TW201606289A - Optical inspection method for a display cell of a thin film structure and false terminal unit for use with the method - Google Patents

Abstract

An optical inspection method for a display cell having a flexible thin-film structure includes: a step for conveying a motherboard structure including at least a cell motherboard comprising a resin substrate and at least one display cell formed on the resin substrate and having a flexible thin-film structure and a display surface in a conveyance direction such that the display surface of the display cell faces upward; a step for forming an adhesive layer on the display surface of the display cell of the motherboard structure conveyed in the conveyance direction; a step for putting the display cell having the adhesive layer formed on the display surface thereof in an excited state by supplying excitation power to the display cell and searching for defects in the display cell in the excited state; and a step for adhering an optical functional film to the adhesive layer formed on the display surface of the display cell for which defect inspection has been completed. As a result, a display cell formed on a resin substrate and having a flexible thin-film structure can be inspected for defects in an excited state without a protective film being adhered to the display cell.

Description

Optical inspection method for display unit of flexible film structure, and virtual terminal unit used in the method

The present invention relates to a method of inspecting a display unit of a flexible film structure to which an optical functional film is bonded, and a dummy terminal unit used in the method. In particular, the present invention is not particularly limited, but the present invention relates to a method for inspecting a display unit capable of forming a flexible film structure such as an organic EL display unit, and a flexible film structure to which an optical functional film is bonded, and the method The virtual terminal unit used.

Since the organic EL display unit can be formed into a flexible film structure, the display device using the display unit can be formed into a curved surface, or the entire display device can be made flexible and can be bent into a roll shape. In such a display unit, a resin film such as a polyimide film is generally formed on a heat-resistant substrate such as a glass substrate, and the resin film is used as a substrate for forming a film-shaped display unit, and is formed on the substrate. It is manufactured by forming a display unit. The display surface of the display unit manufactured as described above is pasted through the adhesive layer It has an optical function film.

Further, a display unit having a relatively small size for use in a smart phone or a tablet-sized display device is manufactured by forming a plurality of cells on one substrate. Korean Patent Application Publication No. 10-1174834 (Patent Document 1) discloses a method of producing an organic EL display unit having a relatively small screen size as described above. According to the method described in Patent Document 1, a film of a resin such as a polyimide resin is formed on a glass substrate, and the resin film is used as a substrate for forming a film-shaped display unit. Then, a plurality of display units arranged in a plurality of columns in the vertical and horizontal directions are formed on the substrate, and are entirely covered with an engineering film, and then the substrate on which the display unit is formed is peeled off from the glass substrate. Then, the film-shaped display unit is cut into a state in which the engineering film is bonded, and the terminal portion having the electrical connection for electrical connection along one side of each film-shaped display unit is exposed, and the terminal portion is corresponding to the terminal portion. The position of the film-forming display unit is formed by peeling off the engineering film.

For the display unit formed as described above, optical inspection is performed. This optical inspection is generally performed in two stages of a surface defect inspection of reflected light, and application of excitation power to the display unit to cause the display unit to be in an excited state, and to check whether or not the operation of the display unit is lit. In the latter lighting inspection, in order to apply excitation power to each display unit, a dummy terminal having an electrical connection terminal connected to an electrical connection terminal of the display unit is used.

Defect inspection in the display unit in an excited state When the inspection is performed in a state immediately after the manufacture of the display unit, foreign matter adheres to the display surface of the display unit to deteriorate the function of the display unit. Therefore, the protective film is usually attached to the front surface of the display unit for inspection. However, if a protective film is used, it is necessary to peel off the protective film in the subsequent step, which increases the number of processes. Here, it is considered that the optical functional film is attached to the display surface and then inspected. However, in the state where the optical functional film is bonded to the display surface, the precise excitation state inspection cannot be performed.

Further, in the case where a plurality of display units are arranged in a matrix structure in the vertical and horizontal directions on the unit mother board, if each display unit is individually activated and the defect inspection is performed, the time and labor required for the inspection increase. It is not good.

[Previous Technical Literature] [Patent Literature]

[Patent Document 1] Korean Patent Application Publication No. 10-1174834

[Patent Document 2] International Publication WO2009/104371A1

[Patent Document 3] Japanese Patent Laid-Open Publication No. 2007-157501

[Patent Document 4] Japanese Patent Laid-Open Publication No. 2013-63892

[Patent Document 5] Japanese Patent Laid-Open Publication No. 2010-13250

[Patent Document 6] Japanese Patent Laid-Open Publication No. 2013-35158

[Patent Document 7] Japanese Patent No. 2013-070787

[Patent Document 8] Japanese Patent No. 2013-070789

[Patent Document 9] Japanese Patent No. 5204200

[Patent Document 10] Japanese Patent No. 5448264

In order to cope with the above-described situation, the present invention has been made to solve the problem of providing a defect inspection of a display unit in an excited state without attaching a protective film to a display unit having a flexible film structure formed on a resin substrate. Inspection Method.

Further, another object of the present invention is to provide a method for efficiently performing an inspection of an excitation state of a display cell in a structure in which a plurality of display cells are formed on a cell mother board.

Still another object of the present invention is to provide a virtual terminal unit used for defect inspection in an active state of a display unit in a unit mother board in which a plurality of display units are formed.

The present invention can solve the above problems and provide an optical inspection method for a display unit having a flexible film structure. The method comprises the steps of: forming a unit mother board from at least one display unit having a display surface constructed of a resin substrate and a flexible film formed on the resin substrate, and forming a mother board structure including at least the unit mother board a stage in which the body is transported in the transport direction with the display surface of the display unit facing up; and a display unit of the motherboard structure that is transported along the transport direction a stage in which the display layer forms an adhesive layer; a stage in which the display unit is provided with an adhesive layer on the display surface of the display unit to supply excitation power to cause the display unit to be in an excited state, and to perform defect inspection on the display unit in an excited state; And a stage in which the adhesive layer formed on the display surface of the display unit after the defect inspection is bonded to the optical functional film.

