WO2006129870A2

WO2006129870A2 - Method of and apparatus for partly cutting laminated film

Info

Publication number: WO2006129870A2
Application number: PCT/JP2006/311374
Authority: WO
Inventors: Haruhito Arimitsu; Toshiyuki Masuda
Original assignee: Fujifilm Corporation
Priority date: 2005-06-01
Filing date: 2006-05-31
Publication date: 2006-12-07
Also published as: JP2006334715A; CN101189178A; WO2006129870A3; KR20080013985A; TW200709902A; CN101189178B

Abstract

A partly cutting apparatus (36) has a heating mechanism (52) for heating a partly cutting region (34) of a photosensitive web (22) to a preset temperature depending on a rotary circular blade (68) or a fixed circular blade (80), and a cutter mechanism (54) for partly cutting the photosensitive web (22) by moving the rotary circular blade (68) or the fixed circular blade (80) along the partly cutting region (34) heated to the preset temperature. The heating mechanism (52) has a sheet heater (76) disposed in a cutter bearing base (70). The cutter bearing base (70) is held in contact with the photosensitive web (22) to heat the partly cutting region (34).

Description

DESCRIPTION

METHOD OF AND APPARATUS FOR PARTLY CUTTING LAMINATED FILM

Technical Field

The present invention relates to a method of and an apparatus for partly cutting a laminated film comprising at least a first resin layer and a second resin layer, leaving part of the laminated film uncut in the laminated direction.

Background Art

Substrates for liquid crystal panels, substrates for printed wiring boards, and substrates for PDP panels, for example, comprise a laminated substrate assembly including a photosensitive laminated film (photosensitive web) having a photosensitive resin layer and applied to substrate surfaces . The photosensitive laminated film is usually constructed as a laminated assembly of a thermoplastic resin layer (hereinafter referred to as "cushion layer"), a photosensitive material layer, and a protective film that are successively laminated on a base film (a flexible plastic support layer) .

Applying apparatus for applying such a photosensitive laminated film usually operate to feed substrates such as glass substrates, resin substrates, or the like at given spaced intervals and peel the protective film off from the photosensitive laminated film by lengths which correspond to thermoplastic resin layer lengths to be applied to the respective substrates.

Before the photosensitive laminated film is delivered to such an applying apparatus, the protective film needs to be cut of at a predetermined position. The photosensitive laminated film is partly cut to sever the protective film, leaving part of the photosensitive laminated film uncut in the laminated direction.

One known film partly cutting apparatus is disclosed in Japanese Laid-Open Patent Publication No. 11-10581, for example. As shown in FIG. 16 of the accompanying drawings, the disclosed film partly cutting apparatus has a pair of guide rollers 2a, 2b for feeding a laminated film 1 in the direction indicated by the arrows and a movable member 4 movably mounted on a rail 3 extending perpendicularly to the direction in which the laminated film 1 is fed. A rotatable shaft 6 is mounted on the movable member 4 by a horizontally extending hollow sleeve 5. A disk cutter 7 is mounted on an end of the rotatable shaft 6. The film partly cutting apparatus also has a cutter base 8 disposed in confronting relation to the disk cutter 7 across the laminated film 1. A cutter receiver 8a for engaging a cutting blade 7a of the disk cutter 7 is mounted on the cutter base 8. When the laminated film 1 is partly cut by the cutting blade 7a of the disk cutter 7 which is held nonrotatable, the cutting blade 7a frictionally contacts the cut region of the laminated film 1 , tending to produce chips .

The laminated film 1 comprises a photosensitive layer and a cover film that are laminated on a support . When the coyer film is cut, the photosensitive layer is liable to be peeled off the support .

According to a film cutting process disclosed in Japanese Laid-Open Patent Publication No. 9-85680, for example, a film is cut while the temperature of the residual volatile portion of the film and the cut region of the film is being kept in a predetermined range, i.e., a range from 60⁰C to TG.

However, it is difficult to apply the film cutting process disclosed in Japanese Laid-Open Patent Publication No. 9-85680 to partly cut a laminated film comprising a plurality of laminated resin layers. Specifically, cutters that are used to partly cut a film include a rotary cutter which rotates when moving in the cutting direction and a fixed cutter^" which does not rotate when moving in the cutting direction. The fixed cutter cuts the laminated film while its cutting edge is being pressed against the laminated film. When the temperature of the laminated film is high, e.g., 60° C or higher, the viscosity of the laminated film becomes high, and the cutting edge tends to produce a lot of filamentary chips in frictional contact with each layer of the laminated film. Disclosure of Invention

It is a primary object of the present invention to provide a method of and an apparatus for partly cutting a laminated film into a high-quality product with a simple process and arrangement.

According to the present invention, there are provided a method of and an apparatus for partly cutting a laminated film, leaving a portion thereof in the laminated direction, the laminated film having at least a first resin layer and a second resin layer.

The laminated film is partly cut by a cutter while a partly cutting region of the laminated film is being heated to a preset temperature depending on the cutter.

Preferably, the laminated film should be partly cut by moving the cutter along the partly cutting region. The cutter may be a strip-shaped pressing blade, a movable cutter, and so on.

The cutter should preferably comprise a rotary circular blade which is rotatable in the direction in which the rotary circular blade moves, and the partly cutting region should preferably be heated in the range from 35° C to 100⁰C. Alternatively, the cutter should preferably comprise a fixed circular blade which is nonrotatable in the direction in which the rotary circular blade moves, and the partly cutting region should preferably be heated in the range from 25° C to 45° C.

Preferably, the laminated film should comprise a photosensitive laminated film with the first resin layer comprising a photosensitive resin layer.

