TWI636866B - Method for laminating an optically functional film to a display cell of a flexible thin film structure - Google Patents

Abstract

An object of the present invention is to provide a method for processing a display unit having a flexible film structure, and a display unit having a flexible film structure formed on a resin substrate and a glass substrate can be used without using a suction disk having a vacuum adsorption function. The heat resistant substrates are transferred together to the next process.

The solution is to provide a method of bonding an optical functional film to an optical display unit of a flexible film structure. This method is a mother board structure in which a unit mother substrate composed of a resin substrate and at least one display unit having a flexible film structure formed on the resin substrate and having a display surface is supported on a heat resistant mother substrate, The display surface of the display unit is conveyed in the upward direction in the transport direction, and in the process, the adhesive layer is formed on the display surface of the display unit of the mother board structure transported in the transport direction. Next, the mother board structure in which the adhesive layer is formed on the display surface of the display unit is transported in the transport direction, and the long strip-shaped optical functional film extending in the transport direction is formed on the display surface of the display unit. Adhesive layer contact, bonding optical function film to display unit, and supporting the mother board structure from above by the long-length strip-shaped optical function film, and moving the mother board structure by the movement of the optical function film This conveyance direction is conveyed, and is supported by the optical functional film of a long strip shape, and the heat resistant mother substrate is peeled off from the mother board structure conveyed in the conveyance direction.

Description

Method for bonding optical functional film to display unit of flexible film structure

The present invention relates to the technical field of bonding an optical functional film to a display unit of a flexible film structure. The present invention is not particularly limited, and provides a technique relating to bonding an optical functional film to a display unit which can form a flexible film structure such as an organic EL display unit.

In order to form a flexible film structure, the organic EL display unit is configured such that a display device using the display unit is formed into a curved surface, or the entire display device is configured to be flexible and roll-wound or bent. However, since such a display unit is a flexible film structure, handling of the display unit at the stage of manufacturing the display device is not easy.

Further, a relatively small-sized display unit used in a smart phone or tablet-sized display device is manufactured by forming a plurality of units on one substrate. Korean Patent Publication No. 10-1174834 (Patent Document 1) is known as a method of producing an organic EL display unit having a small screen size as described above. According to the patent document 1, In the method, 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-form display unit. Further, on the substrate, a plurality of display cells arranged in a plurality of columns in the vertical and horizontal directions are formed, and the entire surface is coated with a film for processing, and then the substrate on which the display unit is formed is peeled off from the glass substrate. Then, in a state in which the film for process is bonded, each film-shaped display unit is divided, and a terminal portion including an electrical terminal for electrical connection formed on one side of each film-shaped display unit is exposed, corresponding to the terminal In some cases, the film for the process is peeled off, thereby forming separate film-shaped display units.

With respect to the display unit formed on the glass substrate as described above, in the process of bonding various thin films required for subsequent processing, a movable support table having a vacuum suction function is generally used. The resin substrate on the glass substrate and a plurality of display units formed thereon are adsorbed and held on the support table with the glass substrate under the surface, and a protective film is attached to the surface of the display unit as needed. Next, the display unit after bonding the protective film is conveyed to the glass substrate peeling position together with the glass substrate. Thereafter, in the glass substrate peeling position, the upper surface of the display unit on the resin substrate is gripped by a suction disk having a vacuum adsorption function, and the vacuum suction of the movable support table is released, and the glass substrate is cut away from the movable support table to form The state in which the suction disk is supported from above. Further, the glass substrate is peeled off from the resin substrate by a method such as laser irradiation from the lower side of the glass substrate. The method of laser irradiation is described in, for example, International Publication No. WO 2009/104371 A1 (Patent Document 2). Next, the inner surface protective film was bonded to the lower surface of the resin substrate to form a display panel.

Further, in such a display panel, in order to prevent or at least reduce external light incident from the display surface side from being reflected by one of the display units and returning from the display surface to the identification side, the polarizer is attached to the polarizer. It is preferable that the optical functional film composed of the 1/4 wavelength retardation film is bonded to the display surface side. Even when the optical functional film is bonded, it is necessary to securely hold the display unit of the flexible film structure at a predetermined position.

In order to complete the above processes, there is a support table having a vacuum suction function and a suction disk having a vacuum suction function, and it is necessary to receive the glass substrate and the resin substrate and the display unit formed thereon from the support table. . Therefore, the device as a whole is bulky and becomes expensive.

[Previous Technical Literature] [Patent Literature]

[Patent Document 1] Korean Patent 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 Application No. 2013-070787

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

[Patent Document 9] Japanese Patent No. 5204200

[Patent Document 10] Japanese Patent No. 5448264

[Summary of the Invention]

The present invention is directed to a treatment method for a display unit that provides a flexible film structure, and a display unit constructed of a flexible film formed on a resin substrate and a glass substrate can be used without using a suction disk having a vacuum adsorption function. Transferring the heat-resistant substrate together to the next process is a problem.

