member bonding body PA5 comprised by bonding the 1st optical member F11 to the surface at the side of a backlight is formed.

A bonding inspection device (not shown) is provided on the downstream side of the panel conveyance from the heating device 50.
In the bonding inspection device, the inspection (not shown whether the position of the optical member F1X is within the tolerance range) is performed by an inspection device (not shown) of the workpiece (liquid crystal panel P) on which the film is bonded. Etc.). The work determined that the position of the optical member F1X with respect to the liquid crystal panel P is not appropriate is discharged out of the system by a not-shown discharging means.

In addition, in this embodiment, the control part 40 as an electronic control apparatus which performs overall control of each part of the film bonding system 1 is comprised including the computer system. This computer system includes an arithmetic processing unit such as a CPU and a storage unit such as a memory and a hard disk.
The control unit 40 of the present embodiment includes an interface that can execute communication with an external device of the computer system. An input device that can input an input signal may be connected to the control unit 40. The input device includes an input device such as a keyboard and a mouse, or a communication device that can input data from a device external to the computer system. The control unit 40 may include a display device such as a liquid crystal display that indicates the operation status of each unit of the film bonding system 1. The control unit 40 may be connected to a display device.

  An operating system (OS) that controls the computer system is installed in the storage unit of the control unit 40. The storage unit of the control unit 40 includes a program that causes the arithmetic processing unit to control each unit of the film bonding system 1 to execute processing for causing each unit of the film bonding system 1 to accurately convey the optical sheet F. It is recorded. Various types of information including programs recorded in the storage unit can be read by the arithmetic processing unit of the control unit 40. The control unit 40 may include a logic circuit such as an ASIC (Application Specific Integrated Circuit) that executes various processes required for controlling each unit of the film bonding system 1.

  The storage unit includes a semiconductor memory such as a RAM (Random Access Memory) and a ROM (Read Only Memory), an external storage device such as a hard disk, a CD-ROM reader, and a disk-type storage medium. The storage unit functionally includes a first adsorption device 11, a first dust collector 12, a first bonding device 13, a first cutting device 31, a reversing device 15, a second adsorption device 20, and a second dust collection device. A storage area for storing program software in which the control procedure of the operation of the apparatus 16, the second bonding apparatus 17, the second cutting apparatus 32, and the heating apparatus 50 is described, and other various storage areas are set.

  Hereinafter, with reference to FIG. 7A and 7B, an example of the determination method of the bonding position (relative bonding position) of the intermediate sheet piece FXw with respect to liquid crystal panel P is demonstrated.

  First, as shown in FIG. 7A, a plurality of inspection points CP are set in the width direction of the optical sheet FX, and the direction of the optical axis of the optical sheet FX is detected at each inspection point CP. The timing for detecting the optical axis may be at the time of manufacturing the original fabric roll R1, or may be until the optical sheet FX is unwound from the original fabric roll R1 and half cut. Data in the optical axis direction of the optical sheet FX is stored in a storage device (not shown) in association with the position of the optical sheet FX (position in the longitudinal direction and position in the width direction of the optical sheet FX).

  The control unit 40 acquires the optical axis data (inspection data on the in-plane distribution of the optical axis) of each inspection point CP from the storage device, and partitions the optical sheet FX (cut line CL) into the portion where the sheet piece FXm is cut out. The direction of the average optical axis of the region to be detected is detected.

  For example, as shown in FIG. 7B, an angle (deviation angle) formed between the direction of the optical axis and the edge line EL of the optical sheet FX is detected for each inspection point CP, and the largest angle (maximum deviation angle) among the deviation angles. Is θmax and the smallest angle (minimum deviation angle) is θmin, the average value θmid (= (θmax + θmin) / 2) of the maximum deviation angle θmax and the minimum deviation angle θmin is detected as the average deviation angle. Then, the direction that forms the average deviation angle θmid with respect to the edge line EL of the optical sheet FX is detected as the direction of the average optical axis of the optical sheet FX. The deviation angle is calculated, for example, with the counterclockwise direction being positive with respect to the edge line EL of the optical sheet FX and the clockwise direction being negative.

