TWI541548B - A manufacturing system for an optical film roll, and a method for manufacturing an optical film roll - Google Patents

Description

Optical film roll manufacturing system and optical film roll manufacturing method Technical field

The present invention relates to an optical film for slitting a long sheet-shaped optical film material along a longitudinal direction thereof to form a long sheet-shaped optical film, and winding the long sheet-shaped optical film into a roll to produce optical A manufacturing system and a manufacturing method of a film roll.

Background technique

In a stereoscopic image display device such as a 3D-LCD TV that displays a stereoscopic image, a right-eye image display region (first phase difference region) and a left-eye image in which phase differences are different from each other are alternately arranged in the width direction. A pattern retardation film such as a display region (second phase difference region) or a pattern film in which a light transmitting region and a light blocking region are disposed. Patterns are formed in advance on these films.

In the production of an optical film roll, a wide optical film material is usually slit at a predetermined width, and the slit optical film is wound into a roll. However, in the case of the optical film in which the pattern is formed in advance as described above, not only the slit width is required to be appropriate, but also the slitting is required to be performed with high precision at an appropriate position with respect to the pattern.

Patent Document 1 discloses a roll formed by winding a pattern retardation film.

Advanced technical literature Patent literature

Patent Document 1: Japanese Special Open 2012-32445

Summary of invention

However, in Patent Document 1, a method of performing slitting with high precision at an appropriate position with respect to the pattern is not specifically described.

The present invention has been made in view of the above-described problems, and it is an object of the invention to provide an optical film roll which can cut a high-order sheet-shaped optical film material having a pattern at a position that is accurately cut at an appropriate position with respect to a pattern. Manufacturing system and method of manufacturing an optical film roll.

In order to solve the above problems, careful study has been made to complete the following invention. In other words, in the production system of the optical film roll according to the present invention, the optical film material is cut while conveying the long sheet-shaped optical film material having the pattern, and the obtained long sheet-shaped optical film is wound into An optical film roll is produced in a roll shape, the manufacturing system of the optical film roll having: an image pickup unit that images the pattern of the conveyed optical film material; and a calibration unit based on the image pickup The image pickup result obtained by the portion adjusts the position in the width direction of the slit portion that slits the optical film material.

According to this configuration, since the position of the slit portion in the width direction is adjusted based on the position in the width direction of the pattern of the optical film material, the optical film material can be accurately divided at a position appropriate for the pattern. cut.

Examples of the pattern include a line (reference line) parallel to the longitudinal direction of the optical film material or a line (reference line) parallel to the transport direction (longitudinal direction) of the long sheet-shaped optical film material to be transported. .

In the present specification, the "width direction" means a direction orthogonal to the transport direction (longitudinal direction) of the long sheet-shaped optical film material to be transported.

Further, in the production system of the optical film roll of another aspect of the present invention, the optical film raw material is cut while conveying the long sheet-shaped optical film raw material having the pattern, and the obtained long sheet-shaped optical film is obtained. An optical film roll is produced by winding into a roll, and the manufacturing system of the optical film roll has a discharge portion that discharges the optical film raw material from the optical film raw material roll, and a conveying portion that will be discharged from the film The optical film material discharged from the portion is transported downstream; the image capturing portion images the pattern of the optical film material conveyed by the transport portion; and the slit portion that conveys the transported portion by the transport portion The optical film material is continuously cut along the longitudinal direction to obtain the elongated sheet-shaped optical film, and the aligning portion adjusts the width direction position of the slit portion based on the image capturing result obtained by the image capturing portion; a winding portion that winds the optical film obtained by the slitting portion into a roll shape.

According to this structure, the width direction of the pattern based on the optical film material The position is adjusted to adjust the position of the slit portion in the width direction, so that the optical film material can be slit with high precision at an appropriate position with respect to the pattern.

Further, in one embodiment of the invention, the imaging unit captures the pattern while adhering the transported optical film material to a convex curved surface formed in an arc shape along a longitudinal direction of the optical film material.