In this case, the display surface of the display unit is a rectangular shape having two short sides and two long sides, and the display unit is configured to form an electrical connection terminal along one of the short side and the long side. The terminal portion and the unit mother board are preferably conveyed in the conveyance direction in a state in which the terminal portion of the display unit is lateral with respect to the conveyance direction.

Further, in another preferred embodiment, the unit mother board includes at least one column of display units arranged in a longitudinal direction parallel to the conveyance direction, and the defect inspection performed in the excited state of the display unit is Superposing a virtual terminal unit on the unit mother board, connecting an electrical connection terminal of the virtual terminal unit to an electrical connection terminal of the display unit, and supplying excitation power to the virtual terminal unit; the virtual terminal unit is An outer frame having a shape corresponding to the periphery of the unit mother board and a gate member disposed in the outer frame form a window corresponding to the display surface of the display unit, and are disposed along the respective sides of the window: and the display unit The electrical connection terminal corresponding to the electrical connection terminal of the terminal portion.

Further, in another preferred embodiment, the unit mother board includes a plurality of columns of display units arranged in a plurality of columns arranged in the longitudinal direction parallel to the conveyance direction, and the defect inspection is performed in the excited state of the display unit. In the checking, the virtual terminal unit is superposed on the unit mother board, and the electrical connection terminal of the virtual terminal unit is connected to the electrical connection terminal of the display unit, and the dummy terminal unit is supplied with excitation power; the virtual terminal unit is borrowed a window having a shape corresponding to the periphery of the unit mother board and a horizontal grid and a vertical grid provided in the outer frame form a vertical and horizontal array of windows corresponding to the display surface of the display unit, and along the window One of the respective sides is provided with an electrical connection terminal corresponding to an electrical connection terminal of the terminal portion of the display unit.

In the present invention, the unit mother board may include at least a plurality of display units arranged in a longitudinal direction parallel to the conveyance direction, and the terminal portions of the plurality of display units are all in a state of being horizontal with respect to the conveyance direction. The direction is carried. The optical functional film may include at least a polarizer. In this case, the optical functional film is a laminate of a polarizer and a 1/4 wavelength retardation film, and the laminate is preferably attached to the display surface such that the 1/4 wavelength retardation film faces the display unit. . The display unit may be an organic EL display unit.

In still another aspect of the present invention, there is provided a virtual terminal unit for applying excitation power for performing defect inspection of the display unit by causing a plurality of display units on the unit mother board to simultaneously be in an excited state. a virtual terminal unit having a plurality of columns of display units arranged in a longitudinal direction of a plurality of display units, the display unit being configured to have a rectangular shape having two short sides and two long sides The display surface is formed with a terminal portion having an electrical connection terminal along one of the short side and the long side. The virtual terminal unit includes: a frame corresponding to the shape of the periphery of the mother board, a horizontal grid and a vertical grid disposed in the outer frame; a window formed by the horizontal grid and the vertical grid respectively corresponding to the display surface of the plurality of display units; Each of the sides of the window is provided with an excitation power supply electrical connection terminal disposed at a position corresponding to the electrical connection terminal of the terminal portion of the display unit; and for supplying excitation power to the excitation power supply electrical connection terminal The power source connection is activated.

According to the method of the present invention, in the case where the display unit is inspected in an excited state, the adhesive layer is inspected on the display surface of the display unit, so that the adhesive layer acts as a protective layer and the protective film is used. In contrast, the protective film peeling step can be omitted. Further, since the inspection is performed in an excited state before the display surface is bonded to the optical functional film, it is possible to perform a precise inspection as compared with the inspection after the optical functional film is bonded.

Further, in the virtual terminal unit of the present invention, a plurality of display units on the unit mother board can be simultaneously activated, so that high-efficiency inspection can be performed.

I‧‧‧Optical function film bonding position

II‧‧‧ Glass substrate peeling position

III‧‧‧Adhesive layer gives position

IV‧‧‧Composite film bonding position

V‧‧‧Optical display unit cut-off position

W‧‧‧width in the horizontal direction

L‧‧‧length in the longitudinal direction

B‧‧‧unit assembly body board

1‧‧‧Optical display unit

1a‧‧‧ Short side

1b‧‧‧Longside

1c‧‧‧Terminal part

1d‧‧‧Display section

3‧‧‧ glass substrate

4‧‧‧Substrate

5‧‧‧Surface protection film

10‧‧‧Attractive retention disk

20‧‧‧Adhesive layer imparting mechanism

21‧‧‧Adhesive tape

21f‧‧‧Adhesive sheet

22‧‧‧Adhesive belt roller

28‧‧‧Incision forming mechanism

28a‧‧‧Incision

29‧‧‧ cutting blade

83‧‧‧Optical functional film

83a‧‧‧Roll of optical functional film

83b‧‧‧ polarizer

83d‧‧1/4 wavelength retardation film

86‧‧‧Adhesive tape

90‧‧‧Composite film

BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a plan view showing an example of an optical display unit usable in a method according to an embodiment of the present invention.

Fig. 2 is a view schematically showing an organic EL having a relatively small display screen A perspective view of an example of a manufacturing step of a display unit.

Fig. 3 is a view showing an example of a unit assembly mother board to which the method of the present invention is applied, wherein (a) is a plan view and (b) is a cross-sectional view.

4(a), (b), (c) and (d) are diagrams showing respective stages of the surface protective film peeling operation.

