KR20190075957A - Method for manufacturing optical display device - Google Patents

Abstract

When an optical display device in which a part of the sheet-like optical functional film F1 is protruded from at least the rear end portion PE of the panel member W is formed near the rear end portion (PE) of the panel member W, Which does not generate air bubbles between the panel member (F1) and the panel member (W). The sheet optical functional film F1 is peeled from the carrier film F3 together with the pressure-sensitive adhesive layer F2 and a pair of joints F2 and F3 are peeled from the joining face front end PA of the panel member to the rear face PB of the joining face at the joining position The panel member W and the sheet-like optical functional film F1 are bonded by the rollers 23 and 24. [ The panel member W and the sheet-like optical member W are joined at a joining speed of less than 100 mm / sec from a predetermined position PC of 2 mm or more from the joining face rear end PB to the joining face front end PA to the joining face rear end PB, Functional film stacks F1 and F2 are bonded.

Description

Method for manufacturing optical display device

The present invention relates to a method of manufacturing an optical display device. More specifically, the present invention relates to a sheet-like optical functional film, and more particularly to a sheet-like optical functional film, And a method of manufacturing an optical display device capable of eliminating the above-mentioned problems.

A manufacturing method of a roll-to-panel (RTP) method has been adopted at the manufacturing site of an optical display device (for example, Patent Document 1). In the RTP system, an optical display device is usually manufactured as follows. First, a strip-shaped optical film laminate having a predetermined width is drawn out from the roll. The band-shaped optical film laminate includes a band-shaped carrier film, a pressure-sensitive adhesive layer formed on one side of the carrier film, and an optical film supported on the carrier film via the pressure-sensitive adhesive layer. The optical film may be a single layer or a multilayer. In the striped optical film laminate, the strip-shaped optical functional film is usually formed between adjacent strip lines by continuously cutting the strip-shaped strips in the width direction.

The sheet-like optical functional film continuously supported on the carrier film is peeled off from the carrier film together with the adhesive layer by the peeling means disposed near the bonding position and sent to the bonding position. In the peeling means, the carrier film side of the optical film laminate is wound around the top portion of the substantially wedge-shaped peeling means having a top portion opposed to the bonding position. The sheet-like optical functional film is peeled together with the pressure-sensitive adhesive layer from the carrier film by folding back the carrier film wound on the peeling means in a direction substantially opposite to the conveying direction of the sheet-like optical functional film facing the joining position. The sheet-like optical functional film which has reached the bonding position is joined to the corresponding bonding surface of the panel member conveyed to the separate bonding position by the bonding means having the pair of bonding rollers.

On the other hand, in recent optical display devices, miniaturization, ultra-thinness, and weight reduction are progressing further, and accordingly frame portions surrounding the liquid crystal display region are required to be narrowed, that is, As a method for complying with such a request, there has been proposed a technique in which a sheet-like optical functional film larger than a panel member is bonded to a panel member, and an excess portion of the film protruded from the end portion of the panel member is cut along the end portion of the panel member For example, Patent Document 2). In the patent document 2, the process of cutting off the surplus portion is performed in a series of production apparatuses. In the optical display device obtained as a product from the production apparatus, the surplus portion is cut along the edge of the panel member, It is the corresponding size.

Japanese Patent No. 4377964 Japanese Patent Application Laid-Open No. 2014-228563

In the method of manufacturing non-liquid-crystal display, after the sheet-like optical functional film is projected from the end of the panel member in the RTP method, the protruding portion of the film is cut along the end portion of the panel member .