According to this configuration, variations in the conveyance of the optical film material can be eliminated, and the measurement variation in the width direction of the measurement pattern can be reduced. Therefore, the optical film material can be slit with high precision at a position more appropriate for the pattern.

Further, in an embodiment of the invention, the optical film roll manufacturing system further includes an illumination unit that illuminates an imaging region including the pattern of the optical film material captured by the imaging unit. .

According to this configuration, since the boundary (edge) of the pattern is conspicuous, the captured image is sharp, and the measurement error of the position in the width direction of the pattern can be reduced. It is preferable that the imaging unit illuminates the pattern by the reflected light method so that the boundary (edge) of the pattern can be made more conspicuous than the pattern by the transmitted light method.

Further, in an embodiment of the invention, the optical film roll manufacturing system further includes a display unit that displays an image captured by the imaging unit.

According to this configuration, by outputting (displaying) an image captured by the imaging unit on a display unit such as a monitor, the operator can easily confirm whether or not the slitting is performed at an appropriate position with respect to the pattern by visual observation.

Further, as an embodiment of the above invention, the optical film A pattern retardation film in which a first phase difference region and a second phase difference region having different phase differences from each other are alternately arranged in the width direction.

The pattern retardation film is, for example, a pattern retardation film (a phase difference for a stereoscopic image display device) provided in a device for displaying a stereoscopic image by displaying a right-eye image and a left-eye image. Membrane).

Further, in one embodiment of the invention, the optical film is a pattern retardation film-integrated polarizing plate having a laminated pattern retardation film and a polarizing film having an absorption axis parallel to the longitudinal direction, and the pattern retardation film edge The first phase difference region and the second phase difference region having different phase differences from each other are alternately arranged in the width direction.

Further, in an embodiment of the invention, the optical film is a pattern film in which a light transmitting region and a light blocking region are disposed.

Further, examples of the cutting member of the slitting portion include a cutter and a laser. Further, the cutting member of the slit portion may be provided, for example, in two or more in the width direction of the optical film material.

Further, in the method for producing an optical film roll according to the present invention, the optical film material is cut while conveying a long sheet-shaped optical film material having a pattern, and the obtained long sheet-shaped optical film is wound into An optical film roll is produced by a roll, the method of manufacturing the optical film roll comprising: an image capture program, wherein the pattern of the optical film material to be conveyed is photographed; and a calibration procedure, wherein The imaging result obtained in the imaging program adjusts the position in the width direction of the slit portion that slits the optical film material.

Further, in the method for producing an optical film roll according to another aspect of the present invention, the optical film material is cut while conveying a long sheet-shaped optical film material having a pattern, and the obtained long sheet-like optical material is obtained. The film is wound into a roll to produce an optical film roll, the method of manufacturing the optical film roll comprising: a discharge process, wherein the optical film raw material is discharged from the optical film raw material roll; and a transporting process, wherein The optical film raw material discharged in the discharging process is transported downstream; an image capturing program, wherein the pattern of the optical film raw material conveyed by the conveying program is photographed; and a slitting program, wherein The optical film raw material conveyed by the transporting process is continuously cut along the longitudinal direction of the optical film, which is a pattern film, to obtain the elongated sheet-shaped optical film on which the light-transmitting region is disposed And a light-shielding region; a calibration procedure, wherein a width of the slit portion that slits the optical film material in the slitting program is adjusted based on an image pickup result obtained in the image capture program Direction position; winding procedure, wherein the optical film obtained in said slitting procedure wound in a roll.