Fig. 5 is a schematic view showing the structure of an optical inspection apparatus, which respectively shows (a) a reflection inspection apparatus and (b) a lighting inspection apparatus.

Fig. 6 is a plan view showing a dummy terminal element for lighting inspection of the unit assembly mother board shown in Fig. 2;

Fig. 7 is a perspective view showing a state in which lighting inspection is performed using the virtual terminal unit shown in Fig. 6;

Fig. 8 is a schematic side view showing the entire adhesive layer applying mechanism.

Fig. 9 (a), (b), (c), (d) and (e) are schematic views showing the bonding procedure of the adhesive sheet of the unit assembly main body in an embodiment of the present invention.

Fig. 10 is a schematic view showing an optical display panel manufacturing apparatus according to an embodiment of the optical functional film bonding method of the present invention.

Fig. 11 is an enlarged cross-sectional view showing an example of an optical functional film.

Fig. 12 is a schematic view showing an apparatus for carrying out another embodiment of the optical functional film bonding method of the present invention.

Fig. 13 is a perspective view showing an example of application of an adhesive layer in an embodiment in which display units are arranged in a vertical row.

Fig. 14 is a plan view showing an example of a unit mother board of a display unit having a large-sized flexible sheet structure.

Figure 15 is a view showing the action of the adhesive layer of the example shown in Figure 14; Stereo picture.

An example of an optical display unit 1 to which the method of one embodiment of the present invention is applied is shown in FIG. The optical display unit 1 has a rectangular shape having a short side 1a and a long side 1b in a planar shape, and a terminal portion 1c having a predetermined width is formed along one short side 1a. A plurality of electrical terminals 2 for electrical connection are disposed in the terminal portion 1c. The area other than the terminal portion 2 of the optical display unit 1 is the display area 1d. The display region 1d has a width W in the lateral direction and a length L in the longitudinal direction. In order to carry out the method of the present invention, the optical display unit 1 is preferably an organic EL display unit, but the method of the present invention can be applied as long as it is a display unit of a flexible film structure. The optical display unit 1 can be of various screen sizes from a mobile phone or a smart phone, or a smaller type of tablet computer to a larger type of television use.

2 is a perspective view schematically showing an example of a manufacturing procedure of an organic EL display unit having a relatively small display screen for use in a smart phone or a tablet. In this step, the glass substrate 3 is first prepared as a heat-resistant substrate, and a heat-resistant resin material having a predetermined thickness is applied onto the glass substrate 3, preferably a polyimide resin, and the resin substrate 4 is formed by drying. As the heat resistant resin material, polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polycarbonate (PC), or the like can be used in addition to the polyimide resin. In addition, as the material of the substrate, the flexibility described in JP-A-2007-157501 (Patent Document 3) can be used. The ceramic sheet is as described in JP-A-2013-63892 (Patent Document 4), JP-A-2010-13250 (Patent Document 5), and JP-A-2013-35158 (Patent Document 6). Flexible glass. When a flexible ceramic sheet or a flexible glass is used as the substrate, it is not necessary to use the glass substrate 3.

In the resin substrate 4, a plurality of organic EL display units 1 are formed in a state in which they are arranged in a matrix of vertical and horizontal directions by a known production method, and the resin substrate 4 and the display unit 1 form a unit assembly mother board B. . When the number of display units formed on the resin substrate 4 is one, this is called a unit mother board. In the conventional method, the surface protective film 5 is bonded to the organic EL display unit 1 formed on the resin substrate 4 after that. A state in which the unit assembly mother board B or the unit mother board is bonded to a heat-resistant substrate such as the glass substrate 3 is sometimes referred to as a mother board structure.

Fig. 3 (a) is a plan view showing a unit assembly mother board B to which the surface protection film 5 is not bonded, and Fig. 3 (b) is a cross-sectional view taken along line bb of Fig. 4, showing a conventional manufacturing method, The unit assembly mother board B of the surface protection film 5 is placed on the glass substrate 3. As shown in Fig. 3 (a), in the unit assembly main plate B, the plurality of optical display units 1 are arranged in a row in the vertical direction and in the horizontal direction in a state in which the terminal portion 1a faces in the lateral direction. As shown in Fig. 3(a), the unit assembly mother board B has a rectangular shape having a short side B-1 and a long side B-2, and is printed near the both ends of one short side B-1. An imprint or other suitable method is attached to the fiducial mark m which becomes the reference point of the mother board B. The benchmark mark m is referred to as a reference when positioning the mother board B. When the optical film is bonded, the unit assembly mother board B is conveyed in the direction indicated by the arrow A in Fig. 3(a), that is, in the longitudinal direction.

The cell assembly mother board B having the glass substrate 3 is conveyed to the peeling position of the glass substrate of the peeling glass substrate 3 after the defect inspection by the optical display unit 1. When the unit assembly mother substrate B having the glass substrate 3 is transferred to the glass substrate peeling position, the optical functional film is bonded. The optical assembly of the unit assembly mother board B is performed before the unit assembly mother board B having the glass substrate 3 is transferred to the optical function film bonding position. For this optical inspection, it has been conventionally necessary to peel the surface protective film 5 from the unit assembly mother board B. The order in which the surface protective film 5 is peeled off is shown in FIG.

Referring to Fig. 4, the unit assembly mother board B is held by the vacuum suction force on the attraction holding tray 10 supported by the guide member 15 and the support mechanism 13, and is fed into the surface at the position shown in Fig. 4(a). The protective film peeling position is raised to a predetermined height by the elevating mechanism at the position shown in FIG. 4(b). The predetermined height is the height of the upper surface of the surface protective film 5 of the unit assembly mother board B, which can be brought into contact with the adhesive tape 16d located between the pair of pressing rolls 16c at a predetermined contact pressure.