Preferably, the cutter mechanism should have a cutter bearing base disposed in confronting relation to the cutter, and the heating mechanism should comprise a heater disposed in the cutter bearing base. Preferably, the heating mechanism should comprise a heating roller disposed near the cutter.

Alternatively, the heating mechanism should comprise a heating box for indirectly heating the cutter and the partly cutting region, the heating box accommodating the cutter and the partly cutting region therein. Further alternatively, the heating mechanism should comprise a heater for heating the laminated film before the laminated film is partly cut . The cutter mechanism should preferably comprise a movable base movable along the partly cutting region, and a rotary circular blade rotatably supported on the movable base. Alternatively, the cutter mechanism should preferably comprise a movable base movable along the partly cutting region, and a fixed circular blade fixedly supported on the movable base.

According to the present invention, the partly cutting region of the photosensitive film has been heated to the preset temperature depending on the cutter when it is partly cut. If the photosensitive film is of a low temperature, the photosensitive film itself is hard and fragile, tending to produce chips and have its layers peeled off when the photosensitive film is partly cut by the rotary circular blade or the fixed circular blade. If the photosensitive film is of a high temperature, the photosensitive film is softened but made viscous, tending to produce filamentary chips due to sliding engagement with the cutter particularly when the photosensitive film is partly cut by the fixed circular blade .

Since the partly cutting region of the photosensitive film has been heated to the preset temperature depending on the type of the cutter, e.g., the rotary circular blade or the fixed circular blade, the photosensitive film is reliably prevented from producing chips and the layers of the photosensitive film are reliably prevented from being peeled off when the photosensitive film is partly cut . Consequently, the photosensitive film can be partly cut into a high-quality product with a simple process and arrangement .

The above and other objects, features, and advantages of the present invention will become more apparent from the following description when taken in conjunction with the accompanying drawings in which preferred embodiments of the present invention are shown by way of illustrative example.

Brief Description of Drawings FIG. 1 is a schematic side elevational view of a manufacturing apparatus which incorporates a partly cutting apparatus according to a first embodiment of the present invention ;

FIG. 2 is an enlarged fragmentary cross-sectional view of an elongate photosensitive web used in the manufacturing apparatus shown in FIG. 1; FIG. 3 is an enlarged fragmentary plan view of the elongate photosensitive web with adhesive labels bonded thereto;

FIG. 4 is a perspective view of the partly cutting apparatus ; FIG. 5 is a side elevational view of the partly cutting apparatus ;

FIG. 6 is a diagram showing evaluations of regions that were partly cut at different temperatures by a rotary circular blade and a fixed circular blade; FIG. 7 is a side elevational view of a partly cutting apparatus according to a second embodiment of the present invention;

FIG. 8 ϊs a side elevational view of a partly cutting apparatus according to a third embodiment of the present invention;

FIG. 9 is a side elevational view of a partly cutting apparatus according to a fourth embodiment of the present invention;

FIG. 10 is a side elevational view of a partly cutting apparatus according to a fifth embodiment of the present invention;

FIG. 11 is a side elevational view, partly in cross section, of a heating mechanism of a partly cutting apparatus according to a sixth embodiment of the present invention;

FIG. 12 is a side elevational view, partly in cross section, of a heating mechanism of a partly cutting apparatus according to a seventh embodiment of the present invention;

FIG. 13 is a side elevational view, partly in cross section, of a heating mechanism of a partly cutting apparatus according to an eighth embodiment of the present invention;

FIG. 14 is a front elevational view, partly in cross section, of a heating mechanism of a partly cutting apparatus according to a ninth embodiment of the present invention;

FIG. 15 is a perspective view of a partly cutting apparatus according to a tenth embodiment of the present invention; and

FIG. 16 is a cross-sectional view of a conventional film partly cutting apparatus.

Best Mode for Carrying Out the Invention

FIG. 1 schematically shows a manufacturing apparatus 20 which incorporates a partly cutting apparatus according to a first embodiment of the present invention. The manufacturing apparatus 20 operates to thermally transfer a photosensitive resin layer 29 (described later) of an elongate photosensitive web (photosensitive laminated film) 22 to glass substrates 24 in a process of manufacturing color filters for use with liquid crystal panels or organic EL panels . FIG. 2 shows in cross section the photosensitive web 22 that is employed in the manufacturing apparatus 20. The photosensitive web 22 comprises a laminated assembly of a flexible base film (support layer) 26, a cushion layer (thermoplastic resin layer) 27, an intermediate layer (oxygen blocking film) 28, a photosensitive resin layer

(first resin layer) 29,. and a protective film (second resin layer) 30. The photosensitive web 22 may alternatively comprise the base film 26, the photosensitive resin layer 29, and the protective film 30. The base film 26 is made of polyethylene terephthalate (PET) . The cushion layer 27 is made of a copolymer of ethylene and vinyl oxide. The intermediate layer 28 is made of polyvinyl alcohol. The photosensitive resin layer 29 is made of a colored photosensitive resin composition including an alkaline soluble binder, a monomer, a photopolymerization initiator, and a colorant. The protective film 30 is made of polyethylene, polypropylene, or the like.

As shown in FIG. 1, the manufacturing apparatus 20 has a web reel-out mechanism 32 for accommodating a photosensitive web roll 22a in the form of the rolled photosensitive web 22 and reeling out the photosensitive web 22 from the photosensitive web roll 22a, a partly cutting apparatus 36^' according to the first embodiment of the present invention for forming a transversely severable partly cutting region 34 in the protective film 30 of the photosensitive web 22 that has been reeled out, and a label 5 bonding mechanism 40 for bonding adhesive labels 38 (see FIG. 3), each having a non-sticky area 38a, to the protective film 30. The manufacturing apparatus 20 may have two partly cutting apparatus 36 spaced a distance from each other in the direction indicated by the arrow A, for forming 0 partly cutting regions 34 simultaneously at respective two locations .