1‧‧‧Optical film roll manufacturing system

10‧‧‧Release Department

30‧‧‧cutting

31, 32, 33‧‧‧ cut parts

41‧‧‧First Camera Department

43, 44‧‧ ‧ slitting camera

50‧‧‧Transportation Department

51a, 51b‧‧‧ conveying roller

51, 52, 53, 54, R2, R3, R4‧‧ ‧ rolls

70‧‧‧Winding Department

80‧‧‧Long sheet of optical film material

81, 82, 83, 84‧‧‧ long strips of optical film

90‧‧‧Information processing device

91‧‧‧Decision Department/Location Information Acquisition Department

92‧‧‧ Computing Department

93‧‧‧Control Department

95‧‧‧Monitor

301‧‧‧Split position adjustment department

411‧‧‧Circular Lighting Department

431, 441‧‧‧ rod-shaped lighting department

C1, C2‧‧‧ tangent

L1‧‧‧ baseline

R1‧‧‧ raw material roll

Fig. 1A is a schematic view showing a manufacturing system of an optical film roll of the first embodiment.

FIG. 1B is a view showing an example of a slitting portion.

FIG. 2 is a view showing an example of a reference line in the first embodiment.

FIG. 3 is a view illustrating a field of view of the first imaging unit.

FIG. 4 is a view illustrating a field of view of a slitting imaging unit.

Detailed description of the preferred embodiment (Embodiment 1)

The long sheet-shaped optical film material of the first embodiment is an optical film material (an example of a pattern retardation film-integrated polarizing plate) obtained by laminating a pattern retardation film and a polarizing film having an absorption axis parallel to the longitudinal direction. The pattern retardation film alternately arranges a first phase difference region and a second phase difference region having phase differences from each other in the width direction. The film width of the optical film raw material is, for example, 1200 mm or more and 2400 mm or less.

A reference line L1 parallel to the longitudinal direction thereof is formed on the long sheet-shaped optical film material. This reference line L1 is a part of the pattern of the pattern retardation film. The reference line L1 may be one or more than two. Further, examples of the line type of the reference line include a solid line and a broken line, but a solid line is preferable. The size of the width of the reference line orthogonal to the longitudinal direction and the color of the reference line are not particularly limited as long as they can be imaged by the imaging unit and subjected to image analysis.

The structure of the optical film roll manufacturing system 1 of the first embodiment will be described with reference to FIGS. 1A and 1B. FIG. 2 shows an example of a reference line L1 formed on the long sheet-shaped optical film material 80.

The discharge unit 10 discharges the long sheet-shaped optical film raw material 80 having the reference line parallel to the longitudinal direction from the raw material roll R1. The discharge portion 10 has a A rotating mechanism in which the raw material roll R1 rotates. The rotating mechanism can be freely rotated or coupled to the motor to be driven to rotate.

The transport unit 50 directs the optical film material 80 discharged from the discharge unit 10 Downstream transport. The conveyance unit 50 may be fed by the nip roller (not shown) with the optical film material 80 interposed therebetween, or the slit sheet-shaped optical film may be wound by the winding portion 70 disposed on the downstream side, which will be described later. The conveyance is carried out on the rolls R2, R3, and R4, and the conveyance may be performed by the above two methods. In the first embodiment, the conveying unit 50 has the conveying rollers 51a and 51b before the slitting portion 30, and the conveying rollers 52, 53, 54 at the rear portion of the slitting portion 30. The conveying rollers 51a, 51b, 52 are preferably composed of, for example, a cylindrical roller or a grooved roller.

The slitting portion 30 will carry the optical film material 80 conveyed by the conveying portion 50 along The longitudinal direction is continuously cut to obtain long strip-shaped optical films 81, 82, 83, and 84. In FIG. 1A, a winding portion for winding the optical film 84 which is one of the width direction end portions of the optical film material 80 is omitted.

The cutting member of the slitting portion 30 is, for example, a cutter or a laser. From the viewpoint of the quality of the cut surface, a cutter is preferable, and it is more preferable to face the cut object with two cutters. A shared cut of the cut. In the first embodiment, the slitting portion 30 is configured such that three cutting members are arranged linearly in the width direction of the optical film material 80.