The unit assembly mother board B which has been raised to a predetermined height by the lifting mechanism is sent to the lower position of the peeling adhesive tape driving device 16. Here, the upper surface of the surface protective film 5 of the mother board B is in contact with the adhesive surface of the adhesive tape 16d located between the pair of pressing rolls 16c. The adhesion force of the adhesive tape 16d to the surface protective film 5 is Since the surface protective film 5 has a large adhesion force to the optical display unit 1, the surface protective film 5 adheres to the adhesive tape 16d, and is peeled off from the optical display unit 1 disposed on the resin substrate 4. The peeled surface protection film 5 is taken up together with the adhesive tape 16d by the take-up roll 16b. The mother board B from which the surface protective film 5 has been peeled off is lowered to the height at the position of FIG. 4(a) at the position shown in FIG. 4(d), and is moved to the optical inspection position.

The above is the peeling operation of the surface protection film which is required in the conventional method. In the present invention, since it is not necessary to bond the surface protective film, the peeling of the surface protective film is not required, and the adhesive layer is provided to the display unit on the unit assembly mother board B. For this reason, the unit assembly mother board B manufactured by the manufacturing process of FIG. 2 is moved to the adhesive layer providing position provided with the adhesive layer providing mechanism 20. FIG. 8 is a schematic side view showing the entirety of the adhesive layer applying mechanism 20.

The adhesive layer applying mechanism 20 is provided with an adhesive tape roll 22 that winds a long adhesive tape 21 into a roll shape. The adhesive tape 21 is fed from the roller 22 at a predetermined speed by a pair of driving rollers 23. In the present embodiment, the adhesive tape 21 is formed such that an adhesive layer 21b is formed on one surface of the tape base material 21a.

Further, referring to Fig. 8, the adhesive tape 21 fed from the adhesive roller 22 by the pair of driving rollers 23 passes through the guide roller 24, the floating roller 25 and the guide roller 26 and the guide which are movable in the vertical direction. The take-up roll 27 is sent to the slit forming mechanism 28. The slit forming mechanism 28 is composed of a cutting blade 29 and a pair of driving rollers 30 for feeding. The slit forming mechanism In the state where the driving roller 30 is stopped at the slit forming position, the cutting blade 29 is operated in a state where the conveyance of the adhesive tape 21 is stopped, leaving the tape base material 21e and forming only the adhesive layer 21b in the width direction thereof. Incision 28a. The interval between the slits 28a corresponds to the distance L of the longitudinal direction L of each display unit 1 on the mother board B. Therefore, the adhesive layer 21b is cut in the width direction by the slit 28a, and becomes the adhesive sheet 21c having the width W of the display unit and the length L of the longitudinal direction. As a result, a plurality of adhesive sheets 21c are continuously formed on the tape base material 21a, and the adhesive sheets 21c are supported by the tape base material 21a and sent to the bonding position.

The floating roller 25 is elastically biased upward, and is driven to continuously drive the adhesive roller 23 in the conveying direction by the driving roller 23 in the conveying direction, and stops the conveyance of the adhesive tape 21 at the time of cutting, and after the cutting is completed Only the adjustment roller that functions to adjust the tape conveyance between the drive rollers 30 of one of the predetermined distance drives is performed. That is, during the stop of the driving roller 30, the floating roller 25 moves upward by absorbing the conveying amount of the driving roller 23 by the elastic pressure, and when the driving roller 30 starts to operate, the driving roller 30 pairs the adhesive. The tension applied by the belt 21 resists the elastic pressure and moves downward.

The series of adhesive sheets 21c formed by the slits 28a are supported by the tape substrate 21a, passed through the guide rolls 31 and the guide rolls 32, and passed through the floating rolls 33 of the same configuration as the dancer rolls 25, and It is sent to the bonding position by the guidance of the guide rollers 34, 35, 36, 37.

A bonding roller 38 and a carrier film peeling machine are provided at the bonding position Structure 39. The bonding roller 38 is disposed to be movable between the upper retracted position and the lower pressing position, and is supported by the continuous adhesive sheet 21c of the tape base material 21a, and the front end of the adhesive sheet 21c of the head is attached to the front end. When the front end of the object display unit 1 is in a position-integrated state, the adhesive sheet 21c is pressed against the display unit 1 on the mother board B from the upper position to the lower pressing position, and an adhesive layer is applied to the display surface.

The tape substrate peeling mechanism 39 is provided with a peeling blade for folding the tape base material 21a at an acute angle at the bonding position, and peeling the front optical film sheet 21c from the tape base material 21a. A tape substrate take-up roll 40 for receiving the tape substrate 21a folded at an acute angle is disposed. The tape base material 21a peeled off from the adhesive sheet 21c is conveyed to the take-up roll 40 via the guide roll 41 and the pair of take-up drive rolls 42, and is taken up by the take-up roll 40.

The operation of the driving roller 30 and the cutting blade 29 is controlled by a control device not shown in Fig. 8 . That is, the control device stores information on the size and position of the display unit 1 on the mother board B, and causes the control device to control the driving and cutting edges of the driving roller 30 based on the information of the length L of the longitudinal direction of the display unit 1. The operation of 29 is such that a slit 28a is formed in the adhesive tape 21 at intervals in the longitudinal direction corresponding to the longitudinal direction length L of the display unit 1. Further, on the upstream side of the bonding position, a sheet position detecting device 43 for detecting the front end of the adhesive sheet 21c is provided, and information on the position of the front end of the adhesive sheet 21c conveyed to the bonding position is supplied to the control device. The position information of the front end of the adhesive sheet is stored in the control device, and the control device is maintained according to the position information of the front end of the adhesive sheet and by suction. The position information of the mother board B obtained by the disk 10 controls the operation of the driving roller 30 and the winding driving roller 42 so as to correspond to the operation of sucking and holding the disk 10, and the adhesive sheet 21c peeled off from the tape substrate 21a. At the front end, the front end of the display unit 1 that is bonded to the mother board B at the bonding position is adjusted to be in positional integration. When the positional integration is achieved, the adhesive sheet 21c and the mother board B are carried at a synchronous speed. The bonding roller 38 is lowered to the lower pressing position, and the adhesive sheet 21f is pressed against the display surface of the display unit 1. As described above, the application of the adhesive layer to the display unit 1 is performed.