The present invention provides a method of bonding an optical functional film to an optical display unit of a flexible film structure, the method comprising: constructing a resin substrate, and a flexible film formed on the resin substrate and having at least one display surface The unit mother board formed of the display unit is supported by the mother board structure on the heat-resistant mother substrate, and the display surface of the display unit is conveyed in the upward direction to the transport direction. In this process, an adhesive layer is formed on the display surface of the display unit of the mother board structure conveyed in the conveying direction.

Further, the mother board structure in which the adhesive layer is formed on the display surface of the display unit is transported in the transport direction, and the long strip-shaped optical functional film extending in the transport direction is formed on the display surface of the display unit. Adhesive layer contact, bonding optical function film to display unit, and supporting the mother board structure from above by the long-length strip-shaped optical function film, and moving the mother board structure by the movement of the optical function film The transport Directional delivery. Further, the heat-resistant mother substrate is peeled off from the mother substrate structure transported in the transport direction by the support of the optical functional film having a long strip shape.

The display surface of the display unit is generally a rectangular shape having two short sides and two long sides. In this case, the display unit is configured to have a terminal portion having electrical connection terminals along one of the short side and the long side. The unit mother board is 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. Moreover, it can be transported in the transport direction by the movement of the optical functional film that moves the unit mother substrate after the heat-resistant mother substrate is removed in the transport direction, and is attached to the lower surface of the unit mother board after the heat-resistant mother substrate is peeled off. Protective film.

The unit mother board may be configured to include at least a plurality of display units arranged in a longitudinal direction parallel to the transport direction. At this time, the terminal portions of the plurality of display units are transported toward the transport direction in a state in which all of them are lateral with respect to the transport direction. It is better. In this case, the cutting step of cutting the unit mother substrate together with the optical functional film into the respective display units may be included.

In the method of the present invention, the optical functional film is preferably at least a polarizer. In this case, the optical functional film is a laminate of a polarizer and a quarter-wave retardation film, and the laminate is bonded to the display surface with the 1/4 wavelength retardation film facing the display unit. good. Further, the display unit may be an organic EL display unit.

According to the method of the present invention, there will be heat resistance such as a glass substrate The mother board structure composed of the mother substrate and the unit mother board is conveyed in the transport direction while the heat-resistant mother substrate is in the downward direction, and is displayed on the display unit of the mother board structure that is transported in the transport direction. An adhesive layer is formed on the display surface to bring the long-length ribbon-shaped optical functional film into contact with the adhesive layer, and the optical functional film is bonded to the display unit, and the mother is supported from the upper surface by the long-length ribbon-shaped optical functional film Since the plate structure moves the adhesive tape in the transport direction, it is not necessary to adsorb and hold the adsorption holding disk of the mother substrate structure from the upper side, and the configuration of the apparatus can be simplified.

