WO2009087895A1 - 光学表示装置の製造システムおよび光学表示装置の製造方法 - Google Patents
光学表示装置の製造システムおよび光学表示装置の製造方法 Download PDFInfo
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- WO2009087895A1 WO2009087895A1 PCT/JP2008/073420 JP2008073420W WO2009087895A1 WO 2009087895 A1 WO2009087895 A1 WO 2009087895A1 JP 2008073420 W JP2008073420 W JP 2008073420W WO 2009087895 A1 WO2009087895 A1 WO 2009087895A1
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- optical
- optical member
- exclusion
- release film
- peeling
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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
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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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- 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
- B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
- B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
- B32B37/18—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only
- B32B37/182—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only one or more of the layers being plastic
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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
- B32B38/0004—Cutting, tearing or severing, e.g. bursting; Cutter details
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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
- B32B38/10—Removing layers, or parts of layers, mechanically or chemically
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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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- 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
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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
- B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
- B32B2309/60—In a particular environment
- B32B2309/65—Dust free, e.g. clean room
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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
- B32B2457/202—LCD, i.e. liquid crystal 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
- B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
-
- 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
- G02B5/3025—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
-
- 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
- G02F1/1306—Details
- G02F1/1309—Repairing; Testing
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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
- Y10T156/1089—Methods of surface bonding and/or assembly therefor of discrete laminae to single face of additional lamina
-
- 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
- Y10T156/11—Methods of delaminating, per se; i.e., separating at bonding face
- Y10T156/1168—Gripping and pulling work apart during delaminating
- Y10T156/1195—Delaminating from release surface
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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
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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
- Y10T156/19—Delaminating means
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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
- Y10T156/19—Delaminating means
- Y10T156/195—Delaminating roller means
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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
- Y10T156/19—Delaminating means
- Y10T156/1994—Means for delaminating from release surface
Definitions
- Patent Document 1 a manufacturing method disclosed in Japanese Patent Application Laid-Open No. 2007-140046 (Patent Document 1) is known.
- a sheet product is fed out from a raw roll on which a sheet product having an optical member is wound, a sheet product defect is detected, the sheet product is cut based on the detection result, and a sheet product is obtained. To process. Next, after the release film is peeled off, the optical member is bonded to the liquid crystal cell.
- the present invention is an optical display device manufacturing system having an optical display unit and an optical member of a predetermined size bonded to the optical display unit, Among the long laminated optical products having the optical member and the release film provided on the optical member, the optical member is cut leaving the release film and bonded to the optical display unit.
- the exclusion device excludes the optical member related to the exclusion at a conveyance position upstream of the laminating device in a conveyance process of the laminated optical product.
- the adhesive surface of the adhesive tape stretched over the exclusion roller is pressed against the optical member related to exclusion located on the roll member of the transport means, and the optical member related to exclusion is attached to the adhesive tape. Together, it can be suitably eliminated.
- the optical member according to exclusion can be suitably excluded without using a peeling means for peeling the release film.
- the bonding apparatus includes a rotatable pressing roller that presses the optical member toward the optical unit, and the release film is peeled off by the pressing roller.
- the optical member which concerns on this is pressed on the surface of the tape member spanned by the said exclusion roller, and the structure which sticks the optical member which concerns on the said exclusion to the said tape member, and is excluded is mentioned.
- the tape member may be a tape on which an adhesive is formed, or a simple tape.
- the size, thickness, material, and the like of the tape are not particularly limited, and examples thereof include various plastic films.
- the tape is preferably made of a material that can be suitably bonded to the adhesive between the optical member and the release film.
- the pressure roller of the laminating apparatus presses the adhesive layer of the optical member related to the removal from which the release film has been peeled against the surface of the tape member that is stretched over the exclusion roller.
- the tape member By sticking to the tape member through the pressure-sensitive adhesive layer of the optical member, it can be suitably excluded. Since an exclusion apparatus is installed in the vicinity of the bonding apparatus and a partial function of the bonding apparatus is used, it is preferable in terms of downsizing the exclusion apparatus.
- the tape member may be a tape on which an adhesive is formed, or a simple tape.
- the size, thickness, material, and the like of the tape are not particularly limited, and examples thereof include various plastic films.
- the tape is preferably made of a material that can be suitably bonded to the adhesive between the optical member and the release film. When a tape is used as the tape member, the cost can be greatly reduced as compared with the pressure-sensitive adhesive tape, and handling in use is simple and preferable.
- the pressure-reducing roller presses the pressure-sensitive adhesive layer of the optical member related to the exfoliation from which the release film has been peeled off against the surface of the tape member spanned over the excluding roller, and the optical related to the exclusion
- the member can be suitably removed by sticking to the tape member.
- optical members and laminated optical products examples include a polarizer film, a retardation film, a viewing angle compensation film, a brightness enhancement film, and the like, or a combination laminated film of two or more of these films.
- a transparent film for protection may be laminated on one surface or both surfaces of these optical members.
- the configuration of the first laminated optical product F1 will be described below, but the second laminated optical product F2 has the same configuration. The configuration of the first laminated optical product F1 and the configuration of the second laminated optical product F2 may be different.