FIG. 9 is a schematic view showing an example of a procedure in which the adhesive sheet 21c is sequentially attached to the mother board B in the order of the display units 1 arranged in the vertical and horizontal rows. In the example of the drawing, the bonding mechanism 20 is fixed in the lateral direction with respect to the conveyance direction, and the suction holding tray 10 of the mother board B is held, and is attached so as to be movable in the lateral direction on the support mechanism 13. As shown in Fig. 9(a), the position of the mother board B is initially controlled so that the display unit 1 at the head of the display unit column at the left end is positioned at the bonding position. In this state, as described above with reference to Fig. 8, the adhesive sheet 21c is bonded to the display portion 1d of the display unit 1 at the front of the left end row.

Next, the suction holding tray 10 is moved in the lateral direction, whereby the mother board B is displaced in the left lateral direction with respect to the conveyance direction, and is displaced by a distance corresponding to the lateral direction of the display unit row. By the lateral displacement, as shown in FIG. 9(b), the display unit 1 before the second column from the left is positioned at the bonding position. Then, the adhesive sheet 21f is bonded to the display portion 1d of the display unit 1 by the same operation as described above. Thereafter, the mother board B is displaced in the left lateral direction by the same operation, and the adhesive sheet 21c is attached. Hehe. When the display unit 1 is in the case of the example of the arrangement of the three columns, the bonding of the adhesive sheet 21c to the front display unit is completed. This state is shown in Fig. 9(c).

Next, the suction holding disk 10 is driven in the conveyance direction at a distance corresponding to the interval between the display units 1 of the respective columns, so that the second display unit 1 is positioned at the bonding position from the front of the right end row, and similarly As shown in Fig. 9 (d), the adhesive sheet 21f is bonded to the display portion 1d of the unit 1. Thereafter, as shown in FIG. 9(e), the mother board B is driven in the conveyance direction, and the adhesive sheet 21c is bonded by the same operation.

The adhesive sheet 21c is applied to the unit assembly mother board B of the display surface of the display unit 1 as described above, and is transported to the inspection position. In one embodiment of the present invention, the optical inspection is performed in two stages of the surface reflection inspection shown in Fig. 5 (a) and the lighting inspection of the display unit shown in Fig. 5 (b). As shown in Fig. 5 (a), the inspection apparatus for surface reflection inspection includes a light source 70 and a light receiver 71, and the unit assembly mother board B is supported by the suction holding tray 10, and moves to the reflection inspection apparatus. Below. At this position, light from the light source 70 reaches the surface of the subject, that is, the optical display unit 1, and is reflected on the surface of the optical display unit 1 to enter the photoreceiver 71, thereby detecting the surface of the optical display unit 1. defect.

Fig. 5(b) is a view showing an outline of the lighting inspection of the excitation display unit 1, and the detectors 72 for detecting the light-emitting state of the optical display unit 1 are arranged in a line in a plurality. The unit assembly mother board B manufactured by the step shown in FIG. 2 has a structure in which a plurality of optical display units 1 are arranged in a matrix of vertical and horizontal directions. Therefore, in this embodiment, in order to make a unit set All of the optical display units 1 in the body mother board B are simultaneously activated, and the dummy terminal unit 75 shown in Fig. 6 (a) and (b) is used.

Referring to Fig. 6(a), the virtual terminal unit 75 includes a rectangular outer frame 75a corresponding to the rectangular shape of the unit assembly mother board B, a plurality of horizontal gates 75b, and a plurality of vertical grids 75c. Inside, a rectangular shape window 75d is formed which is arranged in the vertical direction and the horizontal direction in correspondence with the arrangement of the optical display units 1 in the unit assembly mother board B. A connection terminal 76 is disposed at a position corresponding to the terminal 2 of the terminal portion 1c of each optical display unit 1 along one short side of each of the windows 75d. Further, the virtual terminal unit 75 is provided with power supply terminals 77a and 77b for supplying excitation power to the terminals 2 of the respective optical display units 1 in the unit assembly mother board B.

6(b) is a view showing the inside of the virtual terminal unit 75, and the inside of the dummy terminal unit 75 is provided for connecting the positive electrode side terminal of the connection terminal 76 to the positive electrode side power supply terminal 77a. The connection line 78a and the connection line 78b for connecting the negative side terminal among the connection terminals 76 to the negative electrode side power supply terminal 77b. The positive electrode side power supply terminal 77a and the negative electrode side power supply terminal 77b are connected to the positive electrode side terminal 79a and the negative electrode side terminal 79b of the power supply source 79, respectively.

Fig. 7 shows a state in which the virtual terminal unit 75 shown in Fig. 6 is used. The dummy terminal unit 75 is placed on the unit assembly mother board B by being overlapped on the peripheral portion of the unit assembly mother board B. In this state, the window 75d of the virtual terminal unit 75 overlaps with the optical display unit 1 in the unit assembly mother board B, respectively. Here, the virtual terminal unit When the excitation power is supplied to 75, all of the optical display units 1 of the unit assembly mother board B are simultaneously in an excited state. At this time, the operation state of each unit 1 is checked by the detector 72 for each illuminating color. By using the dummy terminal unit 75, all of the cells of the plurality of mother boards having the plurality of optical display units can be inspected together in an excited state.