  And the direction of the average optical axis of the optical sheet FX detected by the above method makes a desired angle with respect to the long side or the short side of the display region P4 of the liquid crystal panel P. The bonding position (relative bonding position) of the intermediate sheet piece FXw is determined. For example, when the direction of the optical axis of the optical member F1X is set to be 90 ° with respect to the long side or the short side of the display region P4 according to the design specification, the average optical axis of the optical sheet FX is set. The intermediate sheet piece FXw is bonded to the liquid crystal panel P so that the direction is 90 ° with respect to the long side or the short side of the display region P4.

  The above-described cutting devices 31 and 32 detect the outer peripheral edge of the outer shape of the liquid crystal panel P by a detecting means such as a camera, and the intermediate sheet piece FXw bonded to the liquid crystal panel P is liquid crystal along the outer shape of the liquid crystal panel P. Cut endlessly larger than the outer shape of the panel P. The outer shape of the liquid crystal panel P is detected by imaging the outermost edge of the liquid crystal panel P or an alignment mark provided on the liquid crystal panel P. Outside the display area P4, a frame portion G (see FIG. 3) having a predetermined width for arranging a sealant or the like for bonding the first substrate P1 and the second substrate P2 of the liquid crystal panel P is provided. The intermediate sheet piece FXw is cut (cut line: WCL) by the cutting devices 31 and 32 with a size larger than G. In the present embodiment, laser cutting by the cutting devices 31 and 32 is performed with a size larger than the frame portion G. For example, the width of the frame part G is about 250 μm.

  The deflection width (tolerance) of the cutting line of the laser processing machine is smaller than that of the cutting blade. Therefore, in this embodiment, after cutting out the intermediate sheet piece FXw of the optical sheet FX having a size larger than the outer shape of the liquid crystal panel P from the optical sheet FX, and pasting the cut out intermediate sheet piece FXw on the liquid crystal panel P, the intermediate sheet When the piece FXw is cut to be larger than the outer shape of the liquid crystal panel P along the outer shape of the liquid crystal panel P, only the runout tolerance of the cutting line needs to be considered (± 0.1 mm or less).

(Manufacturing method of an optical member bonding body)
FIG. 8 is a flowchart of the manufacturing method of the optical member bonding body of the present embodiment.
First, the raw roll R1 around which the optical sheet FX to be used is wound is loaded into the roll holding unit 22a. After this loading is completed, the operator makes initial settings using the operation panel or the like (step S1 shown in FIG. 8). For example, the cutting size, thickness, and supply speed of the optical sheet FX, the cutting depth of the cutting device 22c (cutting blade), the feeding speed of the roll holding unit 22a, the conveyance speed of the roller conveyor 5, and the like are set by the initial setting.

  When the initial setting is completed, the roll holding unit 22a starts conveying the optical sheet FX based on the control of the control unit 40 (step S2 shown in FIG. 8).

  The cutting device 22c forms a cut line in the optical sheet FX based on the control of the control unit 40 (step S3 shown in FIG. 8). Cut lines are formed at predetermined intervals in the longitudinal direction of the belt-shaped optical sheet FX. Each division part sandwiched between a pair of cutting lines adjacent in the longitudinal direction of the optical sheet FX becomes one intermediate sheet piece FXw in the bonding sheet F5.

  The roller conveyor 5 conveys the liquid crystal panel P to the bonding area in synchronization with the timing at which the bonding sheet F5 is conveyed to the bonding area based on the control of the control unit 40 (step S4 shown in FIG. 8). .

  The 1st bonding apparatus 13 bonds the 1st intermediate sheet piece F1w on the surface by the side of the backlight of liquid crystal panel P based on control of the control part 40 (step S5 shown in FIG. 8). Thereby, 1st optical member bonding body PA1 as a 2nd bonding body is formed.

