WO2009084370A1 - 光学表示装置の製造システム及び製造方法 - Google Patents
光学表示装置の製造システム及び製造方法 Download PDFInfo
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- WO2009084370A1 WO2009084370A1 PCT/JP2008/072093 JP2008072093W WO2009084370A1 WO 2009084370 A1 WO2009084370 A1 WO 2009084370A1 JP 2008072093 W JP2008072093 W JP 2008072093W WO 2009084370 A1 WO2009084370 A1 WO 2009084370A1
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- optical
- optical film
- display unit
- optical display
- film
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/30—Polarising elements
- G02B5/3025—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state
- G02B5/3033—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D11/00—Producing optical elements, e.g. lenses or prisms
- B29D11/0073—Optical laminates
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B38/18—Handling of layers or the laminate
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B41/00—Arrangements for controlling or monitoring lamination processes; Safety arrangements
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/30—Polarising elements
- G02B5/3083—Birefringent or phase retarding elements
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- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
- G02F1/1303—Apparatus specially adapted to the manufacture of LCDs
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2457/00—Electrical equipment
- B32B2457/20—Displays, e.g. liquid crystal displays, plasma displays
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/02—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B38/16—Drying; Softening; Cleaning
- B32B38/162—Cleaning
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- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
- G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
- G02F1/1333—Constructional arrangements; Manufacturing methods
- G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
- G02F1/133528—Polarisers
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- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
- G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
- G02F1/1333—Constructional arrangements; Manufacturing methods
- G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
- G02F1/133528—Polarisers
- G02F1/133531—Polarisers characterised by the arrangement of polariser or analyser axes
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- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
- G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
- G02F1/1333—Constructional arrangements; Manufacturing methods
- G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
- G02F1/13363—Birefringent elements, e.g. for optical compensation
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
- Y10T156/1062—Prior to assembly
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/12—Surface bonding means and/or assembly means with cutting, punching, piercing, severing or tearing
- Y10T156/125—Plural severing means each acting on a different work piece
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/12—Surface bonding means and/or assembly means with cutting, punching, piercing, severing or tearing
- Y10T156/1317—Means feeding plural workpieces to be joined
- Y10T156/1322—Severing before bonding or assembling of parts
- Y10T156/1339—Delivering cut part in sequence to serially conveyed articles
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/17—Surface bonding means and/or assemblymeans with work feeding or handling means
- Y10T156/1702—For plural parts or plural areas of single part
- Y10T156/1712—Indefinite or running length work
- Y10T156/1739—Webs of different width, longitudinally aligned
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/17—Surface bonding means and/or assemblymeans with work feeding or handling means
- Y10T156/1702—For plural parts or plural areas of single part
- Y10T156/1744—Means bringing discrete articles into assembled relationship
- Y10T156/1751—At least three articles
- Y10T156/1761—Stacked serially
Definitions
- the present invention relates to an optical display device manufacturing system and manufacturing method for bonding optical films having optical anisotropy, such as an optical film including a polarizing plate, to the upper and lower sides of an optical display unit.
- FIG. 9 conceptually shows a method for manufacturing an optical display unit mounted on a conventional liquid crystal display device.
- an optical film manufacturer manufactures a long (strip-shaped) sheet-like product having an optical film member as a roll stock (# 1). This specific manufacturing process is a known manufacturing process and will not be described.
- Examples of the “long (strip-shaped) sheet-like product” include a polarizing plate original, a retardation plate original used in a liquid crystal display device, a laminated film original of a polarizing plate and a retardation plate, and the like.
- the original roll is slit to a predetermined size (a size according to the size of the optical display unit) (# 2).
- the slit raw material is cut to a fixed length in accordance with the size of the optical display unit to be bonded (# 3).
- an appearance inspection is performed on the sheet-like product (optical film) that has been cut into pieces (# 4).
- Examples of the inspection method include visual defect inspection and inspection using a known defect inspection apparatus.
- the defect means, for example, a surface or internal stain, scratch, a special defect such as a dent in which a foreign object is bitten (sometimes referred to as a knick), a bubble, a foreign object, or the like.
- the finished product is inspected (# 5).
- the finished product inspection is an inspection that complies with quality standards that are more stringent than the appearance inspection.
- the end surfaces of the four end surfaces of the sheet-like product are processed (# 6). This is performed to prevent the adhesive or the like from protruding from the end face during transportation.
- the single sheet product is clean-wrapped (# 7).
- packaging for transportation (transport packaging) (# 8). A sheet-like product is manufactured as described above and transported to a panel processing manufacturer.
- the panel processing manufacturer packs and disassembles the sheet-like product that has been transported (# 11).
- an appearance inspection is performed in order to inspect for scratches, dirt, etc. that occur during transportation or at the time of unpacking (# 12).
- the sheet-like product that has been determined to be non-defective in the inspection is conveyed to the next process. Note that this appearance inspection may be omitted.
- An optical display unit for example, a glass substrate unit in which a liquid crystal cell is sealed
- the optical display unit is cleaned before the bonding step (# 13).
- the release film is peeled off from the sheet-like product leaving a pressure-sensitive adhesive layer, and the pressure-sensitive adhesive layer is bonded to one surface of the optical display unit as a bonding surface. Further, it can be similarly bonded to the other surface of the optical display unit.
- the optical film of the same structure may be bonded to each surface of the optical display unit, or an optical film of a different structure may be bonded.
- the bonded state inspection and defect inspection are performed (# 15).
- the optical display unit determined to be non-defective in this inspection is transported to the mounting process and mounted on the optical display device (# 16).
- the optical display unit determined to be defective is subjected to a rework process (# 17).
- the optical film is peeled from the optical display unit.
- An optical film is newly bonded to the reworked optical display unit (# 14).
- the present applicant has created an invention described in Japanese Patent Application Laid-Open No. 2007-140046 (Patent Document 1).
- the supply means for pulling out and supplying the belt-like sheet-like product from the roll around which the belt-like sheet-like product having the optical film as the member of the optical display device is wound, and the belt-like sheet shape drawn by the supply means
- Detection means for detecting defects in the product
- cutting means for cutting the strip-like sheet-like product based on the detection result of the detection means, and processing into individual sheet-like products, and sheet-like product cut by the cutting means
- Transfer means for carrying out the laminating process, and a laminating process means for laminating the sheet-like product transferred by the transfer means and the optical display unit as a member of the optical display device.
- Patent Document 1 discloses an optical display unit that is separately provided with an apparatus for attaching an optical film to one side of the optical display unit and then attaching the optical film to the other side. Absent. For this reason, there is room for improving manufacturing efficiency, for example, when an optical film is bonded to the other side using the same manufacturing system, it takes twice when loading the optical display unit after bonding to the apparatus. there were.
- an object of the present invention is to use two rolls having the same optical anisotropy, such as an absorption axis, to bond the upper and lower optical films to the optical display unit so that the optical anisotropy is orthogonal.
- An object of the present invention is to provide an optical display device manufacturing system and method.
- the optical display device manufacturing system of the present invention is an optical display device manufacturing system in which an optical film having optical anisotropy is bonded to an optical display unit, and has a width corresponding to the short side of the optical display unit. After the first optical film is cut to a length corresponding to the long side of the optical display unit using a roll on which the belt-like sheet-shaped product having the first optical film is wound, the first optical film is formed on one surface of the optical display unit.