FIG. 10 is a schematic view showing an optical display panel manufacturing apparatus 80 according to an embodiment of the present invention for bonding an optical functional film. When the optical inspection is completed for all the display units 1 by the above-described steps, the unit assembly mother board B is moved to the optical display panel manufacturing apparatus 80 shown in FIG. 10 while being held by the suction holding tray 10.

The apparatus 80 includes a belt take-up roller 81 and a plurality of guide rollers 84a, 84b, 84c, 84d, and 84e. A roller 83a of a belt-shaped optical function film 83 is attached to the tape take-up roller 81. As shown in FIG. 11, the optical functional film 83 is a long-length mesh-shaped polarizing film in which a protective film 83c such as a TAC film is bonded to both sides of the polarizing plate 83b, and a transparent adhesive layer 83e is bonded thereto. The laminated structure of the long-mesh 1/4 wavelength (λ) retardation film 83d of the polarizing film. The polarizer 83b and the retardation film 83e are arranged such that the absorption axis of the polarizer 83b and the slow axis or the fast axis of the retardation film 83e intersect at an angle of 45°±5°. The optical functional film 83 has a long continuous mesh shape, but has a width which is an upper surface of the entire display unit which can cover a plurality of rows arranged on the mother board B. In other aspects, the optical functional film 83 may have a 1/2 retardation film interposed between the polarizing film and the 1/4 wavelength retardation film 83d in the structure shown in FIG. In this case, the slow axis or the fast axis of the 1/2 retardation film is configured as a phase The absorption axis of the polarizer 83b intersects at an angle ranging from 15° ± 5°, and the slow axis or the fast axis of the 1/2 retardation film and the slow axis or fast axis of the 1/4 wavelength retardation film 83d are arranged. The angle is in the range of 60 ° ± 5 °.

Alternatively, each of the optical functional films is configured to have a width corresponding to each lateral width W of the display unit 1 disposed on the mother board B in a plurality of columns, and the roller 83a of the optical functional film 83 is equivalent to the mother board. The number of the vertical direction of the display unit 1 on B is arranged side by side in the lateral direction, and the optical functional film 83 can be bonded to the display surface of the display unit 1 in each row.

In the case of the present embodiment, the absorption axis of the polarizer 83b is parallel to the longitudinal direction of the polarizer 83b, and the slow axis of the retardation film 83d is 45° with respect to the longitudinal direction of the retardation film 83d. The direction of the angle tilt of the range of ±5°. For this reason, in the manufacturing stage of the retardation film 83d, it is necessary to extend the film obliquely. The oblique extension is described in detail in Japanese Patent Application No. 2013-070787 (Patent Document 7) and Japanese Patent Application No. 2013-070789 (Patent Document 8), and the methods described in the above-mentioned documents can be used. Extended retardation film. Further, as the retardation film 83d, a phase difference corresponding to a film having a reverse dispersion characteristic in which the wavelength is smaller on the shorter wavelength side can be used. The retardation film having the reverse dispersion property is described in Japanese Patent No. 5204200 (Patent Document 9), Japanese Patent No. 5448264 (Patent Document 10), etc., and the patent application can be used in the method of the present embodiment. A retardation film of reverse dispersion characteristics is described.

The optical functional film 83 is sent by the roller 83a to adhere The coating layer 83c faces the horizontal direction along the traveling path on the lower side of the guide rollers 84b, 84c, 84d, 84e. The unit assembly mother board B to which the adhesive sheet 21c is bonded to the display surface of the optical display unit 1 is held together with the glass substrate 3 bonded to the mother board B while being held by the suction holding tray 10. It is carried to a position below the carrier tape 83 that extends in the horizontal direction.

The optical display unit manufacturing apparatus 80 shown in FIG. 10 has an optical function film bonding position I, a glass substrate peeling position II, an adhesive layer application position III, a composite film bonding position IV, and an optical display unit cutting position V. . The unit assembly mother board B to which the adhesive sheet 21c is bonded to the display surface of the optical display unit 1 and the glass substrate 3 are used before the optical function film bonding position I is used, and the supporting mechanism provided on the suction holding tray 10 is used. The height adjustment mechanism of 13 adjusts the height. The height to be adjusted refers to the adhesive sheet 21c to which the optical display unit 1 attached to the unit assembly mother board B is attached, and contacts the height of the retardation film 83d of the optical functional film 83 at a predetermined contact pressure. The unit assembly mother board B and the glass substrate 3 on the suction holding tray 10 after the height adjustment are sent to the lower side of the second guide roller 84b from the left in Fig. 10 . Here, the optical function film 83 fed from the roller 83a is pressed against the adhesive sheet 21f on the unit assembly mother board B by the guide roller 84b. As a result, the optical functional film 83 is bonded to the unit assembly mother board B.

In this process, the optical functional film 83 is in the transport direction shown by the arrow A in Fig. 10 to be synchronized with the suction holding disk 10. Degree is driven. While the unit assembly mother board B is bonded to the position I by the optical function film, the optical function film 83 is bonded to the adhesive sheet 21c of all the display units on the unit assembly mother board B. After the unit assembly mother board B is bonded to the position I by the optical function film, the vacuum suction force of the suction holding disk 10 is released, and the unit assembly mother board B and the glass substrate 3 are made only by the optical function film 83. The state of the support.