Downstream of the label bonding mechanism 40, there are disposed a reservoir mechanism 42 for changing the feed mode of the photosensitive web 22 from a Takt feed mode, i.e., an ,5 intermittent feed mode, to a continuous feed mode, a peeling mechanism 44 for peeling certain lengths of the protective film 30 from the photosensitive web 22, a heating mechanism 45 for heating a glass substrate 24 to a predetermined temperature and feeding the heated glass substrate 24 to a 0 bonding position, and a bonding mechanism 46 for bonding the photosensitive resin layer 29 which has been exposed by peeling off the protective film 30 to the glass substrate 24. A workpiece which is constructed of the glass substrate 24 and the photosensitive web 22 bonded thereto by the 5 bonding mechanism 46 will hereinafter be referred to as "substrate 24a".

A detecting mechanism 47 for directly detecting a partly cutting region 34 which is positioned at a boundary on the photosensitive web 22 is disposed upstream of and near the bonding position in the bonding mechanism 46. An inter-substrate web cutting mechanism 48 for cutting the photosensitive web 22 between two adjacent substrates 24 is disposed downstream of the bonding mechanism 46. A web cutting mechanism 48a which is operated when the manufacturing apparatus 20 starts and ends its operation is disposed upstream of the inter-substrate web cutting mechanism 48.

A joining base 49 for joining the trailing end of a photosensitive web 22 that has essentially been used up and the leading end of a photosensitive web 22 that is to be newly used is disposed downstream of and closely to the web reel-out mechanism 32. The joining base 49 is followed downstream by a film end position detector 51 for controlling a transverse shift of the photosensitive web 22 due to a winding irregularity of the photosensitive web roll 22a. The partly cutting apparatus 36 is disposed downstream of a pair of rollers 50 for calculating the diameter of the photosensitive web roll 22a wound in the web reel-out mechanism 32. As shown in FIGS. 4 and 5, the partly cutting apparatus 36 comprises a heating mechanism 52 for heating a partly cutting region 34 of the photosensitive web 22 to a predetermined temperature (to be described later), and a cutter mechanism 54 for partly cutting the protective film 30 along the partly cutting region 34 that has been heated to the predetermined temperature.

The cutter mechanism 54 has a linear guide 56 extending in the direction indicated by the arrow B which is perpendicular to the direction (indicated by the arrow A) in which the photosensitive web 22 is fed. A slide base 58 is slidably supported on the linear guide 56. The slide base 58 houses therein a motor 60 having a rotational drive shaft 60a with a pinion 62 mounted thereon. The linear guide 56 is combined with a rack 64 extending in the direction indicated by the arrow B and held in mesh with the pinion 62. When the motor 60 is energized, the slide base 58 is movable along the linear guide 56 in the direction indicated by the arrow B through meshing engagement between the pinion 62 and the rack 64.

A rotatable shaft 66 is mounted on the slide base 58 and projects away from the pinion 62. The rotatable shaft 66 on the slide base 58 is positioned opposite to the side of the pinion 62. A rotary circular blade (cutter) 68 is fixedly mounted on the rotatable shaft 66 for rotation therewith. A cutter bearing base 70 is disposed below the rotary circular blade 68 in confronting relation thereto with the photosensitive web 22 interposed therebetween.

The cutter bearing base 70 comprises two metal plates and extends in the direction indicated by the arrow B. The cutter bearing base 70 has a recess 72 defined in an upper surface thereof and extending in the range in which the rotary circular blade 68 is movable in the direction indicated by the arrow B. A cutter receiver 74 of resin is placed in the recess 72.

The heating mechanism 52 comprises a sheet heater 76 embedded in the cutter bearing base 70, i.e., sandwiched between the two metal plates. The cutter bearing base 70 functions as a heating member for contacting the photosensitive web 22 to directly heat the partly cutting region 34. The rotary circular blade 68 may be replaced with a fixed circular blade 80 fixed to a fixed shaft 78 extending from the slide base 58. The fixed circular blade 80 may be angularly adjustable in angular intervals with respect to the fixed shaft 78. As shown in FIG. 2, partly cut regions 34 need to be formed across at least the protective film 30. Actually, the rotary circular blade 68 (or the fixed circular blade 80) is designed to cut into the photosensitive resin layer 29 or the intermediate layer 28 in order to reliably cut the protective film 30. The partly cut regions 34 may be formed by a cutting process using ultrasonic energy, or a cutting process using a knife blade, a strip-shaped pressing blade (Thompson blade) to be described later, or the like, rather than the rotary circular blade 68 (or the fixed circular blade 80). The pressing blade may be pressed vertically or obliquely into the protective film 30.

The partly cutting regions 34 serve to set a spaced interval between two adjacent glass substrates 24. For example, these partly cut regions 34 are formed in the protective film 30 at positions that are 10 mm spaced inwardly from respective edges of the glass substrates 24. The section of the protective film 30 which is interposed between the partly cutting regions 34 and exposed between the glass substrates 24 functions as a mask when the photosensitive resin layer 29 is applied as a frame to the glass substrate 24 in the bonding mechanism 46 to be described later.