However, in the RTP method, when the panel member and the sheet-like optical functional film are joined in such a state that a part of the sheet-like optical functional film is projected from the rear end toward the carrying direction of the panel member, There is a problem that air bubbles are generated between the panel member and the sheet-like optical functional film near the rear end of the panel member (typically at a position about 1 mm from the rear end of the joining face of the panel member). Fig. 1 (a) is a photograph of air bubbles actually generated between the panel member and the sheet-like optical functional film, and Fig. 1 (b) is a schematic view of the panel member and the sheet- . 1 shows an example of a state of bubble generation when a film is bonded to a CF side panel in a liquid crystal panel having a CF side panel and a TFT side panel. In this case, the rear end of the TFT side panel corresponds to the "rear end" of the panel member in this specification, and the rear end of the bonding surface of the CF side panel with the film corresponds to the "rear end of the bonding surface" in this specification. On the other hand, for example, in the example of Fig. 1, when the film is bonded to the TFT side panel, the rear end of the TFT side panel corresponds to the " rear end portion "Quot; rear end of the joint surface " in the specification. Also, unlike the example of Fig. 1, for example, a panel member having a structure in which the TFT side panel and the CF side panel are laminated so that the rear end surfaces of the TFT side panel and the CF side panel are the same height, is considered. In this case, The edge portion corresponds to " the rear surface of the joint surface " in this specification.

When the protruding film portion is pressed in the thickness direction of the panel member by pressing the sheet optical functional film portion protruded from the rear end of the joining surface as it is, the bending roller, which has been attached to the rear end of the joining face of the panel member, It is considered that this is caused by the fact that the sheet-like optical functional film already adhered to the panel member near the rear end of the member floats around the rear end of the joining face of the panel member as a point.

When the joining roller, which has been attached to the rear end of the joining surface of the panel member, presses the portion of the sheet-like optical functional film projected from the rear end of the joining surface as it is, There is a risk of adhering to the surface.

The present invention relates to a manufacturing method which does not generate air bubbles between an optical functional film and a panel member near the rear end of a panel member when an optical display device in which a part of a sheet- And to provide an image processing apparatus.

Another object of the present invention is to provide a manufacturing method in which an adhesive is not adhered to a joining roller when an optical display device in which a part of a sheet-like optical functional film protrudes from at least a rear end portion of a panel member is manufactured.

The above problem can be solved by making the bonding speed of the panel member and the sheet-like optical functional film near the rear end of the panel member less than 100 mm / second.

The present invention provides a method of manufacturing an optical display device. The optical display device manufactured in this method has a part of the sheet-like optical functional film protruding from at least the rear end of the panel member. This optical display device comprises a pressure-sensitive adhesive layer (hereinafter referred to as " pressure-sensitive adhesive layer ") formed from a band-shaped optical film laminate including a carrier film, a pressure-sensitive adhesive layer formed on the carrier film, and a sheet-like optical functional film continuously supported on the carrier film via the pressure- And a sheet-like optical functional film is peeled off from at least a rear end portion of the panel member by a pair of joining rollers in a state in which a part of the sheet-like optical functional film is projected from at least a rear end portion of the panel member, .

The present method includes a step of peeling a sheet-like optical functional film from a carrier film together with a pressure-sensitive adhesive layer and advancing a leading end portion of the sheet-like optical functional film to a joining position with the panel member, And a step of joining the panel member and the sheet-like optical functional film to each other through a pair of joining rollers from the joining face of the panel member to the rear face of the joining face at the joining position. In this method, the panel member and the sheet-like optical functional film laminate are joined at a joining speed of less than 100 mm / second from a predetermined position of 2 mm or more from the rear end of the joining face toward the front end of the joining face.

In one embodiment, it is preferable that the pressure applied from the pair of joining rollers to the laminate of the panel member and the sheet-like optical function is 0.3 MPa to 0.4 MPa when joining from a predetermined position to the rear end of the joining face.

In one embodiment, it is preferable that one roller and the other roller of the pair of joining rollers do not contact each other even after the joining to the rear end of the joining surface is finished.

BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 shows a photograph and a schematic diagram of a state in which air bubbles are generated between a panel member and a sheet-like optical functional film when the sheet-like optical functional film is projected from the rear end of the panel member and joined to the panel member in the RTP system manufacturing method .
Fig. 2 is a conceptual diagram of an entire configuration of a continuous manufacturing apparatus 1 for continuously manufacturing an optical display device according to an embodiment of the present invention.
Fig. 3 shows a series of operations in which a sheet-like optical functional film is peeled from a junction and a panel member and a sheet-like optical functional film are bonded together in an embodiment of the present invention.
Fig. 4 shows a change in the bonding speed when the panel member and the sheet-like optical functional film are bonded in the embodiment of the present invention.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. The present invention is not limited to these embodiments.