I‧‧‧Optical functional film laminating device

II‧‧‧ Glass substrate peeling position

III‧‧‧Adhesive layer gives position

IV‧‧‧Composite film bonding position

V‧‧‧Optical display unit cut-off position

W‧‧‧ transverse width

L‧‧‧ longitudinal length

A‧‧‧ portrait

B‧‧‧unit assembly body board

B-1‧‧‧ Short side

B-2‧‧‧Longside

M‧‧‧ benchmark mark

1‧‧‧Optical display unit

1a‧‧‧ Short side

1b‧‧‧Longside

1c‧‧‧Terminal part

1d‧‧‧Display section

2‧‧‧Electrical terminals

3‧‧‧ glass substrate

4‧‧‧Substrate

5‧‧‧Surface protection film

10‧‧‧Attractive retention disk

13‧‧‧Support institutions

15‧‧‧ Guides

16b‧‧‧ winding roller

16c‧‧‧Pushing roller

16d‧‧‧Adhesive tape

20‧‧‧Adhesive layer imparting mechanism

21‧‧‧Adhesive tape

21a‧‧‧With substrate

21c‧‧‧Adhesive tablets

22‧‧‧Adhesive tape roller

23‧‧‧Drive roller

24‧‧‧guide roller

25‧‧‧Tensile roller

26‧‧‧guide roller

27‧‧‧guide roller

28‧‧‧Incision forming mechanism

28a‧‧‧Incision

29‧‧‧cutting knife

30‧‧‧Drive roller

31‧‧‧guide roller

32‧‧‧guide roller

33‧‧‧Tensile roller

34‧‧‧guide roller

35‧‧‧guide roller

36‧‧‧guide roller

37‧‧‧guide roller

38‧‧‧Finishing roller

39‧‧‧ Carrier film peeling mechanism

40‧‧‧ winding roller

41‧‧‧guide roller

42‧‧‧Rolling drive roller

43‧‧‧Sheet position detecting device

70‧‧‧Light source

71‧‧‧Receiver

72‧‧‧Detector

75a‧‧‧Front frame

75b‧‧‧ horizontal stack

75c‧‧‧ vertical stack

75d‧‧‧ window

76‧‧‧Connecting terminal

77‧‧‧Power supply terminal

83‧‧‧Optical functional film

83a‧‧‧Optical film roll

83b‧‧‧ polarizer

83c‧‧‧Protective film

83d‧‧1/4 wavelength retardation film

83e‧‧‧Adhesive layer

84a‧‧·guide roller

84b‧‧‧guide roller

84c‧‧·guide roller

84d‧‧‧guide roller

84e‧‧·guide roller

85a‧‧‧roll

85b‧‧‧roll

86‧‧‧Adhesive tape

86a‧‧‧roll

86b‧‧‧Adhesive layer

86c‧‧‧1st peeling lining

86d‧‧‧2nd release liner

87‧‧‧Adhesive tape delivery roller

88‧‧‧guide roller

89a‧‧‧ winding roller

89b‧‧‧ winding roller

90‧‧‧Composite film

90a‧‧‧roll

91‧‧‧guide roller

91a‧‧‧Drive roller

91b‧‧‧ drive roller

92‧‧‧Support belt

93‧‧‧cutting knife

100‧‧‧roll

101‧‧‧Optical display unit

101a‧‧‧ Short side

101b‧‧‧Longside

101c‧‧‧Terminal part

101d‧‧‧Display Department

102‧‧‧Substrate

Fig. 1 is a top view showing an example of an optical display unit which can be used in an embodiment of the present invention.

Fig. 2 is a perspective view schematically showing an example of a process of an organic EL display unit having a small display screen.

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 top view and (b) is a cross-sectional view.

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

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

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

Figure 7 shows the lighting check using the quasi-terminal unit shown in Figure 6. A perspective view of the state of the investigation.

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

(a), (b), (c), and (d) are schematic views showing a bonding procedure of the adhesive sheet of the unit assembly mother board according to the 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 the application of the adhesive layer in the embodiment in which the display unit is arranged in a vertical row.

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

Fig. 15 is a perspective view showing an action of imparting an adhesive layer with respect to the example of the 14th chart.

Fig. 1 shows an example of an optical display unit 1 to which the method of one embodiment of the present invention can be applied. 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 excluding the terminal portion 1c of the optical display unit 1 becomes the display area 1d. The display area 1d has a horizontal The width W of the direction and the length L of 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 have a wide variety of screen sizes from a mobile phone or a smart phone, or a smaller type for a tablet computer to a television use.

Fig. 2 is a perspective view schematically showing an example of a process of an organic EL display unit having a smaller display screen for use as a smart phone or a tablet. In this process, the glass substrate 3 is prepared as a heat-resistant substrate, and a heat-resistant resin material having a predetermined thickness is applied to the glass substrate 3, and a polyimide resin is preferably used, and the resin substrate 4 is formed by drying. As the heat resistant resin material, in addition to the polyimide resin, polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polycarbonate (PC), or the like can be used. . For the material of the substrate, the flexible ceramic sheet described in JP-A-2007-157501 (Patent Document 3) or the Japanese Patent Publication No. 2013-63892 (Patent Document 4), and JP-A-2010- A flexible glass described in Japanese Laid-Open Patent Publication No. 2013-35158 (Patent Document 6). When a flexible ceramic sheet or a flexible glass is used as the substrate, it is not necessary to use the glass substrate 3.

On 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 in a vertical and horizontal direction by a conventional manufacturing method, and the resin substrate 4 and the display unit form a unit assembly mother board B. When the number of display units formed on the resin substrate 4 is one, this is referred to as a unit mother board. Thereafter, the surface protective film 5 is bonded to be formed on the resin substrate 4 by coating. Above the organic EL display unit 1. Here, a state in which the unit assembly mother board B or the unit mother board is bonded to the heat resistant substrate such as the glass substrate 3 is referred to as a mother board structure.

Fig. 3(a) is a top view showing the 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 surface protection film to be bonded thereto. The unit assembly body B of 5 is placed on the glass substrate 3. As shown in Fig. 3(a), in the unit assembly mother board B, the plurality of optical display units 1 are arranged in a row in a state in which the terminal portions 1c are oriented in the lateral direction to constitute a vertical column and a horizontal row. The unit assembly mother board B has a rectangular shape having a short side B-1 and a long side B-2 as shown in Fig. 3(a), and serves as a reference for the mother board B in the vicinity of both ends of one short side B-1. The reference mark m of the dot is given by other appropriate methods of printing and marking. This reference mark m is referred to as a reference when positioning the mother board B. At the time of bonding of the optical film, the unit assembly mother board B is conveyed in the direction indicated by the arrow A in the third (a) diagram, that is, in the longitudinal direction.