- the first cutting and bonding apparatus On the short side of the optical display unit, using a roll on which a strip-shaped sheet-like product having a first optical film having a width corresponding to the long side of the optical display unit is wound, and the first cutting and bonding apparatus to be bonded. It is characterized by comprising a second cutting and pasting device for pasting on the other surface of the optical display unit after cutting the second optical film to a corresponding length.
- the optical films supplied from each of the rolls are spaced at regular intervals.
- the optical films corresponding to the short side and the long side of the optical display unit can be obtained by simply cutting the film. Therefore, the former is cut to a length corresponding to the long side, the latter is cut to a length corresponding to the short side, and the optical anisotropy such as an absorption axis is bonded to both surfaces of the optical display unit.
- the upper and lower optical films can be bonded to the optical display unit so that the optical anisotropy is orthogonal.
- An optical display device manufacturing system is an optical display device manufacturing system in which an optical film including a polarizing plate is bonded to an optical display unit, the optical display unit supplying device supplying an optical display unit;
- a first optical film supply device that draws the belt-like sheet-shaped product from the roll around which the belt-like sheet-like product having the first optical film is wound, and supplies the first optical film after being cut into a predetermined length;
- the 1st bonding apparatus which bonds the 1st optical film supplied from the supply apparatus of the said 1st optical film to the one surface of the optical display unit supplied from the supply apparatus, and the optical after bonding of a 1st optical film Conveying and supplying apparatus for conveying and supplying the display unit, and a strip-shaped sheet from a roll around which the strip-shaped sheet-shaped product having the second optical film is wound
- a second optical film supply device that is supplied after the product is pulled out and cut into a predetermined length, and is supplied from the second optical film supply device to the other surface of the optical display unit supplied from
- One supply device cuts an optical film having a width corresponding to the short side with a length corresponding to the long side
- the other supply device cuts an optical film having a width corresponding to the long side to the long side corresponding to the short side. It is configured to be cut at this point.
- the apparatus further includes the above-described transport supply device, the second optical film supply device, and the second bonding device, and the first optical film supply device and the first optical film supply device.
- Two optical film supply devices can be supplied in correspondence with the long side and the short side of the optical display unit by changing the width and cutting length of the optical film. For this reason, the upper and lower optical films can be bonded to the optical display unit on a continuous production line using a roll raw material having the same absorption axis of the polarizing plate.
- the said conveyance supply apparatus has a turning mechanism which turns the optical display unit after bonding by the said 1st bonding apparatus in the bonding direction by the said 2nd bonding apparatus.
- a turning mechanism which turns the optical display unit after bonding by the said 1st bonding apparatus in the bonding direction by the said 2nd bonding apparatus.
- the first optical film supply device and the second optical film supply device have a defect portion elimination mechanism that cuts out and eliminates the defect portion of the optical film.
- a defect portion elimination mechanism that cuts out and eliminates the defect portion of the optical film.
- the supply device of the first optical film and the supply device of the second optical film use the release film formed on the optical film via an adhesive layer as a transport medium, and the first bonding device and the second bonding device. It is preferable to have a transport mechanism for supplying the first optical film and the second optical film to the combined device. By having such a transport mechanism, the first optical film and the second optical film can be supplied to the first bonding apparatus and the second bonding apparatus with high accuracy using a simple transport mechanism.
- the optical display device manufacturing method of the present invention is an optical display device manufacturing method in which an optical film having optical anisotropy is bonded to an optical display unit, and has a width corresponding to the short side of the optical display unit.
- the first optical film is cut on a length corresponding to the long side of the optical display unit and then the first optical film on one surface of the optical display unit
- the first side of the optical display unit, and the roll of the belt-like sheet-like product having the second optical film having a width corresponding to the long side of the optical display unit.
- a second cutting and pasting step of pasting a second optical film to the other surface of the optical display unit is an optical display device manufacturing method in which an optical film having optical anisotropy is bonded to an optical display unit, and has a width corresponding to the short side of the optical display unit.
- the former is cut into a length corresponding to the long side using a roll having a width corresponding to the short side of the optical display unit and a roll having a width corresponding to the long side. Then, the latter is cut to a length corresponding to the short side and bonded to both surfaces of the optical display unit.
- the upper and lower optical films can be bonded to the optical display unit using two rolls having the same optical anisotropy such as an absorption axis so that the optical anisotropy is orthogonal.
- the method for producing an optical display device of the present invention is a method for producing an optical display device in which an optical film including a polarizing plate is bonded to an optical display unit, and a strip-shaped sheet-like product having the first optical film is wound up.
- the optical film having a width corresponding to the short side is cut by a length corresponding to the long side, and when supplying the other, the optical film having a width corresponding to the long side corresponds to the short side. It includes a step of cutting by length.
- the first optical film and the second optical film are supplied, one is supplied in correspondence with the long side and the short side of the optical display unit.
- the optical film having a width corresponding to the short side is cut by a length corresponding to the long side, and when the other is supplied, the optical film having a width corresponding to the long side is cut by a length corresponding to the short side. Since the process is included, the upper and lower optical films can be bonded to the optical display unit on a continuous production line using the roll raw material having the same absorption axis of the polarizing plate.
- a turning step of turning the optical display unit after being bonded in the first cutting and bonding step in the bonding direction in the second cutting and bonding step it is not necessary to vertically arrange the supply direction of the first optical film and the supply direction of the second optical film, and space can be saved in the manufacturing system.
- the bonding angle in a 2nd cutting bonding process can be optimized using a turning process.
- the defect removing step of cutting and removing a portion having the defect of the optical film.
- a release film formed on the optical film via an adhesive layer is used as a transport medium, and a first cutting and pasting step and a second cutting and pasting are performed. It is preferable that the first optical film and the second optical film are conveyed and supplied to the combination step.
- a conveyance system it is possible to convey and supply the first optical film and the second optical film to the first cutting and bonding step and the second cutting and bonding step with high accuracy using a simple conveyance mechanism.
- the flowchart which shows the process by the manufacturing system of this invention
- the figure for demonstrating an example of the manufacturing system of this invention The figure for demonstrating an example of the manufacturing system of this invention
- the figure for demonstrating the apparatus structure of an example of the manufacturing system of this invention The figure for demonstrating the apparatus structure of an example of the manufacturing system of this invention
- the figure for demonstrating the apparatus structure of an example of the manufacturing system of this invention The figure for demonstrating the apparatus structure of an example of the manufacturing system of this invention
- the figure for demonstrating the apparatus structure of an example of the manufacturing system of this invention The figure for demonstrating an example of the laminated structure of a 1st, 2nd optical film
- FIG. 1 shows an example of a flowchart of a method for manufacturing an optical display device.
- FIG. 2 shows a configuration diagram of an example of an optical display device manufacturing system.
- FIG. 3 shows a plan layout view of an example of a manufacturing system for an optical display device.
- optical display unit examples of the optical display unit used in the present invention include a glass substrate unit of a liquid crystal cell and an organic EL light emitting unit.
- the present invention is effective for an optical display unit having a rectangular outer shape, and for example, one having a long side / short side of 16/9 or 4/3 is used.
- members, such as an optical film may be previously laminated and integrated.
- the optical film to be affixed to the optical display unit may have any optical anisotropy.
- an optical film including a polarizing plate is preferable.
- the optical film including the polarizing plate include a polarizing plate, a retardation film, a brightness enhancement film, and an optical film in which two or more combinations of these films are laminated on the polarizing plate.
- a protective transparent film may be laminated on the surface of these optical films.
- an adhesive layer is formed on one surface of the optical film so as to be attached to, for example, an optical display unit, and a release film for protecting the adhesive layer is provided.