The unit assembly mother board B and the glass substrate supported by the optical function film 83 are then conveyed to the glass substrate peeling position II. At this position II, the glass substrate 3 is peeled off from the resin substrate 4 by a known method such as laser irradiation. A technique for peeling a glass substrate from a resin substrate by laser irradiation is described, for example, in International Publication WO 2009/104371 (Patent Document 2). The cell assembly mother substrate B after the glass substrate 3 is peeled off is transferred to the adhesive layer supply position III.

Position III is applied to the adhesive layer, and the lower side of the guide rolls 84c and 84d on the upper side of the optical function film 83 is disposed opposite to the guide rolls 84c and 84d, and the optical functional film 83 is provided by the optical function. The rollers 85a and 85b sandwiched by the unit assembly mother board B supported by the film 83. Further, at the position III of the adhesive layer, an adhesive tape delivery roller 87 is provided, and the roller 86a of the adhesive tape 86 is supported on the delivery roller 87. The adhesive tape 86 is composed of an adhesive layer 86b, a first peeling spacer 86c bonded to one side of the adhesive layer 86b, and a second peeling spacer 86d attached to the other side of the adhesive layer 86b. Composition. The adhesive tape 86 fed by the roller 86a passes through the guide roller 88 and is transported between the roller 85a and the unit assembly mother board B supported by the carrier tape 83.

In this process, after the adhesive tape 86 is fed out from the roller 86a, the first peeling spacer 86c is peeled off before reaching the guide roller 88, and the adhesive layer 86b is exposed. The peeled first peeling pad 86c is taken up by the take-up roll 89a. Next, the adhesive tape 86 is carried between the roller 84c and the roller 85a, and the exposed adhesive layer 86b is brought into contact with the resin substrate 4 on the lower surface of the unit assembly mother substrate B supported by the carrier tape 83. The adhesive layer 86b is bonded to the unit assembly mother board B by being pressed to the resin substrate 4 on the lower surface of the unit assembly mother board B by the rollers 84c and 85a. In this state, the unit assembly mother board B and the adhesive tape 86 are carried between the roller 84d and the roller 85b, and the second peeling spacer 86d is peeled off from the adhesive layer 86b. The peeled second peeling pad 86d is taken up by the take-up roll 89b.

The unit assembly mother board B to which the adhesive layer 86b is provided on the lower surface is supported by the optical function film 83 and moved to the composite film bonding position IV. At this position IV, the roller 90a of the composite film 90 is disposed, and the composite film 90 fed from the roller 90a is pressed to reach the guide roller 84e by the guide roller 91 disposed on the lower side of the guide roller 84e. The adhesive layer 86b to which the lower surface of the unit assembly mother board B is provided is located below. As a result, the composite film adheres to the unit assembly mother board B. Thereafter, the unit assembly mother board B is supported by the optical functional film 83 bonded to the upper surface and the composite film 90 bonded to the lower surface. In order to drive the laminated body composed of the optical function film 83, the composite film 90, and the unit assembly mother board B in the conveyance direction, a pair of drive rolls 91a and 91b can be provided. In this embodiment of the invention, the composite film 90, the structure The laminate is formed of a layer of a light-shielding film and a layer of a film having punching resistance and heat dissipation. However, in another embodiment of the present invention, the composite film may be changed, and a general inner protective film may be used.

The unit assembly mother board B to which the optical function film 83 is bonded to the upper surface and the composite film 90 is bonded to the lower surface is carried to the optical display unit cutting position V. At the cutting position V, a support conveyor belt 92 and a cutting blade 93 made of synthetic resin that receives the composite film 90 are provided, and the unit assembly mother board B is cut and separated into the respective optical display units 1. In this case, the optical function film 83 bonded to the upper surface of the unit assembly mother board B is cut in accordance with the size of the display surface 1d of each display unit 1. The mechanism and operation for the above cutting are well known, and detailed description thereof will be omitted.

Fig. 12 is a view showing another embodiment of the optical functional film bonding. The basic structure and operation of the device are the same as those of the device 80 shown in FIG. 10, and the corresponding portions are denoted by the same reference numerals, and detailed description thereof will be omitted. The apparatus shown in Fig. 12 differs from the apparatus 80 shown in Fig. 10 in that a unit assembly mother board B having an adhesive layer 86b applied to the lower surface between the roller 84c and the roller 85a is optical. The functional film 83 and the second peeling pad 86d are taken up by the roll 100 in the form of a laminate. The layered body taken up by the roll 100 can be fed by the roll 100 in another step, and processed at the composite film bonding position IV and the optical display unit cutting position V.

The method of the present invention can also be applied to the display unit 1 arranged in the vertical column 1 on the mother board B. This example is shown in FIG. In this case, The display unit 1 is arranged such that the orientation of the terminal portion 1c with respect to the column is laterally disposed on the mother board B. The adhesive layer is applied to the display surface 1 of the display unit 1 by the same operation as that described with reference to Fig. 8, and the previously-adhered adhesive sheet 21c can be sequentially attached to the display unit from the front of the column. The display unit 1d of 1 is performed.

The method of the present invention can also be applied to a display unit of a relatively large-sized flexible sheet structure. This example is shown in Figs. 14 and 15 . When the display unit is an organic EL unit, the unit itself can be made into a thin flexible sheet structure. Referring to Fig. 14, an optical display unit 101 of a flexible sheet structure has a rectangular shape having a short side 101a and a long side 101b, and has a terminal portion 101c located along the short side 101a, and a length L and a lateral direction having a longitudinal direction. The display portion 101d of the width W. The display unit 101 is formed on a substrate 102 made of a heat-resistant resin material such as polyimide. In the same manner as the step described in FIG. 3, the resin substrate 102 is formed into a film shape on the glass substrate 3, and an optical display unit 101 such as an organic EL display unit is formed thereon. In contrast to the case of Fig. 3, in the present embodiment, one display unit is formed on the substrate 102. Similarly to the step described in FIG. 3, after the optical display unit 101 is formed on the substrate 102, the adhesive sheet 21c is bonded to the display surface 101d of the display unit 101. In the present embodiment, the same mechanism as the adhesive layer applying mechanism 20 shown in Fig. 8 can be employed for this purpose. In this case, the optical film 21 fed from the belt-shaped adhesive roller 22 has a width corresponding to the width W of the display unit 101 shown in Fig. 16 . Fig. 15 schematically shows the structure of the bonding portion. The function of the bonding portion is the same as that of the foregoing in FIG. 8, and the corresponding portions are denoted by the same reference numerals.