The label bonding mechanism 40 supplies adhesive labels 38 for interconnecting a front peel-off section 30aa and a rear peel-off section 30ab in order to leave a residual section 30b of the protective film 30 between glass substrates 24. As shown in FIG. 2, the front peel-off section 30aa which is to be peeled off initially and the rear peel-off section 30ab which is to be peeled off subsequently are positioned on respective both sides of the residual section 30b. As shown in FIG. 3, each of the adhesive labels 38 is of a rectangular strip shape and is made of the same resin material as the protective film 30. Each of the adhesive labels 38 has a non-adhesion (or slightly adhesive) area 38a positioned centrally which is free of an adhesive, and a first adhesion area 38b and a second adhesion area 38c which are disposed respectively on the longitudinally opposite ends of the non-adhesion area 38a, i.e., on the longitudinally opposite end portions of the adhesive label 38, the first adhesion area 38b and the second adhesion area 38c being bonded respectively to the front peel-off section 30aa and the rear peel-off section 30ab. As shown in FIG. 1, the label bonding mechanism 40 has suction pads 84a through 84e for applying a maximum of five adhesive labels 38 at spaced intervals. A support base 86 that is vertically movable for holding the photosensitive web 22 from below is disposed in a position where adhesive labels 38 are applied to the photosensitive web 22 by the suction pads 84a through 84e.

The reservoir mechanism 42 serves to absorb a speed difference between the intermittent feed mode in which the photosensitive web 22 is fed upstream of the reservoir mechanism 42 and the continuous feed mode in which the photosensitive web 22 is fed downstream of the reservoir mechanism 42. The reservoir mechanism 42 also has a dancer 91 comprising two swingable rollers 90 for preventing the photosensitive web 22 from suffering tension variations. The dancer 91 may have one or three or more rollers 90 depending on the length of the photosensitive web 22 to be reserved.

The peeling mechanism 44 which is disposed downstream of ^"the reservoir mechanism 42 has a suction drum 92 for reducing variations of the tension to which the supplied photosensitive web 22 is subjected for thereby stabilizing the tension of the photosensitive web 22 when it is subsequently laminated. The peeling mechanism 44 also has a peeling roller 93 disposed closely to the suction drum 92. The protective film 30 that is peeled off from the photosensitive web 22 at a sharp peel-off angle through the peeling roller 93 is wound, except a residual section 30b, by a protective film takeup unit 94.

A tension control mechanism 96 for imparting tension to the photosensitive web 22 is disposed downstream of the peeling mechanism 44. The tension control mechanism 96 has a cylinder 98 that is actuatable to angularly displace a tension dancer 100 to adjust the tension of the photosensitive web 22 that the tension dancer 100 is held in rolling contact with. The tension control mechanism 96 may be employed only when necessary, and may be dispensed with. The detecting mechanism 47 has a photoelectric sensor 102 such as a laser sensor, a photosensor, or the like for directly detecting a change in the photosensitive web 22 due to wedge-shaped grooves in the partly cutting regions 34, steps produced by different thicknesses of the protective films 30, or a combination thereof. A detected signal from the photoelectric sensor 102 is used as a boundary position signal representative of the boundary position in the protective film 30. The photoelectric sensor 102 is disposed in confronting relation to a backup roller 103. Alternatively, a non-contact displacement gauges or an image inspecting means such as a CCD camera or the like may be employed instead of the photoelectric sensor 102. The positional data of the partly cutting regions 34 which are detected by the detecting mechanism 47 can be statistically processed and converted into graphic data in real time. When the positional data detected by the detecting mechanism 47 show an undue variation or bias, the manufacturing apparatus 20 may generate a warning.

The manufacturing apparatus 20 may employ a different system for generating boundary position signals. According to such a different system, the partly cutting regions 34 are not directly detected, but marks are applied to the photosensitive web 22. For example, holes or recesses may be formed in the photosensitive web 22 near the partly cutting regions 34 in the vicinity of the partly cutting apparatus 36, or the photosensitive web 22 may be pierced or slit by a laser beam or an aqua jet or may be marked by an ink jet or a printer. The marks on the photosensitive web 22 are detected, and detected signals are used as boundary position signals .

The heating mechanism 45 has a feed mechanism 104 for feeding glass substrates 24 as workpieces in the direction indicated by the arrow C. The feed mechanism 104 has a plurality of disk-shaped feed rollers 106 of resin that are arrayed in the direction indicated by the arrow C. The heating mechanism 45 also has a receiver 108 for receiving glass substrates 24 which is disposed upstream of the feed mechanism 104 in the direction indicated by the arrow C. The heating mechanism 45 further includes a plurality of heating furnaces 110 disposed downstream of the receiver 108.

The heating mechanism 45 monitors the temperature of glass substrates 24 at all times. In the event that the heating mechanism 45 detects an abnormal temperature, the heating mechanism 45 stops the feed rollers 106 or issues a warning, and transmits malfunctioning information which may be used to eject an abnormal glass substrate 24 in the following steps and may also be used for quality control or production management. The feed mechanism 104 may have an air-lifting plate, not shown, for lifting glass substrates 24 while they are being fed in the direction indicated by the arrow C .

As shown in FIG. 1, a substrate storage frame 120 for storing a plurality of glass substrates 24 is disposed upstream of the heating mechanism 45. The substrate storage frame 120 has dust removing fan units (or duct units) 122 disposed on respective three sides except for a providing slot and a discharging slot thereof. The fan units 122 eject electrically neutralizing clean air into the substrate storage frame 120. The glass substrates 24 stored in the substrate storage frame 120 are attracted one by one by suction pads 126 on a hand 124a of a robot 124, taken out from the substrate storage frame 120, and inserted into the receiver 108.