- a surface protective film is provided on the other surface of the optical film, for example, via an adhesive layer.
- the present invention is effective when two rolls having the same optical anisotropy are used, and in particular, two rolls having the same absorption direction of the polarizing plate constituting the optical film are used. It is effective when The direction of the absorption axis of the polarizing plate is usually the long direction of the roll. Further, in the case of a retardation film, there are those in which the slow axis coincides with the long direction of the roll original fabric, those in which the slow axis is vertical, and those in which the slow axis is in an oblique direction with a constant angle.
- an optical film in which a surface protective film and a release film are laminated may be referred to as a sheet product.
- the method for producing an optical display device of the present invention is a method for producing an optical display device in which an optical film having optical anisotropy is bonded to an optical display unit, and preferably an optical film including a polarizing plate is optical. It is a manufacturing method of the optical display device bonded to the display unit.
- the production method of the present invention includes a first cutting and pasting step and a second cutting and pasting step, either step may be performed first, or both steps may be performed simultaneously or substantially simultaneously.
- corresponds to the long side of the said optical display unit using the roll by which the strip
- corresponds to the short side of the said optical display unit using the roll by which the strip
- a second optical film is bonded to the other surface of the optical display unit.
- the manufacturing method of the optical display device of the present invention is, for example, by pulling out the belt-like sheet product from a roll on which the belt-like sheet product having the first optical film is wound, and having a predetermined length.
- the first cutting and bonding step is carried out by, for example, the following (2) conveying step to (5) first optical film bonding step, and the second cutting and bonding step is described below, for example, (8) conveying. Step (11) Implemented by the second optical film laminating step.
- First roll original fabric preparation step (FIG. 1, S1).
- a long first sheet product is prepared as a first roll.
- variety of a 1st roll original fabric is dependent on the bonding size of an optical display unit. Specifically, the width of the first roll original fabric is determined corresponding to one of the long side or the short side of the optical display unit, and the width of the second roll original fabric is determined corresponding to the other side. For this reason, the 1st roll original fabric and the 2nd roll original fabric have different widths, and those previously slit into a predetermined width by slit processing from the roll original fabric before slit are used.
- Slit processing is performed while rewinding the roll material before slitting
- examples of the method include a method using a cutting tool such as a laser cutting device or a rotating round blade.
- the method of cut disconnecting one end surface or both end surfaces of a roll end surface can also be used, without unwinding the roll raw material before a slit.
- corresponding to the long side or short side of the optical display unit means the length of the optical film bonded to the long side or short side of the optical display unit (excluding the exposed portion).
- the length of the long side or the short side of the optical display unit and the width of the optical film do not have to be the same.
- the laminated structure of the first sheet product F1 includes a first optical film F11, a first release film F12, and a surface protective film F13.
- the first optical film F11 includes a first polarizer F11a, a first film F11b having an adhesive layer (not shown) on one side thereof, and a second film having an adhesive layer (not shown) on the other side. F11c.
- the first and second films F11b and F11c are, for example, polarizer protective films (for example, triacetyl cellulose film, PET film, etc.).
- the second film F11c is bonded to the optical display unit surface side via the first adhesive F14.
- a surface treatment can be applied to the first film F11b. Examples of the surface treatment include a hard coat treatment, an antireflection treatment, a treatment for the purpose of prevention of sticking, diffusion or antiglare, and the like.
- the first release film F12 is provided via the second film F11c and the first pressure-sensitive adhesive layer F14.
- the surface protection film F13 is provided through the 1st film F11b and the adhesive layer F15. Specific configurations of the first and second films F11b and F11c will be described later. Below, the laminated structure of a polarizer and a polarizer protective film may be called a polarizing plate.
- the following steps are preferably performed in an isolation structure isolated from the factory so that the cleanliness is maintained.
- the cleanliness is maintained in the bonding step of bonding the optical film to the optical display unit.
- the first sheet material F1 is fed out from the first roll stock prepared and installed, and is conveyed downstream.
- the first conveying device 12 that conveys the first sheet product F1 is configured by, for example, a nip roller pair, a tension roller, a rotation driving device, an accumulating device A, a sensor device, a control device, and the like.
- the defect inspection method includes a method of photographing and processing images with transmitted light and reflected light on both sides of the first sheet product F1, and an inspection polarizing film between the CCD camera and the inspection object.
- a method is mentioned. Note that a known method can be applied to the image processing algorithm, and for example, a defect can be detected by density determination by binarization processing.
- the defect information obtained by the first defect inspection apparatus 14 is linked together with the position information (for example, position coordinates), transmitted to the control apparatus 1, and contributes to a cutting method by the first cutting apparatus 16 described later. be able to.
- the first cutting device 16 cuts the surface protective film F13, the pressure-sensitive adhesive layer F15, the first optical film F11, and the first pressure-sensitive adhesive layer F14 into a predetermined size without cutting the first release film F12.
- the first release film F12 can be used as a transport medium for the first optical film F11. That is, in this invention, the 1st optical film F11 and the 2nd optical film are used for the 1st cutting bonding process and the 2nd cutting bonding process by using the release film formed in the optical film through the adhesive layer as a conveyance medium. It is preferable to transport and supply each F21.
- the width of the first roll original corresponds to the short side corresponding to one of the long side or the short side of the optical display unit
- the length corresponding to the long side of the optical film is long. If the width of the first roll original fabric corresponds to the long side, the optical film is cut to a length corresponding to the short side.
- the width of the first roll original first sheet product F1 corresponds to the short side of the optical display unit W.
- Examples of the cutting means include a laser device, a cutter, and other known cutting means. Based on the defect information obtained by the first defect inspection apparatus 14, the cutting is performed so as to avoid the defect. Thereby, the yield of the first sheet product F1 is greatly improved.
- the first sheet product F1 including the defect is excluded by a first rejection device 19 described later, and is configured not to be attached to the optical display unit W. That is, in this invention, when supplying the 1st optical film F11 and the 2nd optical film F21, it is preferable to include the fault part elimination process of cut
- the transport mechanism R includes, for example, a transport roller, a transport direction switching mechanism, a rotation drive device, a sensor device, and a control device.
- the polishing cleaning device 10 and the water cleaning device 11 will be described later.
- FIG. 1, S6-2 Inspection process
- the surface of the cleaned optical display unit W is inspected by an inspection device D1.
- the panel W after the inspection is transported to the first bonding device 18 by the transport mechanism R.
- the inspection device D1 will be described later.
- steps of the first roll original fabric preparation step, the first inspection step, the first cutting step, the first optical film bonding step, the cleaning step, and the inspection step are preferably performed on a continuous production line.
- the first optical film F11 was bonded to one surface of the panel W.
- the manufacturing process which bonds the 2nd optical film F21 on another surface is demonstrated.
- a long second sheet product F2 is prepared as a second roll material.
- the laminated structure of the second sheet product F2 has the same configuration as that of the first sheet product, but is not limited thereto.
- the second sheet product F2 includes a second optical film F21, a second release film F22, and a surface protection film F23.
- the second optical film F21 includes a second polarizer 21a, a third film F21b having an adhesive layer (not shown) on one side thereof, and a fourth film having an adhesive layer (not shown) on the other side. F21c.
- the third and fourth films F21b and F21c are, for example, polarizer protective films (for example, triacetyl cellulose film, PET film, etc.).
- the fourth film F21c is bonded to the optical display unit surface side via the second pressure-sensitive adhesive layer F24.