The cell assembly mother substrate B having the glass substrate 3 is inspected by the defect of the optical display unit 1 and then sent to the glass substrate peeling position where the glass substrate 3 is peeled off. When the unit assembly mother board B having the glass substrate 3 is transferred to the glass substrate glass position, bonding of the optical functional film of the present invention is performed. The optical assembly of the unit assembly mother board B is performed before the unit assembly mother board B in the state which has the glass substrate 3 is transferred to the optical function film bonding. This optical inspection is necessary to peel the surface protective film 5 from the unit assembly mother board B. 4th chart The order in which the surface protective film 5 is peeled off is shown.

Referring to Fig. 4, the unit assembly mother board B is held by the vacuum suction force on the suction holding disk 10 supported by the guide member 15 and the support mechanism 13, and the surface protective film is fed at the position shown in Fig. 4(a). Stripping position. In the position shown in Fig. 4(b), the lifting mechanism is raised to a predetermined height. The predetermined height is the height at which the predetermined contact pressure of the upper surface of the unit assembly mother board B is in contact with the adhesive tape 16d positioned between the pair of pressing rollers 16c.

The unit assembly mother board B which has been raised to a predetermined height by the elevating mechanism is sent to the lower position of the peeling adhesive tape drive unit 16 in this state. Here, the upper surface of the surface protective film 5 of the mother board B is in contact with the adhesive tape 16d in a pressed state between the pair of pressing rollers 16c, and the adhesive force of the adhesive tape 16d to the surface protective film 5 is a specific surface. Since the protective film 5 has a large adhesive force with respect to the optical display unit 1, the surface protective film 5 is peeled off from the optical display unit 1 which is adhered to the adhesive tape 16d and disposed on the resin substrate 4. The peeled surface protection film 5 is wound together with the winding roller 16b and the adhesive tape 16d. The mother board B after the peeling of the surface protection film 5 is lowered to the height at the time of the feeding of the position of the fourth (a) by the elevating mechanism at the position shown in Fig. 4(d), and is sent to the optical inspection position.

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 1 shown in Fig. 5(b). As shown in Fig. 5(a), the inspection apparatus as the surface inspection includes the light source 70 and the light receiver 71, and the unit assembly mother board B is moved under the reflection inspection apparatus while being supported by the suction holding tray 10. In this position The light from the light source 70 is brought into contact with the surface of the optical display unit 1 of the subject, reflected by the surface of the optical display unit 1 and incident on the photoreceiver 71, thereby detecting surface defects of the optical display unit 1.

Fig. 5(b) is a view showing an outline of the lighting inspection, in which a plurality of detectors 72 for detecting the light-emitting state of the optical display unit 1 are arranged in a line. The unit assembly mother board B manufactured by the process shown in FIG. 2 has a configuration in which the plurality of optical display units 1 are arranged in a row and a row. Therefore, in this embodiment, all the optical displays in the simultaneous excitation unit assembly mother board B are used. Unit 1 uses a pseudo terminal unit 75 as shown in Fig. 6.

Referring to Fig. 6, the pseudo terminal unit 75 includes a rectangular frame 75a having a rectangular shape corresponding to the unit assembly mother board B, a plurality of horizontal stacks 75b, and a plurality of vertical stacks 75c, and a unit is formed in the outer frame 75a. The rectangular body-shaped window 75d in which the optical display unit 1 is arranged in the collective body B is arranged in a vertical and horizontal direction. A connection terminal 76 is disposed at a position corresponding to the terminal 2 provided at the terminal portion of each optical display unit 1 along one short side of each of the windows 75d. Further, the quasi-terminal unit 75 is provided with a power supply terminal 77 for supplying excitation power to the terminals 2 of the respective optical display units 1 in the unit assembly mother board B.

Fig. 7 is a view showing a state in which the pseudo terminal unit 75 shown in Fig. 6 is used. The pseudo terminal unit 75 is placed on the unit assembly mother board B by overlapping the outer frame 75a and the peripheral edge portion of the unit assembly mother board B. In this state, the window 75d of the pseudo terminal unit 75 is overlapped with the optical display unit 1 in the unit assembly mother board B, respectively. Here, when the excitation power is supplied to the quasi-terminal unit 75, the optical display unit of the unit assembly mother board B All of 1 becomes an incentive state. Therefore, the detector 72 checks the operation state of each unit 1 for each illuminating color. By the use of the pseudo terminal unit 75, in a mother board having a plurality of optical display units, all of the units can be inspected together in an energized state.

The unit assembly mother board B after the optical inspection is completed is sent to the adhesive layer application position provided with the adhesive layer providing mechanism 20. Fig. 8 is a schematic side view showing the entire adhesive layer applying mechanism 20.

The adhesive layer applying mechanism 20 is provided with an adhesive tape roll 22 that winds a long-sized adhesive tape 21 into a roll shape. The adhesive tape 21 is fed from the adhesive tape roll 22 at a constant speed by a pair of driving rollers 23. In the present embodiment, the adhesive tape 21 has a structure in which an adhesive layer 21b is formed on one surface of the tape substrate 21a.