The present invention has been described with respect to the specific embodiments, and the present invention is not limited to the illustrated embodiments, and the scope of the present invention is limited only by the claims of the claims.

B‧‧‧unit assembly body board

1‧‧‧Optical display unit

3‧‧‧ glass substrate

4‧‧‧Substrate

10‧‧‧Attractive retention disk

21c‧‧‧Adhesive sheet

70‧‧‧Light source

71‧‧‧Receiver

72‧‧‧Detector

Claims (10)

An optical inspection method for a display unit of a flexible film structure, comprising: at least one display unit having a display surface constructed of a resin substrate and a flexible film formed on the resin substrate a mother board structure configured as a unit mother board is conveyed in a conveyance direction with the display surface of the display unit facing upward; and the display surface of the display unit of the mother board structure conveyed along the conveyance direction a stage of forming an adhesive layer; supplying the excitation power to the display unit having the adhesive layer formed on the display surface of the display unit to cause the display unit to be in an excited state, and performing a defect inspection on the display unit in an excited state And a stage of bonding the optical functional film to the adhesive layer formed on the display surface of the display unit after the defect inspection is completed. The optical inspection method of the display unit of the flexible film structure according to claim 1, wherein the display surface of the display unit is a rectangular shape having two short sides and two long sides, and the display unit is configured as Forming a terminal portion having an electrical connection terminal along one of the short side and the long side, wherein the unit mother board is in a state in which the terminal portion of the display unit is lateral with respect to the conveyance direction Being carried. The optical inspection method of the display unit of the flexible film structure according to claim 2, wherein the unit mother board has at least one The plurality of display cells arranged in the longitudinal direction parallel to the transport direction are subjected to the defect inspection in the excited state of the display unit by superimposing the dummy terminal unit on the unit mother board Connecting the electrical connection terminal of the virtual terminal unit to the electrical connection terminal of the display unit, and supplying excitation power to the dummy terminal unit; the virtual terminal unit is shaped by a shape corresponding to the periphery of the unit mother board a frame and a gate member provided in the outer frame to form a window corresponding to the display surface of the display unit, and disposed along the one side of the window: electrical connection with the terminal portion of the display unit The aforementioned electrical connection terminal corresponding to the connection terminal. The optical inspection method of the display unit of the flexible film structure according to claim 2, wherein the unit mother board includes a plurality of vertical rows of the display unit arranged in a longitudinal direction parallel to the conveyance direction. The defect inspection performed in the excited state of the display unit is performed by superposing the dummy terminal unit on the unit mother board and connecting the electrical connection terminal of the dummy terminal unit to the electrical connection terminal of the display unit And supplying the excitation power to the dummy terminal unit; the dummy terminal unit is formed by an outer frame having a shape corresponding to a periphery of the unit mother board, and a horizontal grid and a vertical grid provided in the outer frame. The vertical and horizontal rows and columns correspond to the windows of the display surface of the display unit, and the electrical connection terminals corresponding to the electrical connection terminals of the terminal portions of the display unit are disposed along one side of the window. The optical inspection method of the display unit of the flexible film structure according to any one of claims 2 to 4, wherein the unit mother board is at least The display unit includes a plurality of display units arranged in a longitudinal direction parallel to the conveyance direction, and the terminal portions of the plurality of display units are conveyed in the conveyance direction in a state of being horizontal with respect to the conveyance direction. The optical inspection method of the display unit of the flexible film structure according to any one of claims 1 to 5, wherein the optical functional film contains at least a polarizer. The optical inspection method of the display unit of the flexible film structure according to claim 6, wherein the optical functional film is a laminate of a polarizer and a 1/4 wavelength retardation film, and the laminate is the aforementioned The /4 wavelength retardation film is attached to the display surface in such a manner as to face the display unit. The optical inspection method of the display unit of the flexible film structure according to claim 6, wherein the optical functional film is a sequential laminated polarizer, a 1/2 wavelength retardation film, or a 1/4 wavelength retardation film. The antireflection film formed of the laminate is bonded to the display surface such that the 1/4 wavelength retardation film faces the display unit. The optical inspection method of the display unit of the flexible film structure according to any one of claims 1 to 8, wherein the display unit is an organic EL display unit. A virtual terminal unit is a virtual terminal unit for applying excitation power for performing defect inspection of a display unit by causing a plurality of display units on a unit mother board to simultaneously be in an excited state, and the unit motherboard includes a plurality of columns a column of display units arranged in a longitudinal direction by a plurality of display units, the display unit being configured to have two short sides and two long a display surface having a rectangular shape on the side, and forming a terminal portion having an electrical connection terminal along one of the short side and the long side, the virtual terminal unit including: a shape corresponding to a periphery of the unit mother board a frame, a horizontal grid and a vertical grid disposed in the outer frame; a window formed by the horizontal grid and the vertical grid respectively corresponding to the display surface of the plurality of display units; and a side of each of the windows An excitation power supply electrical connection terminal disposed at a position corresponding to an electrical connection terminal of the terminal portion of the display unit; and an excitation power source connection portion for supplying excitation power to the excitation power supply electrical connection terminal.