The bonding mechanism 46 has a pair of vertically spaced laminating rubber rollers 130a, 130b that are heated to a predetermined temperature. Backup rollers 132a, 132b are held in rolling contact with the respective laminating rubber rollers 130a, 130b. The backup roller 132b is pressed against the laminating rubber roller 130b by a 5 roller clamp unit 134.

A contact prevention roller 136 is movably disposed near the rubber roller 130a for preventing the photosensitive web 22 from contacting the rubber roller 130a. A preheating unit 137 for preheating the

10 photosensitive web 22 to a predetermined temperature is disposed upstream of and closely to the bonding mechanism 46. The preheating unit 137 comprises a heat applying means such as an infrared bar heater or the like .

Film feed rollers 138a and substrate feed rollers 138b

,15 are disposed between the bonding mechanism 46 and the inter- substrate web cutting mechanism 48. A cooling mechanism 140 is disposed downstream of the inter-substrate web cutting mechanism 48, and a base peeling mechanism 142 is disposed downstream of the cooling mechanism 140. The cooling

20 mechanism 140 supplies cold air to a substrate 24a after the photosensitive web 22 is cut off between the substrate 24a and a following substrate 24a by the inter-substrate web cutting mechanism 48. Specifically, the cooling mechanism 140 supplies cold air having a temperature of 10° C at a rate

25 ranging from 1.0 to 2.0 m/min. However, the cooling mechanism 140 may be dispensed with, and the substrate 24a may be naturally cooled in a photosensitive laminated body storage fraπie 156 .

The base peeling mechanism 142 disposed downstream of the cooling mechanism 140 has a plurality of suction pads 144 for attracting the lower surface of a substrate 24a. While the substrate 24a is being attracted under suction by the suction pads 144, the base film 26 and the residual section 30b are peeled off from the substrate 24a by a robot hand 146. Electrically neutralizing air blowers (not shown) for ejecting electrically neutralizing clean air to four sides of the laminated area of the substrate 24a are disposed upstream, downstream, and laterally of the suction pads 144. The base film 26 and the residual section 30b may be peeled off from the substrate 24a while a table for supporting the substrate 24a thereon is being oriented vertically, obliquely, or turned upside down for dust removal .

The base peeling mechanism 142 is followed downstream by the photosensitive laminated body storage frame 156 for storing a plurality of photosensitive laminated bodies 150. A photosensitive laminated body 150 that is produced when the base film 26 and the residual section 30b are peeled off from the substrate 24a by the base peeling mechanism 142 is attracted by suction pads 154 on a hand 152a of a robot 152, taken out from the base peeling mechanism 142, and placed into the photosensitive laminated body storage frame 156.

The photosensitive laminated body storage frame 156 has dust removing fan units (or duct units) 122 disposed on respective three sides except for a providing slot and a discharging slot thereof. The fan units 122 eject electrically neutralizing clean air into the photosensitive laminated body storage frame 156. In the manufacturing apparatus 20, the web reel-out mechanism 32, the partly cutting apparatus 36, the label bonding mechanism 40, the reservoir mechanism 42, the peeling mechanism 44, the tension control mechanism 96, and the detecting mechanism 47 are disposed above the bonding mechanism 46. Conversely, the web reel-out mechanism 32, the partly cutting apparatus 36, the label bonding mechanism 40, the reservoir mechanism 42, the peeling mechanism 44, the tension control mechanism 96, and the detecting mechanism 47 may be disposed below the bonding mechanism 46 to apply the photosensitive resin layer 29 to the lower surface of the glass substrate 24, while the photosensitive web 22 is upside down. Alternatively, the components of the manufacturing apparatus 20 may be arranged in a linear pattern as a whole . The manufacturing apparatus 20 is controlled in its entirety by a lamination process controller 160. The manufacturing apparatus 20 also has a lamination controller 162, a substrate heating controller 164, and a base peeling controller 166, etc. for controlling the different functional components of the manufacturing apparatus 20. These controllers are interconnected by an in-process network. The lamination process controller 160 is connected to the network of a factory which incorporates the manufacturing apparatus 20, and performs information processing for production, e.g., production management and mechanism operation management , based on instruction information (condition settings and production information) from a factory CPU (not shown) .

The lamination controller 162 serves as a process master for controlling the functional components of the manufacturing apparatus 20. The lamination controller 162 operates as a control mechanism for controlling the heating mechanism 45, for example, based on the positional information, detected by the detecting mechanism 47, of the partly cutting regions 34 of the photosensitive web 22. The base peeling controller 166 controls the base peeling mechanism 142 to peel off the base film 26 from the substrate 24a that is supplied from the bonding mechanism 46, and also to discharge the photosensitive laminated body 150 to a downstream process. The base peeling controller 166 also handles information about the substrate 24a and the photosensitive laminated body 150.

The installation space of the manufacturing apparatus 20 is divided into a first clean room 172a and a second clean room 172b by a partition wall 170. The first clean room 172a houses therein the various components ranging from the web reel-out mechanism 32 to the tension control mechanism 96. The second clean room 172b houses therein the detecting mechanism 47 and the other components following the detecting mechanism 47. The first clean room 172a and the second clean room 172b are connected to each other by a through region 174. Operation of the manufacturing apparatus 20 for carrying out a partly cutting method according to the first embodiment of the present invention will be described below. As shown in FIG. 1, the photosensitive web 22 is reeled out from the photosensitive web roll 22a in the web reel-out mechanism 32, and fed to the partly cutting apparatus 36.