  The first cutting device 31 laser-cuts the first intermediate sheet piece F <b> 1 w along the outer shape of the liquid crystal panel P to be larger than the outer shape of the liquid crystal panel P based on the control of the control unit 40. For example, the first intermediate sheet piece F1w is cut larger by 30 μm to 50 μm than the edge (panel edge) of the liquid crystal panel P. Thereby, 1st optical member bonding body PA1 is set to 2nd optical member bonding body PA2 comprised by bonding the 1st sheet piece F1m to the surface at the side of the backlight of liquid crystal panel P (step shown in FIG. 8). S6).

  Based on the control of the control unit 40, the reversing device 15 reverses the second optical member bonding body PA2 with the display surface side of the liquid crystal panel P as the upper surface so that the backlight side of the liquid crystal panel P is the upper surface, The alignment of the liquid crystal panel P with respect to the 2nd bonding apparatus 17 is performed.

  The 2nd bonding apparatus 17 bonds the 2nd intermediate sheet piece F2w to the surface by the side of the display surface of liquid crystal panel P based on control of the control part 40 (step S5 shown in FIG. 8). Thereby, 3rd optical member bonding body PA3 as a 2nd bonding body is formed.

  The second cutting device 32 laser-cuts the second intermediate sheet piece F2w larger than the outer shape of the liquid crystal panel P along the outer shape of the liquid crystal panel P based on the control of the control unit 40. For example, the second intermediate sheet piece F2w is cut to a size larger by 30 μm to 50 μm than the end edge (panel edge) of the liquid crystal panel P. Thereby, 3rd optical member bonding body PA3 has the 2nd sheet piece F2m bonded to the surface by the side of the display surface of liquid crystal panel P, and the 1st sheet piece F1m to the surface by the side of the backlight of liquid crystal panel P. It is set as 4th optical member bonding body PA4 comprised by bonding (step S6 shown in FIG. 8, 1st process).

  In this embodiment, as the adhesive layer F2a (see FIG. 4) as an adhesive that bonds the liquid crystal panel P and the sheet piece FXm, one having a storage elastic modulus of 0.56 MPa or less at a temperature of 80 ° C. is used. In the present embodiment, for example, an adhesive layer F2a having a storage elastic modulus of 0.24 MPa at a temperature of 80 ° C. is used.

  “Storage elastic modulus” was measured in accordance with JIS K7244-6: 1999 “Plastics—Test method of dynamic mechanical properties—Part 6: Shear vibration—Non-resonance method”. At this time, using a viscoelasticity measuring device ("DVA-220" manufactured by IT Measurement & Control Co., Ltd.), the frequency was set to 1 Hz, the temperature was increased from 20 ° C to 100 ° C at a temperature increase rate of 10 ° C / min, and the temperature increase The storage elastic modulus at 80 ° C. in the middle was measured.

  The heating device 50 heats the fourth optical member bonding body PA4 based on the control of the control unit 40, contracts each of the first sheet piece F1m and the second sheet piece F2m, and the outer shape of the first sheet piece F1m. And the external shape of the 2nd sheet piece F2m is substantially corresponded with the external shape of liquid crystal panel P, respectively.

  The conditions (heating temperature, heating time, etc.) of the heat treatment of the fourth optical member bonded body PA4 are determined based on the conditions for the heat treatment scheduled after the formation step of the fifth optical member bonded body PA5 that is the shipment. Is done. In this case, the conditions for the heat treatment of the fourth optical member bonding body PA4 are set in a range in which heat does not affect the polarizer from the viewpoint of suppressing the change in the color of the display image. Such conditions are stored in the storage unit of the control unit 40 in advance. The size of the sheet piece FXm cut out from the intermediate sheet piece FXw by the cutting devices 31 and 32 is determined as a size that substantially matches the external shape of the liquid crystal panel P when thermally contracted according to the above heat treatment conditions. The

  For example, the heating temperature of 4th optical member bonding body PA4 shall be the temperature of the range of 60 to 100 degreeC currently planned by the attachment process of a touch panel, or a heat test, and heating time is the time of the range of 15 minutes-60 minutes. To do. In this embodiment, heating is performed at 80 ° C. for 30 minutes. Thereby, it is suppressed that the optical member F1X heat-shrinks greatly in the attachment process of a touch panel, or a heat test.