Referring to Fig. 8, the adhesive tape 21 fed from the adhesive tape roller 22 by a pair of driving rollers 23 is formed by the dancer roller 24, the tension adjusting roller 25 which is vertically movable, and the guide roller 26 and the guide roller 27 are fed to the slit. Agency 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 28 stops the driving roller 30 at the slit forming position, and operates the cutting blade 29 in a state where the adhesive tape 21 is stopped. The residual tape substrate 21a is formed only in the width direction of the adhesive layer 21b. Incision 28a. The interval of the slits 28a is the distance corresponding to the length L of the longitudinal direction of each display unit 1 on the mother board B. Therefore, the optical film is cut in the width direction by the slit 28a to form the adhesive sheet 21c having the lateral width W and the longitudinal length L of the display unit. As a result, a plurality of adhesive sheets 21c are continuously formed on the tape substrate 21a, and the adhesive sheets 21c are The support is carried to the tape substrate 21a to the bonding position.

The tension adjusting roller 25 is elastically pushed upward, and the pair of driving rollers 23 that continuously drive the adhesive tape 21 in the conveying direction and the conveyance of the adhesive tape 21 are stopped at the time of cutting, and only a predetermined distance after the cutting is completed An adjustment roller that performs adjustment of the belt conveyance acts between the pair of driving rollers 30 that are driven. That is, during the stop of the driving roller 30, the tension adjusting roller 25 moves the borrowing thrust upward to absorb the conveying amount of the driving roller 23, and when the driving roller 30 starts, the driving roller 30 applies the adhesive to the adhesive. The pulling force of the belt 21 moves downward in response to the elastic thrust action.

By the slit 28a, a continuous adhesive sheet 21c is supported by the belt base material 21a, and the guide roller 34 and the guide roller 32 pass through the tension adjusting roller 33 which is configured similarly to the tension adjusting roller 25, and is guided by the guide roller 34. , 35, 36, 37 guide and send to the fit position.

The bonding roller 38 and the carrier film peeling mechanism 39 are provided in the bonding position. The bonding roller 38 is movably disposed between the upper pulling position and the lower pressing position, and is supported by the continuous adhesive sheet 21c of the tape substrate 21a, and the front end of the adhesive sheet 21c is bonded to the front end. When the front end position of the display unit 1 of the object is integrated, the adhesive sheet 21c is pressed toward the display unit 1 on the mother board B from the upper position to the lower pressing position, and the display surface adhesive layer is applied thereto. .

The carrier film peeling mechanism 39 is provided with a peeling blade at the bonding position, and has a function of folding the tape substrate 21a at an acute angle and peeling the front adhesive sheet 21c from the tape substrate 21a. Further, a winding roller 40 with a base material is disposed for the belt base material 21a which is drawn back at an acute angle. From adhesive tablets The tape substrate 21a after the peeling of 21c is sent to the winding roller 40 via the guide roller 41 and the pair of winding driving rollers 42, and is wound around the winding roller 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 motherboard B, and the control device controls the driving of the driving roller 30 and the actuation of the cutting blade 29 based on the information of the longitudinal length L of the display unit 1 to Corresponding to the longitudinal direction of the longitudinal length L of the display unit 1, a slit 28a is formed in the adhesive tape 21. Further, on the upstream side of the bonding position, a sheet position detecting device 43 for detecting the leading end of the adhesive sheet 21c is provided. Information on the position of the front end of the adhesive sheet 21c sent to the bonding position is supplied to the control device. The front end position information of the adhesive sheet is stored in the control device, and the control device controls the driving roller 30 and the winding driving roller 42 based on the position information of the front end of the adhesive sheet and the position information of the mother board B obtained from the suction holding tray 10. The operation corresponds to the operation of the suction holding disk 10, and the front end of the adhesive sheet 21c peeled off from the tape substrate 21a is adjusted to be integrated with the front end position of the display unit 1 which is bonded to the mother substrate B located at the bonding position. Once the position integration is achieved, the adhesive sheet 21c and the mother board B are conveyed at a synchronized speed. The bonding roller 38 is lowered to the lower pressing position, and the adhesive sheet 21c 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 display unit 1 arranged in a matrix in the vertical and horizontal directions on the mother board B. In the illustrated example, the adhesive layer imparting mechanism 20 is fixed in a lateral position with respect to the conveying direction, and the suction holding tray 10 holding the mother board B is held. It is mounted to be laterally movable on the support mechanism 13. As shown in Fig. 9(a), the position of the mother board B is controlled at a position where the front display unit 1 of the display unit row initially positioned at the left end is attached. In this state, as described above, the adhesive sheet 21c is bonded to the display region 1d of the display unit 1 at the front of the left end row as described above.