- the third film F21b can be subjected to a surface treatment. Examples of the surface treatment include a hard coat treatment, an antireflection treatment, a treatment for the purpose of prevention of sticking, diffusion or antiglare, and the like.
- the second release film F22 is provided via the fourth film F21c and the second pressure-sensitive adhesive layer F24.
- the surface protection film F23 is provided through the 3rd film F21b and the adhesive layer F25.
- the second sheet material F2 is fed out from the prepared and installed second roll, and is conveyed downstream.
- the second conveying device 22 that conveys the second sheet product includes, for example, a nip roller pair, a tension roller, a rotation driving device, an accumulating device A, a sensor device, a control device, and the like.
- Second inspection step (FIG. 1, S13).
- the second sheet material F2 is inspected for defects using the second defect inspection device 24.
- the defect inspection method here is the same as the method using the first defect inspection apparatus described above.
- the second cutting device 26 cuts the surface protective film F23, the pressure-sensitive adhesive layer F25, the second optical film F21, and the second pressure-sensitive adhesive layer F24 into a predetermined size without cutting the second release film F22. Specifically, in correspondence with one of the long side or the short side of the optical display unit, when the width of the second roll raw material corresponds to the short side, the optical film is cut at a length corresponding to the long side. Alternatively, when the width of the second roll original fabric corresponds to the long side, the optical film is cut to a length corresponding to the short side. In the present embodiment, as shown in FIG. 3, an example is shown in which the width of the second roll original (second sheet product F2) corresponds to the long side of the optical display unit W.
- Examples of the cutting means include a laser device, a cutter, and other known cutting means. Based on the information on the defect obtained by the second defect inspection apparatus 24, it is configured to cut so as to avoid the defect. Thereby, the yield of the second sheet product F2 is greatly improved.
- the second sheet product F2 including the defect is excluded by a second rejection device 29 described later, and is not attached to the optical display unit W.
- Second optical film bonding step (FIG. 1, S15). Next, after the second cutting step, the second optical film from which the second release film F22 has been removed using the second laminating apparatus 28 while removing the second release film F22 using the second peeling apparatus 27.
- the film F21 is bonded to a surface different from the surface to which the first optical film F11 of the optical display unit W1 is bonded via the second pressure-sensitive adhesive layer F24. Before the second optical film F21 is bonded to the optical display unit W1, the optical display unit W1 is rotated 90 degrees by the transport direction switching mechanism of the transport mechanism R, and the first optical film F11 and the second optical film F21 are crossed. There may be a Nicole relationship.
- the turning process which turns the optical display unit F11 after bonding in a 1st cutting bonding process to the bonding direction in a 2nd cutting bonding process.
- the direction of the long side of the first optical film F11 bonded to the optical display unit W1 after turning and the direction of the long side of the second optical film F21 bonded after cutting are 0 ⁇ 5 °
- the turning angle in the turning step is 85 to 95 °. Is preferred.
- the second optical film F21 and the optical display unit W1 are sandwiched between rolls and are bonded.
- the inspection apparatus 30 inspects the optical display unit W12 having the optical film attached to both sides.
- Examples of the inspection method include a method of capturing an image and processing an image using reflected light on both surfaces of the optical display unit W12.
- a method of installing a polarizing film for inspection between the CCD camera and the inspection object is also exemplified. Note that a known method can be applied to the image processing algorithm, and for example, a defect can be detected by density determination by binarization processing.
- the optical display unit W12 is determined to be non-defective.
- the optical display unit W12 determined to be non-defective is conveyed to the next mounting process. If a defective product is determined, a rework process is performed, a new optical film is applied, and then inspected.If a good product is determined, the process proceeds to a mounting process. Discarded.
- the optical display unit can be suitably manufactured by executing the bonding process of the first optical film F11 and the second optical film F21 bonding process on a continuous production line.
- the optical film can be bonded to the optical display unit in an environment in which cleanliness is ensured, and a high-quality optical display unit is manufactured. Can do.
- defect information defect coordinates, defect type, size, etc.
- code information for example, QR code, barcode
- a part including defects is excluded or configured to be bonded to a member that is not an optical display unit, and a non-defective sheet-shaped product cut to a predetermined size is configured to be bonded to the optical display unit. .
- the yield of the optical display unit is greatly improved.
- the production system of the present invention is a production system of an optical display device in which an optical film having optical anisotropy is bonded to an optical display unit, preferably an optical film in which an optical film including a polarizing plate is bonded to an optical display unit.
- This is a display device manufacturing system.
- the manufacturing system of this invention is equipped with the 1st cutting bonding apparatus which performs a 1st cutting bonding process, and the 2nd cutting bonding apparatus which performs a 2nd cutting bonding process.
- the supply apparatus M1 of the optical display unit W, the supply apparatus M2 of the first optical film F11, the first bonding apparatus M3 for bonding the first optical film F11, and the bonding The example provided with the conveyance supply apparatus M4 which conveys and supplies the optical display unit W after matching, the supply apparatus M5 of the 2nd optical film F21, and the 2nd bonding apparatus M6 which bonds the 2nd optical film F21. Indicates.
- the first cutting and bonding apparatus includes a supply device M2 for the first optical film F11 and a first bonding apparatus M3 for bonding the first optical film F11. 2 The supply apparatus M5 of the optical film F21 and the 2nd bonding apparatus M6 which bonds the 2nd optical film F21 are included.
- FIG. 4 is a diagram illustrating the first transport device 12, the first pre-inspection peeling device 13, the first defect inspection device 14, the first release film sticking device 15, and the first cutting device 16.
- FIG. 5 is a diagram showing the first peeling device 17, the first sticking device 18, and the first exclusion device 19.
- FIG. 6 is a diagram illustrating the second transport device 22, the second pre-inspection peeling device 23, the second defect inspection device 24, the second release film sticking device 25, and the second cutting device 26.
- FIG. 7 is a view showing the second peeling device 27, the second sticking device 28, and the second exclusion device 29.
- the manufacturing system of the present invention includes an optical display unit supply device M1 for supplying the optical display unit W.
- the optical display unit supply device M1 includes a polishing cleaning device 10, a water cleaning device 11, an inspection device D1, and a drying device 113 is shown.
- the panel W is taken out from the storage box and placed on the transport mechanism R.
- the conveyance is stopped and the end of the panel W is held by the holding means.
- the polishing means is brought into contact with the upper surface of the panel W from vertically above, and the polishing means is brought into contact with the bottom surface of the panel from vertically below.
- Each polishing means is rotated on both surfaces of the panel W.
- the adhered foreign matter on both surfaces of the panel W is removed. Examples of the adhering foreign matter include glass fine pieces (cullet), fiber pieces, and the like.
- the panel W that has been polished and cleaned is transported to the water bath by the transport mechanism R, where it is cleaned with water. Pure water flows inside the bath. Both surfaces of the panel W conveyed from the water bath are further rinsed with pure water flowing out from the flowing water pipe.
- the inspection apparatus D1 supplies the liquid R having a wettability to the surface of the transport apparatus R that can support the optical display unit W in a horizontal state and the entire surface of the optical display unit W so as to contact the surface.
- the liquid supply device also serves as a rinsing liquid supply device in the cleaning device 11.
- the optical display unit W can be inspected in a wet state.
- an inspection apparatus capable of inspecting the optical display unit W in a dry state may be provided. In that case, an inspection apparatus similar to the inspection apparatus described later is provided on the downstream side of the drying apparatus. Further, the inspection device D1 can be omitted.