Fig. 2 is a conceptual diagram of an overall configuration of an apparatus 1 for continuously manufacturing an optical display device according to an embodiment of the present invention. Fig. 3 shows a series of operations for peeling the sheet-like optical functional film at the joint and joining the panel member and the sheet-like optical functional film. Fig. 4 shows a change in the bonding speed when the panel member and the sheet-like optical functional film are bonded.

In the continuous manufacturing apparatus 1, the optical film laminate (F) in which the sheet-like optical functional film (F1) is continuously laminated on the carrier film (F3) on the belt via the pressure-sensitive adhesive layer . In the continuous manufacturing apparatus 1, the sheet-like optical functional film F1 is peeled from the carrier film F3 in a belt together with the pressure-sensitive adhesive layer F2, and the peeled sheet optical functional film F1 is adhered to the panel member W ) Of the sheet-like optical functional film F1 is projected from at least the rear end PE of the panel member W to the joint surface PL of the panel member W by using a pair of joining rollers 23, Whereby the optical display device P can be continuously manufactured.

The operations of the respective units of the continuous manufacturing apparatus 1 can be controlled by the control unit 51 of the control unit 50. The data used in the respective units are stored in the storage unit 52 and used as necessary . In the present invention, the sheet-like optical functional film (F1) may comprise any one of a polarizing film, an antireflection film, a retardation film, a light diffusion film, a brightness enhancement film, The panel member W may be a liquid crystal panel, an organic EL panel, or the like.

The continuous manufacturing apparatus 1 operates as follows. First, a strip-shaped optical film laminate (F ') is fed from a roll 11. The optical film laminate (F ') is obtained by laminating a band-shaped optical functional film (F1') on a band-shaped carrier film (F3) with a pressure-sensitive adhesive layer (F2) interposed therebetween. Subsequently, the pressure-sensitive adhesive layer F2 and the band-shaped carrier film F3 are laminated in the width direction of the optical film laminate (F ') with respect to the optical film laminate (F') in the cut portion 15 having the cutter formed in the middle of the conveying path. (This operation is also referred to as " half cut "). The optical film laminate (F) is the optical film laminate (F) in which the line of cut (CL) is put in the optical film laminate (F '). In another embodiment, it is also possible to use an optical film laminate in which a pre-cut line CL is formed. In this case, the cut portion 15 is unnecessary.

The optical film laminate (F) comprises feed rollers (13 and 17) for feeding the film as required, dancer rollers (14 and 18) for adjusting the feed speed of the film, (Not shown) or the like.

On the other hand, the panel member W, which is a substrate to which the sheet-like optical functional film F1 is adhered, is fed out one by one from a magazine (not shown) containing a plurality of panel members W, And conveyed by conveying means 30 such as a roller conveyor. The panel member W is detected by the panel position detecting means 33 in the alignment portion 32 and the posture is corrected (aligned) according to the state of deviation of the sheet-like optical functional film F1, And then sent to the joining portion 20.

In the joining portion 20, the peeling means 21 separates the sheet-like optical functional film F1 from the carrier film F3 together with the pressure-sensitive adhesive layer F2. The peeled sheet-like optical functional film F1 is formed by the joining rollers 23 and 24 in such a state that a part of the sheet-like optical functional film F1 is protruded from at least the rear end portion PE of the panel member W, (W).

In the present invention, the projecting amount of the sheet-like optical functional film F1 from the rear end portion (PE) is not limited, but is preferably 3 mm or more. The protruding portion of the sheet-like optical functional film F1 can be more stably cut along the end portion of the panel member W when the protruding amount is 3 mm or more.

The carrier film F3 after the sheet-like optical functional film F1 and the pressure-sensitive adhesive layer F2 are peeled off is wound up by the winding means 40. [ The panel laminate P in which the sheet-like optical functional film F1 is bonded to the panel member W and a part of the sheet optical functional film F1 protrudes from at least the rear end PE of the panel member W, Is carried out of the joint portion (20) by the conveying means (30).

Next, the operation of the joint portion 20 will be described with reference to Fig. In Fig. 3, the processing is shown to proceed in the order from (a) to (d). The sheet-like optical function film F1 is peeled off and the leading end of the sheet-like optical function film F1 is detected and the sheet-like optical function film F1 and the panel member W are bonded to each other.