  Thereby, the 4th optical member bonding body PA4 has the 2nd optical member F12 bonded to the surface by the side of the display surface of liquid crystal panel P, and the 1st optical member F11 to the surface by the side of the backlight of liquid crystal panel P. It is set as the 5th optical member bonding body PA5 comprised by bonding (step S7 shown in FIG. 8, 2nd process).

  In a conventional configuration, a polarizing plate cut out from a long film is bonded to a liquid crystal panel to form a bonded body, and even if the outer shape of the polarizing plate and the outer shape of the liquid crystal panel are matched in the bonded body, heating is performed by a thermal durability test or the like. Then, the polarizing plate may shrink in size and become smaller than the display area. For example, when a thermal endurance test is performed at a temperature of 80 ° C. for 100 hours to 300 hours and left at a temperature of 80 ° C. for 30 minutes in a touch panel attachment process or the like, the polarizing plate shrinks in the range of 250 μm to 1000 μm. When the width of the frame portion is set to less than 250 μm, the polarizing plate shrinks and becomes smaller than the display area. For this reason, the frame portion cannot be reduced, and downsizing of the device is hindered.

  On the other hand, according to the manufacturing method of the optical member bonding body of this embodiment, it is bonded to the liquid crystal panel P in a state where the first optical member F11 and the second optical member F12 are heated and contracted, and the fourth optical member bonding body PA4. Therefore, even if 4th optical member bonding body PA4 is heated by the subsequent heat endurance test etc., it is suppressed that the 1st optical member F11 and the 2nd optical member F12 shrink in size and become smaller than a display area. Is done. Therefore, the frame portion G can be narrowed to enlarge the display area and downsize the device.

  In this embodiment, as the adhesive layer F2a, an adhesive having a storage elastic modulus under heat treatment conditions of 0.24 MPa at a temperature of 80 ° C. and a relatively weak adhesive force is used. Therefore, the warp of the liquid crystal panel P when the heat treatment is performed is suppressed as compared with the case where an adhesive that adheres firmly and firmly is used. In the present embodiment, the adhesive force between the liquid crystal panel P and the sheet piece FXm is not strengthened, and the adhesive layer F2a easily follows the contraction of the sheet piece FXm during the heat treatment, whereby the warpage of the liquid crystal panel P is achieved. Is suppressed. Therefore, the manufacturing yield of the fifth optical member bonded body PA5 as a shipped product can be improved, and the manufacturing yield of a final product in which a touch panel or the like is attached to the fifth optical member bonded body PA5 can also be improved.

Further, the first sheet piece F1m and the second sheet piece are bonded to the liquid crystal panel P by bonding the first intermediate sheet piece F1w and the second intermediate sheet piece F2w larger than the first sheet piece F1m and the second sheet piece F2m. It becomes easy to adjust the outer shape of F2m larger than the outer shape of the liquid crystal panel P by a desired amount.
Furthermore, even when the optical axis direction changes according to the positions of the first intermediate sheet piece F1w and the second intermediate sheet piece F2w, the liquid crystal panel P can be aligned and bonded in accordance with the optical axis direction. .
Thereby, the precision of the optical axis direction of the 1st optical member F11 and the 2nd optical member F12 with respect to liquid crystal panel P can be improved, and the clarity and contrast of an optical display device can be improved.