- the liquid supplied from the liquid supply device may be any liquid as long as it has wettability with respect to the surface of the optical display unit W. From the viewpoint of using rinse washing as it is, pure water, ion exchange water, distilled water, etc. Of water is preferred.
- the liquid is supplied so as to be in contact with the entire surface without deviation by simply supplying the liquid from the liquid supply device to the surface by the flow of the liquid on the surface.
- the optical display unit W can be observed while being transported, but once the transport device R is stopped and the observation is performed, fluctuations in the liquid can be eliminated, and the inspection accuracy can be improved. Can be increased.
- a camera that captures the surface of the optical display unit W and outputs image information in the observation area is provided, a boundary portion of a portion where repelling occurs is specified from the image information output from the camera, and the portion
- an image information processing apparatus for determining presence or absence is provided. This makes it possible to automate the detection and determination of defective cleaning parts.
- the image information processing apparatus displays image information from a high-luminance portion generated by reflection near the boundary between the portion where the repelling occurs and the other portion. It is preferable to implement a process including a step of specifying the boundary portion by using.
- the panel W is drained by blowing clean air with a drying device. Then, the panel W is conveyed to the 1st bonding apparatus 18.
- FIG. it is possible to wash with an aqueous ethanol solution instead of pure water. In another embodiment, the water bath can be omitted.
- the production system of the present invention supplies the first optical film that is supplied after the belt-like sheet-shaped product F1 is drawn from the roll around which the belt-shaped sheet-like product having the first optical film F11 is wound and cut into a predetermined length.
- a device M2 is provided.
- the first optical film supply device M2 as shown in FIG. 4, is a first transport device 12, a first pre-inspection peeling device 13, a first defect inspection device 14, and a first release film bonding.
- the example provided with the apparatus 15 and the 1st cutting device 16 is shown.
- the first optical film can be inspected with high precision. It can be omitted.
- the first optical film supply device M2 cuts an optical film having a width corresponding to the short side to a length corresponding to the long side, corresponding to the long side and the short side of the optical display unit. Or an optical film having a width corresponding to the long side is cut by a length corresponding to the short side.
- the first optical film supply device M2 is configured to cut an optical film having a width corresponding to the short side of the optical display unit with a length corresponding to the long side.
- the first roll of the long first sheet product F1 is installed on a roller mount device that is linked to a motor or the like so as to rotate freely or at a constant rotational speed.
- the rotation speed is set by the control device 1 and the drive is controlled.
- the first transport device 12 is a transport mechanism that transports the first sheet product F1 to the downstream side.
- the first transport device 12 is controlled by the control device 1.
- the first pre-inspection peeling device 13 is configured to peel the release film H11 from the conveyed first sheet product F1 and to wind it on a roll 132.
- the winding speed around the roll 132 is controlled by the control device 1.
- the peeling mechanism 131 has a knife edge portion with a sharp tip.
- the release film H11 is wound around the knife edge portion and reversely transferred, whereby the release film H11 is peeled off and the release film H11 is removed. It is comprised so that the 1st sheet material F1 after peeling may be conveyed in a conveyance direction.
- the first defect inspection device 14 performs defect inspection after the release film H11 is peeled off.
- the first defect inspection device 14 detects the defect by analyzing the image data captured by the CCD camera, and further calculates its position coordinates. The position coordinates of this defect are provided for the skip cut by the first cutting device 16 described later.
- 1st release film bonding apparatus 15 bonds the release film H12 to the 1st optical film F11 via the 1st adhesive layer F14 after a 1st fault test
- the release film H12 is unwound from a roll 151 of the release film H12, and the release film H12 and the first optical film F11 are sandwiched by one or a plurality of roller pairs 152.
- a predetermined pressure is applied to bond together.
- the rotation speed, pressure control, and conveyance control of the roller pair 152 are controlled by the control device 1.
- the first cutting device 16 does not cut the release film H12 after laminating the release film H12, but the first optical film F11, the surface protective film 15, the first pressure-sensitive adhesive layer F14, and the pressure-sensitive adhesive layer F15. Is cut into a predetermined size.
- the first cutting device 16 is, for example, a laser device. Based on the position coordinates of the defect detected in the first defect inspection process, the first cutting device 16 cuts to a predetermined size so as to avoid the defect portion. That is, the cut product including the defective portion is rejected as a defective product by the first rejecting device 19 in a subsequent process.
- the first cutting device 16 may continuously cut into a predetermined size while ignoring the existence of the defect. In this case, it can be configured such that the portion is removed without being bonded in the bonding process described later. Control in this case also depends on the function of the control device 1.
- the first cutting device 16 is provided with a holding table that sucks and holds the first sheet product F1 from the back surface, and the laser device is provided above the first sheet product F1.
- the first sheet product F1 is moved horizontally so as to scan the laser in the width direction, the first optical film F11, the first pressure-sensitive adhesive layer F14, the surface protective film F13, the pressure-sensitive adhesive layer leaving the lowermost release film H12.
- F15 is cut at a predetermined pitch in the conveying direction (hereinafter referred to as “half cut” as appropriate).
- this laser apparatus collects gas (smoke) generated from the air nozzle that blows warm air toward the cutting site and the cutting site conveyed by the hot air so as to be sandwiched from the width direction of the first sheet product F1. It is preferable that the smoke collecting duct that smokes is configured integrally.
- the accumulation device A of the transport mechanism moves in the vertical direction so as not to stop the continuous transport of the downstream and upstream first sheet products F1. It is configured. This operation is also controlled by the control device 1.
- the manufacturing system of the present invention is a first paste for bonding the first optical film F11 supplied from the first optical film supply device M2 to one surface of the optical display unit W supplied from the optical display unit supply device M1.
- a combination device 18 (M3) is provided.
- the 1st bonding apparatus 18 (M3) is further provided with the 1st peeling apparatus 17 and the 1st exclusion apparatus 19 while being comprised by the pressing roller 181 and the guide roller 182 as shown in FIG. An example is shown.
- the first exclusion device 19 and the first cutting device 16 constitute a defect elimination mechanism that cuts and eliminates a defect portion of the optical film. However, such an exclusion mechanism may be omitted. .
- the 1st bonding apparatus 18 is 1st sheet product F1 (1st optical film F11) from which the release film H12 was peeled by the 1st peeling apparatus 17 after the said cutting process via the 1st adhesive layer F14. Affixed to the optical display unit W.
- the conveyance path of the first sheet product F1 is above the conveyance path of the optical display unit W.
- the first optical film F11 is bonded to the surface of the optical display unit W by the pressing roller 181 and the guide roller 182 while being bonded.
- the control device 1 controls the pressing pressure and driving operation of the pressing roller 181 and the guide roller 182.
- the peeling mechanism 171 of the first peeling device 17 has a knife edge portion having a sharp tip, and the release film H12 is wrapped around the knife edge portion and reversely transferred to peel the release film H12.
- the first sheet product F1 (first optical film F11) after the release film H12 is peeled off is sent out to the optical display unit W surface.
- the peeled release mold H12 is wound around a roll 172.
- the winding control of the roll 172 is controlled by the control device 1.
- the supply device M2 for the first optical film in the present invention supplies the first optical film F11 to the first bonding device M3 using the release film formed on the optical film via the adhesive layer as the transport medium. It has a transport mechanism.
- the laminating mechanism is composed of a pressing roller 181 and a guide roller 182 disposed opposite thereto.
- the guide roller 182 is composed of a rubber roller that is rotationally driven by a motor, and is arranged so as to be movable up and down.
- a pressing roller 181 made of a metal roller that is rotationally driven by a motor is disposed directly above it.