The bonding portion 20 has peeling means 21 for peeling the sheet-like optical functional film F1 together with the pressure-sensitive adhesive layer F2 from the band-shaped carrier film F3 as shown in Fig. 2, A front end detecting means 25 for detecting the posture of the front end portion of the function film F1 and a pair of front end detecting means 25 for joining the sheet optical function film F1 and the panel member W via the pressure- And joining rollers 23 and 24, respectively.

As shown in Fig. 3 (a), the optical film laminate (F) is conveyed to the joining portion (20). 3 (a) shows the panel laminate P immediately after the preceding sheet-like optical functional film F1 is bonded to the panel member W. In Fig. The optical film laminate (F) is conveyed along the lower surface of the peeling means (21) on the side of the carrier film (F3). The carrier film F3 is wound by the winding means 40 while being folded back in a direction substantially opposite to the direction of the bonding position 26 so as to be wound on the top portion 22 of the peeling means 21. [

Subsequently, as shown in Fig. 3 (b), the sheet-like optical functional film F1 is formed so that the carrier film F3 is wound up by the winding means 40 so as to extend rearward from the front end portion together with the pressure- (F3). 3, when the sheet-like optical functional film F1 and the pressure-sensitive adhesive layer F2 are peeled from the front end portion by a predetermined length, the driving of the winding means 40 is stopped, Is stopped. At this time, the tip of the sheet-like optical functional film F1 is located at any position between the top portion 22 of the peeling means 21 and the bonding position 26, and at this position, the tip end detecting means 25 See Fig. 2).

The leading end of the sheet-like optical functional film F1 is detected by the leading end detecting means 25 as required, and then the driving of the winding means 40 is resumed. When the carrier film F3 is conveyed again according to the resumption of the driving of the winding means 40, the remaining portion of the sheet-like optical functional film F1, which has been headed out together with the pressure-sensitive adhesive layer F2, ). The position of the panel member W on which the front end portion of the sheet-like optical functional film F1 reaches the joining position 26 and the front and rear ends are joined to each other at the joining position 26 as shown in Fig. 3 (b) The panel member W is conveyed. At the time of being conveyed to the joining position 26, the panel member W is aligned according to the state of deviation of the sheet-like optical functional film F1.

The sheet optical functional film F1 and the panel member W are brought into contact with the joining rollers 23 and 24 in a state in which the front end portion of the sheet optical functional film F1 is in contact with the joining face PL of the panel member W, And the joining of the sheet-like optical functional film F1 and the panel member W is started as the joining rollers 23 and 24 rotate.

When the panel laminate P in which a part of the sheet-like optical functional film F1 protrudes from the rear end portion PE of the panel member W as described above is formed on the joining face PL of the panel member W And the rear end PB of the abutting surface PL (hereinafter referred to as abutting surface leading edge PA) (hereinafter referred to as abutting surface leading edge PA) The sheet-like optical functional film F1 is bonded to the panel member W in the vicinity of the rear end PE of the panel member W (a certain range from the rear end of the panel member toward the front end of the panel member) There is a problem that bubbles are generated between the panel member W and the sheet-like optical functional film F1. This generation of bubbles can be avoided by bonding the panel member W and the sheet-like optical functional film F1 more strongly with a low bonding speed in a range where bubbles are generated.

More specifically, in the present invention, as shown in Fig. 3 (c), most of the length d1 from the front end PA of the joining surface of the panel member W to the predetermined position PC on the upstream side in the carrying direction, For example, at a bonding speed (v1) usually used in the RTP system. The bonding speed between the panel member W and the sheet-like optical functional film F1 is lowered to the speed v2 when the joining of the panel member W and the sheet-like optical functional film F1 reaches the predetermined position PC . The portion of the length d2 from the predetermined position PC of the panel member W to the rear end PB of the joining surface is moved at the joining speed v2 to the panel member W as shown in Fig. And the sheet-like optical functional film F1.

Fig. 4 is a diagram showing the change in the bonding speed when the sheet-like optical functional film F1 is bonded to the panel member W in the present invention. Fig. 4 shows the distance from the front end PA of the joining surface of the panel member W to the rear end PB of the joining surface and the vertical axis shows the joining speed between the sheet optical functional film F1 and the panel member W .