The first imaging unit 41 images the pattern of the optical film material 80 transported by the transport unit 50. The first imaging unit 41 is constituted by, for example, a zone camera. As shown in FIG. 3, the first imaging unit 41 captures a pattern (reference line L1) in its field of view.

The first imaging unit 41 causes the transported optical film material 80 to be A convex curved surface formed in an arc shape along the longitudinal direction of the optical film material 80 is adhered to the imaging pattern (reference line L1). As the convex curved surface, a roller 51 constituting a part of the conveying portion 50 is used.

In the present embodiment, the first imaging unit 41 is included as a pair. The annular illumination unit 411 is used as an illumination unit that illuminates an imaging region including the pattern (reference line L1) of the optical film material 80 to be imaged. In the present embodiment, as shown in FIG. 1 , the first imaging unit 41 is disposed on the same side as the annular illumination unit 411 with respect to the optical film material 80 , and is disposed away from the optical film material 80 than the annular illumination unit 411 . s position. Further, between the first imaging unit 41 and the optical film material 80, a circularly polarizing plate having a relationship in which one of the reference lines is formed as a crossed polarizer and the other region is a parallel polarizer is provided.

The image captured by the first imaging unit 41 is processed by the information processing device 90. Perform image analysis. The determination unit (position information acquisition unit) 91 of the information processing device 90 detects the reference line of the image obtained by performing image analysis. As shown in FIG. 3, the detected reference line is used as a detection line. It is determined whether the detection line is located at a predetermined standard position within the field of view of the camera (the position in the width direction where the reference line should be) (or is disposed within a predetermined range). The determination unit 91 measures, for example, the vertical distance from the right end on the drawing surface of the visual field range (imaging region) to the reference line (detection line), and determines whether or not the measured value is within a predetermined value range. When the determination unit 91 determines that the position in the width direction of the reference line is at a predetermined position (the position in the width direction where the reference line should be) (or is disposed within a predetermined range), the determination unit 91 may not, for example, The monitor 95 of the display unit outputs an image.

On the other hand, the determination unit 91 determines that the reference line (detection line) is not When the predetermined standard position (the position in the width direction where the reference line should be) is (or is not disposed within a predetermined range), the calculation unit 92 obtains the slitting unit 30 (cutting members 31, 32, and 33). The direction of movement and the amount of movement. The calculation unit 92 measures, for example, the shift direction and the shift amount of the reference line from the standard position, and obtains the moving direction (the direction opposite to the shift direction) and the amount of movement of the emitting unit 10. The amount of movement can be the same as the offset, and can be larger than the offset or smaller than the offset. Then, the control unit 93 instructs the obtained cutting direction and amount of movement to the slitting position adjustment unit 301 (corresponding to the calibration unit) which will be described later.

The slitting position adjustment unit 301 (corresponding to the calibration unit) follows the information The processing device 90 adjusts the width direction position of the slit portion 30 based on the measurement result (moving direction, movement amount) measured by the imaging result (image) obtained by the first imaging unit 41. The slit position adjusting unit 301 has a moving mechanism for moving the slitting portion 30 in the width direction thereof, and the width direction of the slitting portion 30 is adjusted based on the moving direction and the amount of movement transmitted from the control unit 93 by the moving mechanism. position. As the moving mechanism, for example, a linear motion mechanism can be cited.

The slit position adjusting unit 301 can cut the cutting unit 30 31, 32, and 33 move as a unitary structure. Further, as another embodiment, the cutting members 31, 32, and 33 may be independently adjusted. For example, the cutting member 31 can be moved in a state where the cutting members 32 and 33 are fixed.

The winding portion 70 cuts the long sheet-like light cut by the slit portion 30 The films 81, 82, and 83 are wound around the rolls R2, R3, and R4, respectively. The winding unit 70 includes a motor and a rotating mechanism (not shown), and rotates the rolls R2, R3, and R4 at the same speed and at the same speed to wind the long-length optical films 81, 82, and 83, respectively.