- the pressing roller 181 is raised to a position higher than the upper surface so as to open a roller interval.
- both the guide roller 182 and the pressing roller 181 may be rubber rollers or metal rollers.
- the optical display unit W is cleaned by various cleaning devices and is transported by the transport mechanism R.
- the transport control of the transport mechanism R is also controlled by the control device 1.
- the first rejection apparatus 19 that excludes the first sheet product F1 including the defects.
- the guide roller 182 moves vertically downward.
- the roller 192 around which the adhesive tape 191 is stretched moves to a fixed position of the guide roller 182.
- the first sheet product F1 including the defect is pressed against the adhesive tape 191 by moving the pressing roller 181 vertically downward, and the first sheet product F1 is attached to the adhesive tape 191, and the first sheet including the defect together with the adhesive tape 191.
- the product F1 is wound around the roller 193.
- the optical display unit W1 manufactured as described above is transported to the downstream side, and the second optical film F21 (second sheet product F2) is bonded thereto.
- the description of the same device configuration will be briefly described.
- the manufacturing system of the present invention includes a transport supply device M4 that transports and supplies the optical display unit W after the first optical film F11 is bonded.
- the transport supply device M4 is bonded by the first bonding device 18. It is preferable to have a turning mechanism 20 that turns the combined optical display unit W in the bonding direction in the second bonding apparatus 28.
- the optical display unit W1 is moved by the transport direction switching mechanism (the turning mechanism 20) of the transport mechanism R.
- the second optical film F21 is bonded after being rotated by 90 °.
- each step is processed in a state where the second sheet product F2 is inverted (with the release film on the upper surface), and the second optical film F21 is processed. Is configured to be bonded from the lower side of the optical display unit W1.
- the production system of the present invention supplies the second optical film that is supplied after the belt-like sheet-shaped product F2 is drawn from the roll around which the belt-shaped sheet-like product having the second optical film F21 is wound and cut into a predetermined length.
- a device M5 is provided.
- the second optical film supply device M5 is, as shown in FIG. 6, a second transport device 22, a second pre-inspection peeling device 23, a second defect inspection device 24, and a second release film bonding.
- the example provided with the apparatus 25 and the 2nd cutting device 26 is shown.
- the second optical film can be inspected with high accuracy by including the second pre-inspection peeling device 23, the second defect inspection device 24, and the second release film laminating device 25. It can be omitted.
- the second optical film supply device M5 cuts an optical film having a width corresponding to the short side to a length corresponding to the long side, corresponding to the long side and the short side of the optical display unit W.
- the optical film having a width corresponding to the long side is cut by a length corresponding to the short side.
- the 2nd optical film supply apparatus M5 shows the example comprised so that the optical film F21 of the width
- the second roll of the long second sheet product F2 is installed on a roller mount device that is linked to a motor or the like so as to rotate freely or at a constant rotational speed.
- the rotation speed is set by the control device 1 and the drive is controlled.
- the second transport device 22 is a transport mechanism that transports the second sheet product F2 to the downstream side.
- the second transport device 22 is controlled by the control device 1.
- the second pre-inspection peeling device 23 is configured to peel the release film H21 from the conveyed second sheet product F2 and to wind it on a roll 232.
- the winding speed around the roll 232 is controlled by the control device 1.
- the peeling mechanism 231 has a knife edge portion with a sharp tip.
- the release film H21 is wrapped around the knife edge portion and transferred in reverse, thereby peeling the release film H21 and removing the release film H21. It is comprised so that the 2nd sheet material F2 after peeling may be conveyed in a conveyance direction.
- the second defect inspection device 24 performs defect inspection after the release film H21 is peeled off.
- the second defect inspection device 24 analyzes the image data picked up by the CCD camera, detects the defect, and calculates its position coordinates. The position coordinates of this defect are provided for the skip cut by the second cutting device 26 described later.
- the production system of the present invention is a second laminating device 28 for laminating the second optical film F21 supplied from the second optical film supply device M5 to the other surface of the optical display unit W supplied from the conveyance supply device M4. (M6).
- the second bonding device 28 (M6) includes a pressing roller 281 and a guide roller 282, and further includes a second peeling device 27 and a second excluding device 29.
- An example is shown.
- the second exclusion device 29, together with the second cutting device 26, constitutes a defect portion elimination mechanism that cuts and eliminates the defective portion of the optical film. However, such an exclusion mechanism may be omitted. .
- the second release film laminating apparatus 25 bonds the release film H22 to the second optical film F21 via the second pressure-sensitive adhesive layer F24 after the second defect inspection.
- the release film H22 is unwound from the roll 251 of the release film H22, and the release film H22 and the second optical film F21 are sandwiched by one or a plurality of roller pairs 252, and the pair of rollers At 252, a predetermined pressure is applied to perform bonding.
- the rotation speed, pressure control, and conveyance control of the roller pair 252 are controlled by the control device 1.
- the second cutting device 26 after bonding the release film H22, without cutting the release film H22, the second optical film F21, the surface protective film 25, the second pressure-sensitive adhesive layer F24, the pressure-sensitive adhesive layer F25. Is cut into a predetermined size.
- the second cutting device 26 is, for example, a laser device. Based on the position coordinates of the defect detected in the second defect inspection process, the second cutting device 26 cuts to a predetermined size so as to avoid the defect portion. That is, the cut product including the defective portion is rejected as a defective product by the second rejection device 29 in a later process. Or the 2nd cutting device 26 may ignore the presence of a fault, and may cut continuously to a predetermined size. In this case, it can be configured such that the portion is removed without being bonded in the bonding process described later. Control in this case also depends on the function of the control device 1.
- the second cutting device 26 is provided with a holding table for sucking and holding the second sheet product F2 from the back surface, and a laser device is provided below the second sheet product F2. It moves horizontally so as to scan the laser in the width direction of the second sheet product F2, leaving the bottom release film H22, the second optical film F21, the second pressure-sensitive adhesive layer F24, the surface protective film F23, the pressure-sensitive adhesive layer F25 is cut at a predetermined pitch in the conveying direction.
- the accumulation device A of the transport mechanism moves in the vertical direction so as not to stop the continuous transport of the downstream and upstream second sheet products F2. It is configured. This operation is also controlled by the control device 1.
- the 2nd bonding apparatus 28 optically transmits 2nd sheet product F2 (2nd optical film F21) from which the release film H22 was peeled by the 2nd peeling apparatus 27 through the 2nd adhesive layer F24 after a cutting process. Affixed to the display unit W1. As shown in FIG. 7, when bonding, the second optical film F ⁇ b> 21 is bonded to the surface of the optical display unit W ⁇ b> 1 by the pressing roller 281 and the guide roller 282.
- the control device 1 controls the pressing pressure and driving operation of the pressing roller 281 and the guide roller 282.
- the peeling mechanism 271 of the second peeling device 27 has a knife edge portion with a sharp tip, and the release film H22 is wound around the knife edge portion and reversely transferred to peel the release film H22.
- the second sheet product F2 (second optical film) after the release film H22 is peeled off is sent to the surface of the optical display unit W1.
- the peeled release mold H22 is wound around a roll 272.
- the winding control of the roll 272 is controlled by the control device 1.
- the 2nd optical film supply apparatus M5 in this invention supplies the 2nd optical film F21 to the 2nd bonding apparatus M6 by using the release film formed in the optical film via the adhesive layer as a conveyance medium. It has a transport mechanism.
- the laminating mechanism is composed of a pressing roller 281 and a guide roller 282 arranged to face it.