As shown in Fig. 4, the joining of the sheet-like optical functional film F1 and the panel member W is started and the portion from the joining surface front end PA of the panel member W to the predetermined position PC, the joining of the sheet-like optical functional film F1 and the panel member W is carried out with the joining speed v1 at the maximum speed until joining of the sheet-like optical functional film F1 and the panel member d1.

Subsequently, when the joint reaches the predetermined position PC, the joining speed of the panel member W and the sheet-like optical functional film F1 is reduced to the speed v2. The portion from the predetermined position PC to the rear end PB of the joining face, that is, the portion of the length d2 is bonded at the bonding speed v2.

The predetermined position PC of the panel member W is located on the upstream side in the conveying direction (side of the front end PA of the joining surface) from the position where the bubbles are generated and in the present invention, from the predetermined position PC to the rear end PB of the joining face Is set to be 2 mm or more. The length d2 is not limited as long as it is 2 mm or more, but it is preferable that the length d2 is made as short as possible because the length of the portion to be bonded at a low speed becomes too long and productivity is lowered.

The joining speed v2 is determined by the joining rollers 23 and 24 attached to the rear end PB of the joining face of the panel member W so that the projecting portion When the panel member W is pressed in the thickness direction of the panel member W so that the sheet-like optical functional film F1 already bonded to the panel member W near the rear end PB of the joining surface is not pressed, Is set at a speed at which the film F1 can be sufficiently adhered. In the present invention, the bonding speed v2 is less than 100 mm / sec.

The joining speed v2 is not limited to less than 100 mm / sec. The slower the speed, the stronger the panel member W and the optical function film F1 can be adhered to, but if too late, the productivity deteriorates. In one embodiment, the bonding speed v2 is preferably 5 mm / sec or more. The speed at which the portion of the length d2 is bonded is not necessarily constant, and may fluctuate if it is less than 100 mm / sec. For example, the speed of joining from the predetermined position PC toward the rear end PB of the joining face may be gradually reduced.

The pressing force to be applied from the pair of joining rollers 23 and 24 to the laminated body of the panel member W and the sheet-like optical functional film F1 is at least from the predetermined position PC of the panel member W to the rear end (Part of the length d2) from the joining face rear end PB to the joining face PB of the sheet-like optical functional film F1 does not protrude from the joining face rear end PB, More preferably 0.3 MPa to 0.4 MPa. Since the panel member W and the sheet-like optical functional film F1 are more strongly adhered by bonding with the strong pressing force, the sheet-like optical functional film F1 can be more reliably prevented from lifting from the panel member W can do. The pressing force may be smaller than 0.3 MPa so long as the generated bubbles do not hinder the performance as a product. It is not preferable that the pressing force is larger than 0.4 MPa because the panel member W may be damaged.

In the apparatus 1, after one roller 23 and the other roller 24 of the pair of joining rollers 23 and 24 are joined to the rear end PB of the joining face of the panel member W It is preferable that they are configured not to come into contact with each other. When the bonding rollers 23 and 24 which are attached to the rear end PB of the bonding face push the portion of the sheet-like optical functional film F1 protruding from the rear face PB of the bonding face as it is, the adhesive layer F2 May be adhered to the joining roller (23 or 24). A gap is formed between the rollers so that the rollers 23 and 24 do not come into contact with each other even when the rollers 23 and 24 are in the closed state. This prevents the bonding roller 23 or 24 from contacting the adhesive layer F2, Can be prevented.

The joining speed v1 joining the portion from the joining face front end PA of the panel member W to the predetermined position PC, that is, the portion of the length d1 is equal to the joining speed v2, ) And the optical function film (F1) is not adversely affected, but the production time per unit time is sacrificed because the bonding time is prolonged. Therefore, from the viewpoint of productivity, the bonding speed v1 of the portion of the length d1 is preferably higher than the bonding speed v2, more preferably 200 mm / sec to 800 mm / sec. In addition, it is preferable that the length to be bonded at the bonding speed v1 is as long as possible so that the bonding time is as short as possible.

Example

Hereinafter, examples and comparative examples of the present invention will be described.