As shown in FIGS..4 and 5, in the partly cutting apparatus 36, the sheet heater 76 of the heating mechanism 52 has been energized to heat the cutter bearing base 70 to a desired temperature. The photosensitive web 22 that is being fed in the direction indicated by the arrow A is directly held in contact with and heated by the cutter bearing base 70 which moves in synchronism with the photosensitive web 22. The partly cutting region 34 is partly cut by the cutter mechanism 54 while being heated to a predetermined temperature which is preset depending on the rotary circular blade 68. Alternatively, the partly cutting region 34 may be partly cut by the cutter mechanism 54 while the photosensitive web 22 is being held at rest.

Specifically, the motor 60 mounted in the slide base 58 is energized to rotate the pinion 62. As the pinion 62 is held in mesh with the rack 64, the slide base 58 moves in the direction indicated by the arrow B while being supported by the linear guide 56. The rotary circular blade 68 is cut into a desired depth in the partly cutting region 34 of the photosensitive web 22, and rotates while moving in the direction indicated by the arrow B. Therefore, a slit cut to the desired depth from the protective film 30 is formed in the partly cutting region 34 of the photosensitive web 22 (see FIG. 2) .

According to the first embodiment , the partly cutting region 34 of the photosensitive web 22 is partly cut by the cutter mechanism 54 while being heated by the heating mechanism 52. At this time, chips are prevented from being produced and the layers of the photosensitive web 22 are prevented from being peeled off by presetting the temperature to which the photosensitive web 22 is heated with respect to each of the rotary circular blade 68 and the fixed circular blade 80.

Specifically, as shown in FIG. 6, if the temperature of the photosensitive web 22 was 30° C or lower with respect to the rotary circular blade 68, then the layers of the photosensitive web 22 were peeled off. If the temperature of the photosensitive web 22 was 35° C or higher, then the layers of the photosensitive web 22 were not peeled off, and the photosensitive web 22 was well partly cut.

Therefore, when the photosensitive web 22 is to be cut by the rotary circular blade 68, the temperature of the partly cutting region 34 of the photosensitive web 22 should be in the range from 35° C to 100° C, or more preferably in the range from 45° C to 60⁰C. Though the evaluation of the partly cutting region 34 was good if the temperature of the photosensitive web 22 was HO⁰C, the upper limit for the temperature of the photosensitive web 22 should be 100° C because the quality of the photosensitive web 22 tends to be lowered at higher temperatures .

If the temperature of the photosensitive web 22 was 20° C or lower with respect to the fixed circular blade 80, then chips were produced from the photosensitive web 22 and the layers of the photosensitive web 22 were peeled off. If the temperature of the photosensitive web 22 was 50° C or higher, then chips were produced from the photosensitive web 22. Therefore, when the photosensitive web 22 is to be cut by the fixed circular blade 80, the temperature of the partly cutting region 34 of the photosensitive web 22 should ^' be in the range from 25° C to 45° C.

In the first embodiment, the partly cutting region 34 may be heated to a preset temperature depending on the rotary circular blade 68 or the fixed circular blade 80. Thus, the photosensitive web 22 can be partly cut into a high-quality product with a simple process and arrangement. As shown in FIG. 1, the partly cut photosensitive web 22 is fed a distance corresponding to the dimension of the residual section 30b of the protective film 30 in the direction indicated by the arrow A, and then stopped, whereupon a next partly cut region 34 is formed therein by the rotary circular blade 68. As shown in FIG. 2, a front peel-off section 30aa and a rear peel-off section 30ab are now provided in the photosensitive web 22, with the residual section 30b interposed therebetween.

Then, the photosensitive web 22 is fed to the label bonding mechanism 40 to place a bonding area of the protective film 30 on the support base 86. In the label bonding mechanism 40, a predetermined number of adhesive labels 38 are attracted and held by the suction pads 84b through 84e and are securely bonded to the front peel-off section 30aa and the rear peel-off section 30ab of the protective film 30 across the residual section 30b thereof (see FIG. 3) .

The photosensitive web 22 with the five adhesive labels 38 bonded thereto, for example, is isolated by the reservoir mechanism 42 from variations of the tension to which the supplied photosensitive web 22 is subjected, and then continuously fed to the peeling mechanism 44. In the peeling mechanism 44, the base film 26 of the photosensitive web 22 is attracted to the suction drum 92, and the protective film 30 is peeled off from the photosensitive web 22, leaving the residual section 30b. The protective film 30 is peeled off at a sharp peel-off angle by the peeling roller 93 and wound by the protective film takeup unit 94. It is preferable to apply an electrically neutralizing air flow to the region where the protective film 30 is peeled off.

At this time, inasmuch as the photosensitive web 22 is firmly held by the suction drum 92, shocks produced when the protective film 30 is peeled off from the photosensitive web 22 are not transferred to the photosensitive web 22 downstream of the suction drum 92. Consequently, such shocks are not transferred to the bonding mechanism 46, and hence laminated sections of glass substrate 24 are effectively prevented from developing a striped defective region.

After the protective film 30 has been peeled off from the base film 26, leaving the residual section 30b, by the peeling mechanism 44, the photosensitive web 22 is adjusted in tension by the tension control mechanism 96, and then partly cutting regions 34 of the photosensitive web 22 are detected by the photoelectric sensor 102 of the detecting mechanism 47.

Based on detected information of the partly cutting regions 34, the film feed rollers 138a are rotated to feed the photosensitive web 22 a predetermined length to the bonding mechanism 46. At this time, the contact prevention roller 136 is waiting above the photosensitive web 22 and the rubber roller 130b is disposed below the photosensitive web 22.