- the guide roller 282 is composed of a rubber roller that is rotationally driven by a motor, and is arranged so as to be movable up and down.
- a pressing roller 281 made of a metal roller that is rotationally driven by a motor is disposed directly below it.
- the pressing roller 281 is moved to a lower position so as to open a roller interval.
- both the guide roller 282 and the pressing roller 281 may be rubber rollers or metal rollers.
- the second rejection apparatus 29 that excludes the second sheet material F2 including the defects.
- the guide roller 282 moves vertically upward.
- the roller 292 around which the adhesive tape 291 is stretched moves to a fixed position of the guide roller 282.
- the pressing roller 281 By moving the pressing roller 281 vertically upward, the second sheet product F2 including the defect is pressed against the adhesive tape 291 and the second sheet product F2 is attached to the adhesive tape 291.
- the product F2 is wound around the roller 293.
- the optical display unit W12 to which the first and second sheet products are bonded is conveyed to the inspection device 30.
- the inspection device 30 performs an inspection on both sides of the optical display unit W12 that has been conveyed.
- the light source irradiates the upper surface of the optical display unit W12 perpendicularly with a half mirror, and the reflected light image is picked up as image data with a CCD camera.
- the light source and the CCD camera perform an inspection of the opposite surface.
- the light source irradiates the surface of the optical display unit W12 at a predetermined angle, and the reflected light image is captured as image data by a CCD camera.
- the light source and the CCD camera perform an inspection of the opposite surface. Defects are subjected to image processing analysis from these image data, and non-defective products are determined.
- the operation timing of each device is calculated by, for example, a method of detecting by arranging a sensor at a predetermined position, or calculated by detecting a rotating member of the transfer device or the transfer mechanism R with a rotary encoder or the like.
- the control device 1 may be realized by a cooperative action of a software program and hardware resources such as a CPU and a memory.
- a memory is stored in advance for the program software, processing procedure, various settings, and the like. Further, it can be configured by a dedicated circuit or firmware.
- the optical film according to the present invention can be preferably used for forming an image display device (corresponding to an optical display device) such as a liquid crystal display device, an organic EL display device, and a PDP.
- an image display device corresponding to an optical display device
- an organic EL display device such as a liquid crystal display device, an organic EL display device, and a PDP.
- the optical film of the present invention can be preferably used for forming various devices such as a liquid crystal display device.
- the liquid crystal display device can be formed according to the conventional method. That is, a liquid crystal display device is generally formed by appropriately assembling components such as a liquid crystal cell (corresponding to an optical display unit), an optical film, and an illumination system as necessary, and incorporating a drive circuit. In the present invention, there is no particular limitation except that the optical film according to the present invention is used.
- the liquid crystal cell any type such as a TN type, an STN type, or a ⁇ type can be used.
- Appropriate liquid crystal display devices such as a liquid crystal display device in which an optical film is disposed on one side or both sides of a liquid crystal cell, and a backlight or reflector used in an illumination system can be formed.
- the optical film according to the present invention can be installed on one side or both sides of the liquid crystal cell.
- they may be the same or different.
- a single layer or a suitable part such as a diffusion plate, an antiglare layer, an antireflection film, a protective plate, a prism array, a lens array sheet, a light diffusion plate, a backlight, Two or more layers can be arranged.
- the optical film according to the present invention can be preferably used for forming various devices such as a liquid crystal display device.
- the liquid crystal display device may be formed as a transmission type or a reflection type in which the optical film according to the present invention is arranged on one side or both sides of the liquid crystal cell, or an appropriate structure according to the conventional type of a transmission / reflection type. it can.
- the liquid crystal cell forming the liquid crystal display device is arbitrary, and for example, a liquid crystal cell of an appropriate type such as a simple matrix driving type typified by a thin film transistor type may be used.