Next, by moving the suction holding disk 10 laterally, the mother board B is moved in the left lateral direction with respect to the conveying direction, and only the distance corresponding to the lateral interval of the display unit row is displaced. Thereby, the lateral displacement is as shown in Fig. 9(b), and the position where the display unit 1 at the head before the second column is attached from the left is attached. Then, the adhesive sheet 21f is bonded to the display region 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 bonded. When the display unit 1 is arranged in three rows of the example of the drawing, 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 tray 10 is driven in the transport direction only by the distance corresponding to the interval between the display units 1 of the respective columns, and is positioned at the position where the second display unit 1 at the front of the right end row is attached, similarly as the ninth ( d) The figure shows that the adhesive sheet 21c is bonded to the display area 1d of the unit 1. Thereafter, as shown in Fig. 9(e), the mother board B is driven in the transport direction, and the adhesive sheet 21c is bonded by the same operation.

Fig. 10 is a schematic view showing an optical display panel manufacturing apparatus 80 according to an embodiment of the optical functional film bonding method of the present invention. By the above process, the bonding of the adhesive sheet 21c with respect to all the display units 1 At the end, the mother board B is held on the suction holding tray 10, and is sent to the optical display panel manufacturing apparatus 80 shown in FIG.

The apparatus 80 is provided with a take-up roll 81 and a plurality of guide rolls 84a, 84b, 84c, 84d, and 84e. The belt take-up roller 81 is attached with a roller 83a of a belt-shaped optical functional film 83. As shown in Fig. 11, the optical functional film 83 is formed by bonding a long polarizing film of a protective film 83c such as a TAC film to both sides of the polarizer 83b, and bonding the polarizing film to the polarizing film through the adhesive layer 83e. The lamellar 1/4 wavelength (λ) retardation film 83d is formed by lamination. The polarizer 83b and the retardation film 83d are disposed so that the absorption axis of the polarizer 83b and the slow axis or the advancing axis of the retardation film 83d intersect at an angle of 45°±5°. Although the optical functional film 83 has an elongated continuous strip shape, the width thereof has a lateral width of the upper surface of the entire display unit which can be covered in a plurality of rows on the mother board B. In the other aspect, the optical functional film 83 is a configuration shown in Fig. 11, and a 1/2 retardation film can be provided between the polarizing film and the 1/4 wavelength retardation film 83d. At this time, the slow axis or the phase axis of the 1/2 retardation film is disposed so as to intersect with the absorption axis of the polarizer 83b at an angle of 15°±5°, and is disposed with a 1/2 wavelength retardation film. The slow axis or the phase advance axis intersects the slow axis or the phase axis of the 1/4 wavelength retardation film 83d at an angle of 60 ° ± 5 °.

Instead of the above, the roller 83a of the optical function film 83 having the width of each lateral width W of the display unit 1 in which the respective optical functional films are arranged in a plurality of rows on the mother board B may be equivalent to only the mother board B. The number of columns in the longitudinal direction of the upper display unit 1 is arranged side by side in the lateral direction, and the optical functional film is bonded to the display surface of the display unit 1 of each column at the same time. 83.

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 only 45° ± 5° with respect to the longitudinal direction of the retardation film 83d. The range angle is oriented toward the oblique side. For this reason, it is necessary to make the film extend obliquely in the manufacturing stage of the retardation film 83d. 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 can be extended by the method described in the documents. Out of phase difference film. As the retardation film 83d, a film having a phase difference having a reverse dispersion characteristic having a smaller wavelength side on the shorter wavelength side of the wavelength 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), and the like, and the method of the present embodiment can be used as described in the patent specifications. A retardation film of inverse dispersion characteristics.

The optical function film 83 is sent out from the roller 83a, and the adhesive layer 83e is made to communicate in a horizontal direction along the traveling path on the lower side of the guide rolls 84b, 84c, 84d, and 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, and is held on the suction holding tray 10, and is sent to the level. The position below the optical functional film 83 extending in the direction.

The optical display panel manufacturing apparatus 80 shown in Fig. 10 includes an optical functional film bonding apparatus I, a glass substrate peeling position II, an adhesive layer providing position III, a composite film bonding position IV, and an optical display unit cutting position V. Adhesive sheet is attached to the display surface of the optical display unit 1 The unit assembly main plate B of 21c and the glass substrate 3 are height-adjusted by the height adjustment mechanism provided in the support mechanism 13 of the suction holding disk 10 before reaching the optical function film bonding position I. The height of the adjustment is the height of the retardation film 83d of the optical function film 83 at a predetermined contact pressure with the adhesive sheet 21c of the optical display unit 1 attached to the unit assembly mother board B. The unit assembly main plate B and the glass substrate 3 on the suction holding tray 10 after the height adjustment are sent from the left to the lower side of the second guide roller 84b in the tenth diagram. Here, the optical function film 83 sent from the roller 83a is the adhesive sheet 21f which presses the retardation film 83d on the unit assembly mother board B by the guide roller 84b. As described above, the optical functional film 83 is bonded to the unit assembly mother board B.

In this process, the optical functional film 83 is driven at a speed synchronized with the suction holding disk 10 in the transport direction indicated by the arrow A in FIG. While the unit assembly mother board B is bonded to the position I by the optical functional 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 functional 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 in a state of being supported only by the optical function film 83.