The slitting imaging units 43 and 44 are arranged to be smaller than the slitting unit 30 (and the first shot) On the downstream side of the image portion 41), the slit lines C1 and C2 which are the end faces in the longitudinal direction of the transported optical film are cut. The slitting imaging units 43, 44 are composed of a linear camera.

The slitting imaging units 43 and 44 have the optical films 81 and 82 along the light side The slits (the cut surfaces after slitting) are taken while the convex curved surfaces of the film 81 and 82 are formed in an arc shape in close contact with each other. As the convex curved surface, rollers 53 and 54 constituting a part of the conveying portion 50 are used.

As a pair of slit lines included by the slitting imaging sections 43, 44 In the illumination unit that illuminates the imaging area including C1 and C2, rod-shaped illumination units 431 and 441 are used. As shown in FIG. 1A, the slitting imaging units 43 and 44 are disposed on the same side as the rod-shaped illumination units 431 and 441 with respect to the optical films 81 and 82, and are disposed farther from the rod-shaped illumination units 431 and 441. The position of the membranes 81, 82. Further, between the slitting imaging units 43 and 44 and the optical films 81 and 82, a circularly polarizing plate having a relationship in which one of the reference lines is formed as a crossed polarizer and the other region is a parallel polarizer is provided. .

The image captured by the slitting cameras 43 and 44 can be sent to the monitor Send and display. By outputting (displaying) the slit position captured by the slitting imaging units 43, 44 on the monitor 95, the operator can easily visually confirm the slit lines C1, C2. FIG. 4 shows an example of an image of the slit line C1 captured by the slitting imaging units 43 and 44.

<Manufacturing method>

The optical film roll is produced by slitting the optical film material while conveying a long sheet-shaped optical film material having a pattern. Method for manufacturing an optical film roll by winding a strip-shaped optical film into a roll shape, comprising: an image capturing program in which the pattern of the optical film material to be conveyed is photographed; a calibration procedure, Here, the position in the width direction of the slit portion that slits the optical film material is adjusted based on the imaging result obtained in the imaging program.

In addition, another method of manufacturing the optical film roll is a A method of producing an optical film roll by slitting the optical film material while conveying the optical film material having a long strip shape, and winding the obtained long sheet-shaped optical film into a roll shape, which includes a releasing process, wherein the optical film raw material is discharged from an optical film raw material roll; and a transporting process, wherein the optical film raw material discharged in the discharging process is transported downstream; an image capturing program, wherein The pattern of the optical film material conveyed by the transport program is photographed; and a slitting process, wherein the optical film material conveyed by the transporting process is continuous along a length direction of the optical film which is a pattern film Grounding to obtain the long strip-shaped optical film on which the light-transmitting region and the light-shielding region are disposed; a calibration procedure in which the adjustment is performed based on the image capturing result obtained in the image capturing program a position in the width direction of the slitting portion of the optical film material in the slitting process; a winding process in which the optical film obtained in the slitting process is wound into Like.

(Other embodiments of optical film)

In the above embodiment, the optical film material is described as an example of the pattern retardation film-integrated polarizing plate. However, the film material is not particularly limited thereto. For example, the pattern film of the optical film material may be alternately arranged in the width direction. Light Pattern film of area and shading area.

1‧‧‧Optical film roll manufacturing system

10‧‧‧Release Department

30‧‧‧cutting

41‧‧‧First Camera Department

43, 44‧‧ ‧ slitting camera

50‧‧‧Transportation Department

51a, 51b‧‧‧ conveying roller

52, 53, 54, R2, R3, R4‧‧·roll

70‧‧‧Winding Department

80‧‧‧ Optical film materials

81, 82, 83‧‧‧ optical film

90‧‧‧Information processing device

91‧‧‧The judgment department pulls the information acquisition department

92‧‧‧ Computing Department

93‧‧‧Control Department

95‧‧‧Monitor

411‧‧‧Circular Lighting Department

431, 441‧‧‧ rod-shaped lighting department

R1‧‧‧ optical film material roll

Claims (10)