- liquid crystal display device When providing polarizing plates and optical members on both sides of the liquid crystal cell, they may be the same or different. Furthermore, when forming the liquid crystal display device, for example, appropriate components such as a prism array sheet, a lens array sheet, a light diffusing plate, and a backlight can be arranged in one or more layers at appropriate positions.
- each device of the production system of the present invention may be any, for example, the supply device M1 of the optical display unit W, the supply device M2 of the first optical film F11, and the first bonding device M3 are linear. It is arrange
- the supply apparatus M2 of the 1st optical film F11 and the 1st bonding apparatus M3 are the supply apparatus M5 of the 2nd optical film F21, and 2nd. It is preferable to arrange
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Abstract
Description
即ち、本発明の光学表示装置の製造システムは、光学異方性を有する光学フィルムを光学表示ユニットに貼り合せた光学表示装置の製造システムであって、前記光学表示ユニットの短辺に対応する幅の第1光学フィルムを有する帯状シート状製品が巻き取られたロールを用いて、前記光学表示ユニットの長辺に対応する長さに第1光学フィルムを切断した後、光学表示ユニットの一方表面に貼り合せる第1切断貼合装置と、前記光学表示ユニットの長辺に対応する幅の第2光学フィルムを有する帯状シート状製品が巻き取られたロールを用いて、前記光学表示ユニットの短辺に対応する長さに第2光学フィルムを切断した後、光学表示ユニットの他方表面に貼り合せる第2切断貼合装置とを備えることを特徴とする。
F2 第2シート製品
F11 第1光学フィルム
F11a 第1偏光子
F11b 第1フィルム
F11c 第2フィルム
F12 第1離型フィルム
F13 表面保護フィルム
F14 第1粘着剤層
F21 第2光学フィルム
F21a 第2偏光子
F21b 第3フィルム
F21c 第4フィルム
F22 第2離型フィルム
F23 表面保護フィルム
F24 第2粘着剤層
M1 光学表示ユニットの供給装置
M2 第1光学フィルムの供給装置
M3 第1貼合装置
M4 搬送供給装置
M5 第2光学フィルムの供給装置
M6 第2貼合装置
1 制御装置
10 研磨洗浄装置
11 水洗浄装置
12 第1搬送装置
13 第1検査前剥離装置
14 第1欠点検査装置
15 第1離型フィルム貼合装置
16 第1切断装置
17 第1剥離装置
18 第1貼合装置
19 第1排除装置
20 旋回機構
22 第2搬送装置
23 第2検査前剥離装置
24 第2欠点検査装置
25 第2離型フィルム貼合装置
26 第2切断装置
27 第2剥離装置
28 第2貼合装置
29 第2排除装置
R 搬送機構
W パネル(光学表示ユニット)
まず、本発明に用いられる光学表示ユニットとしては、例えば、液晶セルのガラス基板ユニット、有機EL発光体ユニット等が挙げられる。本発明は、長方形の外形を有する光学表示ユニットに有効であり、例えば、長辺/短辺が16/9であるものや、4/3であるものなどが用いられる。なお、光学表示ユニットとしては、予め、光学フィルム等の部材が積層一体化されたものであってもよい。
光学表示ユニットに貼り付けられる光学フィルムとしては、光学異方性を有するものであればよく、例えば、偏光板、偏光反射板、位相差フィルム、輝度向上フィルム、これらを2つ以上積層した光学フィルム等が挙げられる。
本発明の本発明の光学表示装置の製造方法は、光学異方性を有する光学フィルムを光学表示ユニットに貼り合せた光学表示装置の製造方法であり、好ましくは、偏光板を含む光学フィルムを光学表示ユニットに貼り合せた光学表示装置の製造方法である。
また、上記第1切断工程および第2切断工程の別実施形態を以下に説明する。この実施形態は、上記の第1検査工程、第2検査工程を備えていない場合に特に有効である。第1および第2ロール原反の幅方向の一方の端部には、所定ピッチ単位(例えば1000mm)に第1、第2シート状製品の欠点情報(欠点座標、欠点の種類、サイズ等)がコード情報(例えばQRコード、バーコード)として付されている場合がある。このような場合、切断する前段階で、このコード情報を読み取り、解析して欠点部分を避けるように、第1、第2切断工程において所定サイズに切断する(スキップカットと称することがある)。そして、欠点を含む部分は排除あるいは光学表示ユニットではない部材に貼り合わせるように構成し、所定サイズに切断された良品判定の枚葉のシート状製品を光学表示ユニットに貼り合わされるように構成する。これにより、光学表示ユニットの歩留まりが大幅に向上される。
次に、本発明の製造システムの全体の構成について説明する。本発明の製造システムは、光学異方性を有する光学フィルムを光学表示ユニットに貼り合せた光学表示装置の製造システムであり、好ましくは、偏光板を含む光学フィルムを光学表示ユニットに貼り合せた光学表示装置の製造システムである。本発明の製造システムは、第1切断貼合工程を行う第1切断貼合装置と、第2切断貼合工程を行う第2切断貼合装置とを備えている。
以下に、本発明の製造システムの各部の構成の一例について説明する。図4は、第1搬送装置12、第1検査前剥離装置13、第1欠点検査装置14、第1離型フィルム貼付装置15、第1切断装置16について示す図である。
本発明の製造システムの各装置の配置は、何れでも良く、例えば光学表示ユニットWの供給装置M1と、第1光学フィルムF11の供給装置M2と、第1貼合装置M3とが、直線状に配置されると共に、第2光学フィルムF21の供給装置M5と第2貼合装置M6とが、これに平行に配置され、第1貼合装置M3と第2貼合装置M6との間に、搬送供給装置M4が設けられるように配置してもよい。
Claims (10)
- 光学異方性を有する光学フィルムを光学表示ユニットに貼り合せた光学表示装置の製造システムであって、
前記光学表示ユニットの短辺に対応する幅の第1光学フィルムを有する帯状シート状製品が巻き取られたロールを用いて、前記光学表示ユニットの長辺に対応する長さに第1光学フィルムを切断した後、光学表示ユニットの一方表面に貼り合せる第1切断貼合装置と、
前記光学表示ユニットの長辺に対応する幅の第2光学フィルムを有する帯状シート状製品が巻き取られたロールを用いて、前記光学表示ユニットの短辺に対応する長さに第2光学フィルムを切断した後、光学表示ユニットの他方表面に貼り合せる第2切断貼合装置とを備える光学表示装置の製造システム。 - 偏光板を含む光学フィルムを光学表示ユニットに貼り合せた光学表示装置の製造システムであって、
光学表示ユニットを供給する光学表示ユニットの供給装置と、
第1光学フィルムを有する帯状シート状製品が巻き取られたロールから帯状シート状製品を引き出して、所定の長さに切断した後に供給する第1光学フィルムの供給装置と、
前記光学表示ユニットの供給装置から供給された光学表示ユニットの一方表面に、前記第1光学フィルムの供給装置から供給された第1光学フィルムを貼り合せる第1貼合装置と、
第1光学フィルムの貼り合せ後の光学表示ユニットを搬送して供給する搬送供給装置と、
第2光学フィルムを有する帯状シート状製品が巻き取られたロールから帯状シート状製品を引き出して、所定の長さに切断した後に供給する第2光学フィルムの供給装置と、
前記搬送供給装置から供給された光学表示ユニットの他方表面に、前記第2光学フィルムの供給装置から供給された第2光学フィルムを貼り合せる第2貼合装置とを備え、
前記第1光学フィルムの供給装置および前記第2光学フィルムの供給装置は、前記光学表示ユニットの長辺と短辺とに対応させて、一方の供給装置が短辺に対応する幅の光学フィルムを長辺に対応する長さで切断し、他方の供給装置が長辺に対応する幅の光学フィルムを短辺に対応する長さで切断するように構成してある光学表示装置の製造システム。 - 前記搬送供給装置は、前記第1貼合装置で貼り合せた後の光学表示ユニットを、前記第2貼合装置での貼り合せ方向に旋回させる旋回機構を有する請求項2に記載の光学表示装置の製造システム。
- 前記第1光学フィルムの供給装置および前記第2光学フィルムの供給装置は、光学フィルムの欠点を有する部分を切断排除する欠点部分の排除機構を有する請求項2又は3に記載の光学表示装置の製造システム。
- 前記第1光学フィルムの供給装置および前記第2光学フィルムの供給装置は、光学フィルムに粘着剤層を介して形成された離型フィルムを搬送媒体として、第1貼合装置および第2貼合装置に第1光学フィルムおよび第2光学フィルムを各々供給する搬送機構を有する請求項2~4いずれかに記載の光学表示装置の製造システム。
- 光学異方性を有する光学フィルムを光学表示ユニットに貼り合せた光学表示装置の製造方法であって、
前記光学表示ユニットの短辺に対応する幅の第1光学フィルムを有する帯状シート状製品が巻き取られたロールを用いて、前記光学表示ユニットの長辺に対応する長さに切断した後、前記光学表示ユニットの一方表面に第1光学フィルムを貼り合せる第1切断貼合工程と、
前記光学表示ユニットの長辺に対応する幅の第2光学フィルムを有する帯状シート状製品が巻き取られたロールを用いて、前記光学表示ユニットの短辺に対応する長さに切断した後、前記光学表示ユニットの他方表面に第2光学フィルムを貼り合せる第2切断貼合工程とを含む光学表示装置の製造方法。 - 偏光板を含む光学フィルムを光学表示ユニットに貼り合せた光学表示装置の製造方法であって、
第1光学フィルムを有する帯状シート状製品が巻き取られたロールから帯状シート状製品を引き出して、所定の長さに切断した後に供給しながら、前記光学表示ユニットの一方表面に第1光学フィルムを貼り合せる第1切断貼合工程と、
第2光学フィルムを有する帯状シート状製品が巻き取られたロールから帯状シート状製品を引き出して、所定の長さに切断した後に供給しながら、前記光学表示ユニットの他方表面に第2光学フィルムを貼り合せる第2切断貼合工程とを含み、
前記第1光学フィルムおよび前記第2光学フィルムを供給する際に、前記光学表示ユニットの長辺と短辺とに対応させて、一方を供給する際には短辺に対応する幅の光学フィルムを長辺に対応する長さで切断し、他方を供給する際には長辺に対応する幅の光学フィルムを短辺に対応する長さで切断する工程を含む光学表示装置の製造方法。 - 前記第1切断貼合工程で貼り合せた後の光学表示ユニットを、前記第2切断貼合工程での貼り合せ方向に旋回させる旋回工程を含む請求項7に記載の光学表示装置の製造方法。
- 前記第1光学フィルムおよび前記第2光学フィルムを供給する際に、光学フィルムの欠点を有する部分を切断排除する欠点部分の排除工程を含む請求項7又は8に記載の光学表示装置の製造方法。
- 前記第1光学フィルムおよび前記第2光学フィルムを供給する際に、光学フィルムに粘着剤層を介して形成された離型フィルムを搬送媒体として、第1切断貼合工程および第2切断貼合工程に第1光学フィルムおよび第2光学フィルムを各々搬送して供給する請求項7~9いずれかに記載の光学表示装置の製造方法。
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