The cell assembly mother board B supported by the optical functional film 83 and the glass substrate are then sent to the glass substrate peeling position II. In this position II, the glass substrate 3 is peeled off from the resin substrate 4 by a conventional 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 WO2009/104371 (Patent Document) Offer 2). The unit assembly mother board B after peeling of the glass substrate 3 is sent to the adhesive layer supply position III.

The adhesive layer is provided with a position III, and rollers 85a and 85b are disposed on the lower side of the guide rollers 84c and 84d on the upper side of the optical function film 83 to sandwich the optical functional film 83 and the unit assembly supported by the optical functional film 83. The mother board B is opposed to the guide rollers 84c, 84d. Further, an adhesive tape delivery roller 87 is provided at the adhesive layer supply position III, and a 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 release liner 86c bonded to one side of the adhesive layer 86b, and a second release liner bonded to the other side of the adhesive layer 86b. Made up of 86d. The adhesive tape 86 fed from the roller 86a is fed between the roller 85a and the unit assembly mother board B supported by the optical function film 83 via the guide roller 88.

In this process, after the adhesive tape 86 is fed out from the roller 86a, before reaching the guide roller 88, the first release liner 86c is peeled off, and the adhesive layer 86b is exposed. The peeled first release liner 86c is wound by a winding roller 89a. Next, the adhesive tape 86 is fed between the roller 84c and the roller 85a so that the exposed adhesive layer 86b is connected to the resin substrate 4 supported under the unit assembly mother substrate B of the optical functional film 83. The adhesive layer 86b is pressed against the resin base material 4 on the lower surface of the unit assembly mother board B by the rollers 84c and 85a, and joined to the unit assembly mother board B. In this state, the unit assembly mother board B and the adhesive tape 86 are fed between the roller 84d and the roller 85b, and the second release liner 86d is peeled off from the adhesive layer 86b. The peeled second release liner 86d is wound by the winding roller 89b.

The unit assembly mother board B to which the adhesive layer 86b is provided below is supported by the optical function film 83 and sent to the composite film bonding position IV. The roller 90a of the composite film 90 is disposed at the position IV, and the composite film 90 sent from the roller 90a is a unit assembly that is disposed below the guide roller 84e by the guide roller 91 disposed on the lower side of the guide roller 84e. The adhesive layer 86b under the mother board B is pressed. In this way, the composite film is bonded to the unit assembly mother board B. Thereafter, the unit assembly mother board B is supported by the optical function film 83 bonded to the lower 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 and the composite film 90 and the unit assembly mother board B in the conveyance direction, a pair of drive rolls 91a and 91b may be provided. In the embodiment of the present invention, the composite film 90 is a laminate of a layer having a light shielding film and a layer of a film having impact resistance and heat dissipation. However, in another embodiment of the present invention, the composite film may be modified, and a normal inner surface protective film may be used.

The optical function film 83 is bonded to the upper surface, and the unit assembly mother board B to which the composite film 90 is bonded is attached to the optical display unit cutting position V. At the cutting position V, a synthetic resin support belt 92 and a cutting blade 93 that receive the composite film 90 are provided, and the unit assembly mother board B is cut and the optical display units 1 are cut away. In this case, the optical function film 83 attached to the upper surface of the unit assembly mother board B is cut to fit the size of the display area 1d of each display unit 1. The above-described mechanism and operation for cutting are conventional, and detailed description thereof will be omitted.

Fig. 12 is a view showing another embodiment of the optical functional film bonding method of the present invention. The device is represented by Figure 10 The basic configuration and operation are the same, and the corresponding parts are denoted by the same reference numerals, and detailed description is omitted. The apparatus shown in Fig. 12 differs from the apparatus 80 shown in Fig. 10 in that the unit assembly mother board B which is provided with the adhesive layer 86b between the roller 84c and the roller 85a is bonded to the optical functional film 83 and the second peeling. The lining sheets 86d are wound around the roll 100 in the form of a laminate. The laminated body wound around the roll 100 is sent from the roll 100 in another process, and the process of the composite film bonding position IV and the optical display unit cutting position V can be performed.

The method of the present invention can also be applied to the display unit 1 in which a vertical column is arranged on the mother board B. A column is shown in Fig. 13. In this case, the display unit 1 is disposed on the mother board B such that the terminal portion 1c is lateral with respect to the direction of the column. The adhesive layer of the display surface 1 of the display unit 1 is given the same operation as that described in connection with Fig. 8, and the adhesive sheet 21c which is previously cut can be attached to the display unit 1 in order from the front of the column. The display area 1d is performed.