A manufacturing system for an optical film roll, which cuts an optical film material while conveying a long sheet-shaped optical film material having a pattern, and winds the obtained long sheet-shaped optical film into a roll shape. An optical film roll is produced, the optical film roll manufacturing system having: an image pickup unit that images the pattern of the conveyed optical film material; and a calibration unit that is based on the image pickup unit The image capturing result adjusts the position in the width direction of the slit portion that slits the optical film material. A manufacturing system for an optical film roll, which cuts an optical film material while conveying a long sheet-shaped optical film material having a pattern, and winds the obtained long sheet-shaped optical film into a roll shape. An optical film roll having a discharge portion that discharges the optical film material from an optical film raw material roll, and a transport portion that emits the optical light from the discharge portion The film material is transported downstream; the image capturing portion images the pattern of the optical film material conveyed by the transport portion; and the slitting portion that transports the optical film material conveyed by the transport portion along the length The direction is continuously cut to obtain the strip-shaped optical film; a calibration unit that adjusts a position in a width direction of the slit portion based on an image pickup result obtained by the image pickup unit, and a winding portion that winds the optical film obtained by the slit portion into a roll shape. The manufacturing system of the optical film roll according to claim 1 or 2, wherein the image pickup unit forms the optical film material to be conveyed on one side and the arc along the longitudinal direction of the optical film material The convex curved surface is closely attached to the side to take the pattern. The manufacturing system of the optical film roll according to claim 1, further comprising an illuminating unit that illuminates an imaging region including the pattern of the optical film material photographed by the imaging unit. A manufacturing system of an optical film roll according to claim 1, further comprising a display portion that displays an image captured by the imaging unit. The optical film roll manufacturing system according to claim 1, wherein the optical film is a pattern retardation film in which a first phase difference region and a second phase difference region having different phase differences from each other are alternately arranged in the width direction. The optical film roll manufacturing system according to claim 6, wherein the optical film is a pattern retardation film-integrated polarization formed by a laminated pattern retardation film and a polarizing film having an absorption axis parallel to the longitudinal direction. In the pattern, the pattern retardation film alternately has a first phase difference region and a second phase difference region in which phase differences are different from each other in the width direction. A manufacturing system of an optical film roll according to claim 1, wherein the optical film is a pattern film in which a light transmitting region and a light blocking region are disposed. A method for producing an optical film roll, which is obtained by slitting an optical film material while conveying a long sheet-shaped optical film material having a pattern, and winding the obtained long sheet-shaped optical film into a roll shape to produce An optical film roll, the method of manufacturing the optical film roll comprising: an image capture program, wherein the pattern of the optical film material being conveyed is photographed; a calibration procedure, wherein, based on the image capture program The obtained imaging result adjusts the position in the width direction of the slit portion that slits the optical film material. A method for producing an optical film roll, which is obtained by slitting an optical film material while conveying a long sheet-shaped optical film material having a pattern, and winding the obtained long sheet-shaped optical film into a roll shape to produce An optical film roll, the method of manufacturing the optical film roll comprising: a discharge process, wherein the optical film material is discharged from an optical film material roll; and a transport program in which the release process is to be released The optical film material is transported downstream; an image capture program in which the pattern of the optical film material conveyed by the transport program is photographed; a slitting process in which the optics are conveyed by the transport program The film material is along the length direction of the optical film which is a pattern film Continuously cutting to obtain the long strip-shaped optical film on which the light-transmitting region and the light-shielding region are disposed; a calibration procedure in which the adjustment is performed based on the image pickup result obtained in the image capturing program In the slitting program, the position in the width direction of the slitting portion of the optical film material; and the winding procedure, wherein the optical film obtained in the slitting process is wound into a roll shape.