  In the present embodiment, the example in which the heating device 50 is provided on the downstream side of the panel conveyance with respect to the second cutting device 32 has been described, but the present invention is not limited thereto. For example, the first heating device is provided downstream of the first cutting device 31 in the panel conveyance (between the first cutting device 31 and the reversing device 15), and the second heating device is conveyed in the panel more than the second cutting device 32. It may be provided on the downstream side. In this case, the first heating device heat-shrinks the first sheet piece F1m so that the outer shape of the first sheet piece F1m substantially matches the outer shape of the liquid crystal panel P. On the other hand, the second heating device heat-shrinks the second sheet piece F2m so that the outer shape of the second sheet piece F2m substantially matches the outer shape of the liquid crystal panel P.

  In the present embodiment, in the first step, an intermediate sheet piece FXw larger than the outer shape of the sheet piece FXm is bonded to the liquid crystal panel P to form a second bonded body, and the intermediate sheet piece FXw is applied to the outer shape of the liquid crystal panel P. Along with the example, the second bonded body was cut with a laser larger than the outer shape of the liquid crystal panel P along with the liquid crystal panel P and the first bonded body including the sheet piece FXm overlapping the liquid crystal panel P. However, it is not limited to this. For example, in the first step, without forming the intermediate sheet piece FXw, a sheet piece FXm larger than the outer shape of the liquid crystal panel P may be bonded to the liquid crystal panel P to form a first bonded body.

  In the present embodiment, the optical sheet FX is pulled out from the original roll, and an intermediate sheet piece FXw larger than the outer shape of the liquid crystal panel P is bonded to the liquid crystal panel P, and then the intermediate sheet piece FXw is removed from the outer shape of the liquid crystal panel P. However, the present invention is not limited to this. For example, the present invention can be applied to the case where a single-wafer optical film chip cut out to a size larger than the outer shape of the liquid crystal panel P is bonded to the liquid crystal panel without using the roll material.

  The preferred embodiment according to the present embodiment has been described above with reference to the accompanying drawings, but the present invention is not limited to such an example. Various shapes, combinations, and the like of the constituent members shown in the above-described examples are examples, and various modifications can be made based on design requirements and the like without departing from the gist of the present invention.

  F2a ... adhesive layer (adhesive), P ... liquid crystal panel (optical display component), FX ... optical sheet, FXm ... sheet piece (first optical member sheet), FXw ... intermediate sheet piece (second optical member sheet), F1X ... Optical member, PA1 ... 1st optical member bonding body (2nd bonding body), PA2 ... 2nd optical member bonding body (1st bonding body), PA3 ... 3rd optical member bonding body (2nd bonding body), PA4 ... 4th optical member bonding body (1st bonding body), PA5 ... 5th optical member bonding body (optical member bonding body).

Claims (4)

It is a manufacturing method of an optical member bonding body constituted by bonding an optical member to an optical display component,
A first step of bonding a first optical member sheet larger than the outer shape of the optical display component to the optical display component to form a first bonded body;
The first bonded body is heated by heating the first bonded body, shrinking the first optical member sheet, and substantially matching the outer shape of the first optical member sheet with the outer shape of the optical display component. A second step of making the optical member bonded body including the optical member that overlaps the optical display component and the optical display component;
The manufacturing method of the optical member bonding body containing this.   The optical member bonding according to claim 1, wherein in the first step, the optical display component and the first optical member sheet are bonded together using an adhesive having a storage elastic modulus of 0.56 Mpa or less at a temperature of 80 ° C. Manufacturing method of coalescence.   In the first step, a second optical member sheet larger than the outer shape of the first optical member sheet is bonded to the optical display component to form a second bonded body, and the second optical member sheet is used as the optical display component. The first bonded body including the first optical member sheet that overlaps the optical display component and the optical display component by cutting the laser along the outer shape larger than the outer shape of the optical display component. The manufacturing method of the optical member bonding body of Claim 1 or 2.   It is an optical member bonding body comprised by bonding an optical member to an optical display component, Comprising: Optical member bonding manufactured by the manufacturing method of the optical member bonding body as described in any one of Claim 1 to 3. Coalescence.

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