The method of the present invention can also be applied to display units of relatively large-sized flexible sheet construction. Examples thereof are shown in Fig. 14 and Fig. 15. When the display unit is an organic EL unit, the unit itself may be a flexible sheet structure having a small thickness. Referring to Fig. 14, the optical display unit 101 of the flexible sheet structure has a rectangular shape having a short side 101a and a long side 101b, and has a terminal portion 101c positioned along the short side 101a and a length L and a lateral width having a longitudinal direction. The display unit 101d of W. The optical display unit 101 is formed at a manufacturing stage on a substrate 102 made of a heat resistant resin material such as polyimide. The process is the same as the process described in Figure 3. The substrate 102 having a resin on the glass substrate 3 is formed into a film shape, and thereon, for example, an optical display unit 101 such as an organic EL display unit is formed. The point different from the case of Fig. 3 is that in the present embodiment, one display unit is formed on the substrate 102. Similarly to the process described in connection with FIG. 3, after the optical display unit 101 is formed on the substrate 102, the adhesive sheet 21c is bonded to the display portion 101d of the optical display unit 101. In the present embodiment, the same mechanism as the adhesive layer applying mechanism 20 shown in Fig. 8 can be employed. At this time, the optical film 21 fed from the belt-shaped adhesive tape roll 22 has a width corresponding to the width W of the optical display unit 101 shown in Fig. 16. Fig. 15 is a view schematically showing the configuration of the bonding portion. The function of the bonding portion is the same as that described above with reference to Fig. 8, and corresponding portions are denoted by the same reference numerals.

The present invention has been described with respect to the specific embodiments, and is not limited to the illustrated embodiments, and the scope of the present invention is determined only in accordance with the claims of the patent application.

Claims (10)

A method of bonding an optical functional film to an optical display unit of a flexible film structure, comprising: a resin substrate, and a flexible film formed on the resin substrate and having at least one display surface The unit mother board formed of the unit is supported by the mother board structure on the heat-resistant mother substrate, and the display surface of the display unit is transported in an upward direction toward the transport direction; and the mother board is transported in the transport direction. a step of forming an adhesive layer on the display surface of the display unit of the structure; and transporting the mother board structure in which the adhesive layer is formed on the display surface of the display unit toward the transport direction, and in the transport direction An extended long strip-shaped optical functional film is in contact with an adhesive layer formed on the display surface of the display unit, and the optical functional film is bonded to the display unit, and the long-length strip-shaped optical functional film is supported from above The state of the mother board structure is such that the mother board structure body faces the conveying direction by the movement of the optical function film Feeding stage; and through the optical function of the long dimension of the ribbon membrane support, the heat-resistant substrate is peeled off from the master mother structure conveyed toward the conveying direction of the stage. The method of bonding an optical functional film to an optical display unit of a flexible film structure according to the first aspect of the invention, wherein the display surface of the display unit has a rectangular shape having two short sides and two long sides. The display unit is configured to have a terminal portion having an electrical connection terminal along one of the short side and the long side, and the unit mother board is The terminal portion of the display unit is conveyed toward the transport direction with respect to the horizontal direction of the transport direction. The method of bonding an optical functional film to an optical display unit of a flexible film structure according to the first aspect of the invention, wherein the unit mother board after peeling off the heat resistant mother substrate is moved in the transport direction The movement of the optical functional film is carried out in the transport direction, and the protective film is bonded to the lower surface of the unit mother substrate after the heat-resistant mother substrate is peeled off. The method of bonding an optical functional film to an optical display unit of a flexible film structure according to the second aspect of the invention, wherein the unit mother board after peeling off the heat resistant mother substrate is moved in the transport direction The movement of the optical functional film is carried out in the transport direction, and the protective film is bonded to the lower surface of the unit mother substrate after the heat-resistant mother substrate is peeled off. The method of bonding an optical functional film to an optical display unit of a flexible film structure according to the second aspect of the invention, wherein the unit mother board includes at least a plurality of display units arranged in a longitudinal direction parallel to the transport direction, The terminal portions of the plurality of display units are transported toward the transport direction in a state in which all of them are lateral with respect to the transport direction. The method of bonding an optical functional film to an optical display unit of a flexible film structure according to claim 5, further comprising cutting the unit mother board and the optical function film into respective display units. stage. As described in any one of items 1 to 6 of the patent application scope A method of bonding an optical functional film to an optical display unit of a flexible film structure, wherein the optical functional film contains at least a polarizer. The method of bonding an optical functional film to an optical display unit of a flexible film structure according to claim 7, wherein the optical functional film is a reflection preventing structure composed of a laminate of a polarizer and a quarter-wave retardation film. In the film, the 1/4 wavelength retardation film is bonded to the display surface with the 1/4 wavelength retardation film facing the display unit. The method of bonding an optical functional film to an optical display unit of a flexible film structure according to claim 7, wherein the optical functional film is a photo-polarized film and a 1/2 wavelength retardation film and a 1/4 wavelength phase. An antireflection film comprising a laminate in which the film is laminated in this order, and the laminate is bonded to the display surface with the 1/4 wavelength retardation film facing the display unit. The method of bonding an optical functional film to an optical display unit of a flexible film structure according to any one of claims 1 to 6, wherein the display unit is an organic EL display unit.