In the heating mechanism 45, the heating temperatures in the heating furnaces 110 are set to values depending on the lamination temperature in the bonding mechanism 46. The robot 124 grips a glass substrate 24 stored in the substrate storage frame 120, and introduces the gripped glass substrate 24 into the receiver 108. In the receiver 108, the glass substrate 24 is fed by the feed rollers 106 of the feed mechanism 104 from the receiver 108 successively to the heating furnaces 110 in the intermittent feed mode. In the heating furnace 110 at the downstream end of the heating mechanism 45 in the direction indicated by the arrow C, the glass substrate 24 is stopped accurately in a given stop position. The glass substrate 24 is temporarily positioned between the rubber rollers 130a, 130b in alignment with the bonded region of the photosensitive resin layer 29 of the photosensitive web 22.

Then, the roller clamp unit 134 is operated to lift the backup roller 132b and the rubber roller 130b to clamp the glass substrate 24 under a predetermined pressure between the rubber rollers 130a, 130b. The rubber roller 130a is rotated to transfer, i.e., laminate, the photosensitive resin layer 29, which is melted with heat, to the glass substrate 24.

The photosensitive resin layer 29 is laminated onto the glass substrate 24 under following conditions: the photosensitive resin layer 29 is fed at a speed in the range from 1.0 m/min. to 10.0 m/min. ; and the rubber rollers 130a, 130b have a temperature ranging from 100° C to 140° C and a hardness ranging from 40 to 90, and apply a pressure (linear pressure) ranging from 50 N/cm to 400 N/cm.

The substrate 24a, which comprises the glass substrate 24 and the photosensitive web 22 bonded thereto, is fed a certain distance in the direction indicated by the arrow C, cooled by the cooling mechanism 140, and then delivered to the base peeling mechanism 142. In the base peeling mechanism 142, while the substrate 24a is being attracted by the suction pads 144, the base film 26 and the residual section 30b are peeled off by the robot hand 146, thereby producing a photosensitive laminated body 150.

At this time, electrically neutralizing clean air is being ejected to four sides of the laminated area of the substrate 24a from the air blowers disposed upstream, downstream, and laterally of the suction pads 144. The photosensitive laminated body 150 is held by the hand 152a of the robot 152 and placed into the photosensitive laminated body storage frame 156. The above operation is repeated until a predetermined number of photosensitive laminated bodies 150 are stored in the photosensitive laminated body storage frame 156.

FIG. 7 shows in side elevation a partly cutting apparatus 180 according to a second embodiment of the present invention. Those parts of the partly cutting apparatus 180 which are identical to the partly cutting apparatus 36 according to the first embodiment are denoted by identical reference characters, and will not be described in detail below. Those parts of partly cutting apparatus according to third through ninth embodiments described later which are identical to the partly cutting apparatus 36 according to the first embodiment are also denoted by identical reference characters , and will not be described in detail below.

As shown in FIG. 7, the partly cutting apparatus 180 has a cutter bearing base 182 in the form of a metal plate disposed in confronting relation to the cutter mechanism 54.

The cutter bearing base 182 has a bearing film 184 of resin disposed on its upper surface facing the photosensitive web

22. The cutter bearing base 182 does not have a recess similar to the recess 72 defined in the upper surface of the cutter bearing base 70. The bearing film 184 of resin can easily be replaced, and is less expensive than the expendable cutter receiver of resin.

FIG. 8 shows in side elevation a partly cutting apparatus 190 according to a third embodiment of the present invention.

As shown in FIG. 8, the partly cutting apparatus 190 has a cutter bearing base 192 in the form of a metal plate disposed in confronting relation to the cutter mechanism 54.

The cutter bearing base 192 accommodates therein a plurality of sheath heaters or pipe heaters 196 of a heating mechanism

194.

FIG. 9 shows in side elevation a partly cutting apparatus 200 according to a fourth embodiment of the present invention. As shown in FIG. 9, the partly cutting apparatus 200 has a cutter bearing base 202 in the form of a metal plate.

The cutter bearing base 202 accommodates therein a heat insulation 204 disposed in confronting relation to the rotary circular blade 68 (or the fixed circular blade 80). A heating mechanism 206 comprises pipe heaters 208 embedded in the portion of the metal cutter bearing base 202 which is surrounded by the heat insulation 204.

According to the fourth embodiment, the area that is heated by the heating mechanism 206 does not extend fully over the cutter bearing base 202, but is limited to an area near the partly cutting region 34. Accordingly, the photosensitive web 22 is heated efficiently and the area of the photosensitive web.22 that can be damaged by heat is reduced.

FIG. 10 shows in side elevation a partly cutting apparatus 210 according to a fifth embodiment of the present invention.

As shown in FIG. 10, the partly cutting apparatus 210 has a cutter bearing base 212 disposed in confronting relation to the rotary circular blade 68 (or the fixed circular blade 80), and a heating mechanism 214 has a heating box 216 housing therein the cutter mechanism 54 and the partly cutting region 34. In the heating box 216, the rotary circular blade 68 (or the fixed circular blade 80) and the partly cutting region 34 are indirectly heated by hot air. The cutter bearing base 212 may comprise the cutter bearing base 70, 182, 192, or 202 described above.

FIGS. 11 through 13 show in side elevation heating mechanisms 220, 230, 240 of partly cutting apparatus according to sixth, seventh, and eighth embodiments, respectively, of the present invention.

The heating mechanisms 220, 230, 240 are disposed upstream of the cutter mechanism 54. As shown in FIG. 11, the heating mechanism 220 has a pair of heating plates

(heaters) 222a, 222b disposed respectively above and below upper and lower surfaces of the photosensitive web 22.