Table 1 shows examples and comparative examples of the present invention. When the amount of protrusion of the sheet-like optical functional film F1 from the rear end portion PE of the panel member W is 3 mm, The joining speed v2 at the time of joining the portion of the length d2 from the predetermined position PC to the joining face rear end PB and the pressing force of the joining rollers 23 and 24 It is determined whether bubbles have occurred between the panel member W and the sheet-like optical functional film F1 in the vicinity of the rear end PE of the panel member W when the panel member W is changed. The inspection was carried out by visually checking the presence or absence of bubbles.

From the results of Embodiments 1 to 5, it was found that at the portion of the length d2 from the predetermined position PC of the panel member W to the rear end PB of the joining surface, the joining speed v2 of 90 mm / When the panel member W and the sheet-like optical functional film F1 were bonded to each other, there was no generation of air bubbles or there was no problem as a product even if air bubbles were generated. However, this is a case where the length d2 is 5 mm or more. When the d2 is shorter than 5 mm, for example, the bonding speed v2 is used in Comparative Example 1 and Comparative Example 2 (that is, when d2 is 0 or 1 mm) The air bubbles were generated even at 25 mm / sec.

Also, as shown in Comparative Example 4, when the length d2 was 40 mm, bubbles were generated when the bonding speed of the portion of the length d2 was 150 mm / sec.

When the pressure applied to the laminated body of the panel member W and the sheet-like optical functional film F1 from the pair of bonding rollers 23 and 24 at the portion of the length d2 is 0.25 MPa, Bubbles were generated, but in this case, there was no problem as a product.

1: continuous production apparatus 11: roll of optical film laminate (F ')
13, 17: Feed rollers 14, 18: Dancer rollers
15: cut section 20:
21: peeling means 22: top of peeling means
23, 24: joining roller 25: leading end detecting means
26: bonding position 30: conveying means
32: Position adjusting section 33: Panel position detecting means
40: winding means 41: feed roller
50: control unit 51: control means
52: storage means F ', F: optical film laminate
F1 ': strip-shaped optical functional film F1: sheet-shaped optical functional film
F2: pressure-sensitive adhesive layer F3: carrier film
PA: Front edge of the joining face of the panel member PB: Front edge of the joining face of the panel member
PC: a predetermined position on the joint surface of the panel member; PE:
PL: a joining surface with the sheet-like optical functional film of the panel member
W: panel member P: panel laminate
d1: length from the front edge PA of the joining surface of the panel member to the predetermined position PC
d2: length from the predetermined position PC of the panel member to the rear end PB of the joining face
v1: the joining speed from the joining surface front end PA of the panel member to the predetermined position PC
v2: the joining speed from the predetermined position PC of the panel member to the rear end PB of the joining face

Claims (3)

A pressure-sensitive adhesive layer formed on the carrier film, and a sheet-like optical functional film continuously supported on the carrier film with the pressure-sensitive adhesive layer interposed therebetween, The sheet-like optical functional film is peeled off from the joining surface of the panel member by a pair of joining rollers in a state in which a part of the sheet-like optical functional film is projected from at least the rear end of the panel member A method of manufacturing an optical display device by bonding,
The step of peeling the sheet-like optical functional film from the carrier film together with the pressure-sensitive adhesive layer and advancing the front end portion of the sheet-like optical functional film to the bonding position with the panel member and,
Advancing the panel member to the joining position;
And joining the panel member and the sheet-like optical functional film with the pair of joining rollers from the front end of the joining surface of the panel member to the rear end of the joining surface at the joining position,
The panel member and the sheet-like optical functional film laminate are bonded at a bonding speed of less than 100 mm / second from a predetermined position of 2 mm or more from the rear end of the bonding face toward the front end of the bonding face to the rear end of the bonding face. How to. The method according to claim 1,
Wherein the pressing force applied to the laminate of the panel member and the sheet-like optical function from the pair of joining rollers when joining from the predetermined position to the rear end of the joining surface is 0.3 MPa to 0.4 MPa. 3. The method according to claim 1 or 2,
Wherein one roller of the pair of joining rollers and the other of the rollers do not contact each other even after joining to the rear end of the joining surface.

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