As shown in FIG. 12, the heating mechanism 230 has a pair bar heaters 232a, 232b disposed respectively above and below upper and lower surfaces of the photosensitive web 22. As shown in FIG. 13, the heating mechanism 240 has a heating box 242 disposed in surrounding relation to upper and lower surfaces of the photosensitive web 22.

FIG. 14 shows in front elevation a partly cutting apparatus 250 according to a ninth embodiment of the present invention.

As shown in FIG. 14, the partly cutting apparatus 250 has a cutter mechanism 252 including a slide base 254 movable selectively in the directions indicated by the arrow B. Heating rollers 256 are disposed on both sides of the rotary circular blade 68 (or the fixed circular blade 80) mounted on the slide base 254. Alternatively, at least one heating roller 256 may be disposed forwardly of the rotary circular blade 68 (or the fixed circular blade 80) in the direction in which the cutter mechanism 252 moves to partly cut the photosensitive web 22. The heating rollers 256 are heated to a predetermined temperature by a heat source, not shown, and are held in contact with the partly cutting region 34 of the photosensitive web 22 to heat the partly cutting region 34 to a predetermined temperature.

FIG. 15 shows in perspective a partly cutting apparatus 260 according to a tenth embodiment of the present invention.

As shown in FIG. 15, the partly cutting apparatus 260 has a strip-shaped pressing blade (hereinafter referred to as "Thompson blade" ) 262 extending transversely across the photosensitive web 22 in the directions indicated by the arrow B. The Thompson blade 262 is held on a vertically movable base 264 and hence is vertically movable toward and away from the photosensitive web 22. A cutter bearing base 266 is disposed in confronting relation to the Thompson blade 262 with the photosensitive web 22 interposed therebetween. When the vertically movable base 264 is lowered, the Thompson blade 262 is pressed into the photosensitive web 22 against the cutter bearing base 266, partly cutting the photosensitive web 22 to a predetermined depth therein.

Although certain preferred embodiments of the present invention have been shown and described in detail, it should be understood that various changes and modifications may be made therein without departing from the scope of the appended claims.

Claims

1. A method of partly cutting a laminated film (22), leaving a portion thereof in the laminated direction, said laminated film (22) having at least a first resin layer (29) and a second resin layer (30), comprising the step of partly cutting said laminated film (22) with a cutter (68) while heating a partly cutting region (34) of said laminated film (22) to a preset temperature depending on said cutter (68).

2. A method according to claim 1 , further comprising the step of moving said cutter (68) along said partly cutting region (34) to partly cut said laminated film (22).

3. A method according to claim 2, wherein said cutter comprises a rotary circular blade (68) which is rotatable in the direction in which said rotary circular blade (68) moves, and said partly cutting region (34) is heated in the range from 35° C to 100⁰C.

4. A method according to claim 2 , wherein said cutter comprises a fixed circular blade (80) which is nonrotatable in the direction in which said rotary circular blade (68) moves, and said partly cutting region (34) is heated in the range from 25° C to 45⁰C.

5. A method according to claim 1 , wherein said laminated film comprises a photosensitive laminated film (22) with said first resin layer comprising a photosensitive resin layer (29).

6. An apparatus for partly cutting a laminated film (22), leaving a portion thereof in the laminated direction, said laminated film (22) having at least a first resin layer (29) and a second resin layer (30), comprising: a cutter mechanism (54) for partly cutting said laminated film (22), said cutter mechanism (54) comprising a cutter (68) ; and a heating mechanism (52) for heating a partly cutting region (34) of said laminated film (22) to a preset temperature depending on said cutter (68) when said laminated film (22) is partly cut by said cutter mechanism (54).

7. An apparatus according to claim 6 , wherein said cutter (68) is movable along said partly cutting region (34) of said laminated film (22).

8. An apparatus according to claim 6 , wherein said cutter mechanism (54) has a cutter bearing base (70) disposed in confronting relation to said cutter (68), and said heating mechanism (52) comprises a heater (76) disposed in said cutter bearing base (70).

9. An apparatus according to claim 6 , wherein said heating mechanism (52) comprises a heating roller (256) disposed near said cutter (68).

5 10. An apparatus according to claim 6, wherein said heating mechanism (214) comprises a heating box (216) for indirectly heating said cutter (68) and said partly cutting region (34), said heating box (216) accommodating said cutter (68) and said partly cutting region (34) therein. 10

11. An apparatus according to claim 6, wherein said heating mechanism (220) comprises a heater (222a) for heating said laminated film (22) before said laminated film (22) is partly cut.

15_.

12. An apparatus according to claim 6, wherein said cutter mechanism (54) comprises: a movable base (58) movable along said partly cutting region (34); and

20 a rotary circular blade (68) rotatably supported on said movable base (58).

13. An apparatus according to claim 12, wherein when said laminated film (22) is partly cut by said rotary

25 circular blade (68), said heating mechanism (52) heats said partly cutting region (34) in the range from 35° C to 100⁰C.

14. An^' apparatus according to claim 6, wherein said cutter mechanism (54) comprises: a movable base (58) movable along said partly cutting region (34) ; and

5 a fixed circular blade (80) fixedly supported on said movable base (58).

15. An apparatus according to claim 14, wherein when said laminated film (22) is partly cut by said fixed

10 circular blade (80), said heating mechanism (52) heats said partly cutting region (34) in the range from 25° C to 45° C.

16. An apparatus according to claim 6, wherein said laminated film comprises a photosensitive laminated film

,15 (22) with said first resin layer comprising a photosensitive resin layer (29).