- first and second polarizer protective films F11b and F11c examples include a triacetyl cellulose (TAC) film and a polyethylene terephthalate (PET) film.
- TAC triacetyl cellulose
- PET polyethylene terephthalate
- the surface protection member F13 is provided through the 1st polarizer protective film F11b and the weak adhesive layer F15.
- the release film F12 is provided through the 2nd polarizer protective film F11c and the adhesive layer F14.
- the first and second polarizer protective films F11b and F11c are not particularly limited.
- a film made of a thermoplastic resin that is excellent in transparency, mechanical strength, thermal stability, moisture barrier property, isotropy, and the like. Consists of.
- an optical film used for forming a liquid crystal display device such as a reflection plate, a semi-transmission plate, a phase difference plate (including a wave plate ( ⁇ plate) such as 1/2 or 1/4), a viewing angle compensation film, etc.
- a layer or a laminate of two or more layers is also included.
- the first polarizer F11a is made of, for example, a polyvinyl alcohol film.
- the surface protection member F13 is formed through the weak adhesive layer F15. Its main purpose is to prevent scratches and pollution.
- a suitable thin leaf body such as a plastic film, rubber sheet, paper, cloth, nonwoven fabric, net, foamed sheet or metal foil, laminate thereof, if necessary, silicone-based or long-chain alkyl-based, Appropriate ones according to the prior art such as those coated with an appropriate release agent such as fluorine-based or molybdenum sulfide can be used.
- the pressure-sensitive adhesive layer F14 and the weak pressure-sensitive adhesive layer F15 are provided to adhere to other members such as a liquid crystal cell. Although it does not specifically limit as an adhesive which comprises the adhesive layer F14 and the weak adhesive layer F15, It can each form with appropriate adhesives based on the past, such as an acryl type.
- a long first laminated optical product F1 is prepared as a first roll raw material.
- variety of a 1st roll original fabric is dependent on the bonding size of an optical display unit.
- the first pre-inspection peeling apparatus 13 shown in FIG. 4 peels the release film F12 from the first laminated optical product F1 being conveyed.
- the first pre-inspection peeling device 13 rolls the peeled release film F12 from the first laminated optical product F1 that has been conveyed by winding the release film F12 around the knife edge portion of the peeling mechanism 131 and rolls the peeled release film F12. It is the structure wound up by 132.
- the first defect inspection apparatus 14 shown in FIG. 4 inspects the defect of the first laminated optical product F1 after the release film removing step (S3). It is not necessary to consider the phase difference inherent in the release film F12, and the defect inspection of the first optical member F11 can be performed.
- the 1st cutting device 16 shown in FIG. 4 leaves the release film 12a, the surface protection member 13, the weak adhesive layer 15, the 1st optical member 11, and the 1st. 1 Adhesive layer F14 is cut.
- the first cutting device 16 preferably cuts to a predetermined size so as to avoid the defect portion. Examples of the cutting method include laser cutting, cutter cutting, and other known cutting methods. 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 laminated optical product F1 is greatly improved.
- the first laminated optical product F1 including the defect is excluded by a first rejection device 19 described later, and is not attached to the optical display unit W.
- Non-defective product determination (FIG. 1, S7).
- the determination criteria for the non-defective product determination are set in advance, and are set according to, for example, the number of defects per predetermined area, the defect size, and the type of defect. Non-defective product judgment becomes more severe as the display performance with higher accuracy is required.
- Exclusion step (FIG. 1, S7-1). Exclusion processing of the first optical member F11 determined to be non-defective in the defect inspection is performed (FIGS. 5A to 5C). A configuration example of the exclusion process will be described later.
- the second pre-inspection peeling apparatus shown in FIG. 9 peels the release film F22 from the second laminated optical product F2 being conveyed.
- the peeling mechanism is similar to the above-described peeling mechanism, and the second pre-inspection peeling device rolls the release film F22 peeled off by winding the release film F22 around the knife edge portion of the peeling mechanism 231. It is a structure wound up to H.232.
- a bonding process is performed on the second optical member determined to be non-defective in the defect inspection.
- the second release film F22 was removed using the second bonding device 28.
- the second optical member F21 is bonded to the optical display unit W1 via the second pressure-sensitive adhesive layer F24.
- the optical display unit W1 is rotated 90 degree
- the F21 polarizer may be in a crossed Nicols relationship.
- the accumulator A is in a driving state and operates so that the bonding process between the optical display unit W and the first optical member F11 is not interrupted during the exclusion process.
- the exclusion pressing roller 194 moves to the bonding position that is the exclusion position.
- the exclusion pressing roller 194 presses the pressure-sensitive adhesive layer F14 surface of the first optical member F11 related to the exclusion to the exclusion roller 192 side, and affixes the first optical member F11 to the tape 191.
- the first optical member F ⁇ b> 11 is wound around the winding roller 193 together with the tape 191.
- the discharge pressing roller 194 rises and the peeling mechanism 195 returns to the original position.
- the above operation is controlled by the control device 1.
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Abstract
Description
前記光学部材と当該光学部材に設けられた離型フィルムとを有する長尺の積層光学製品のうち、当該離型フィルムを残して当該光学部材を切断して、前記光学表示ユニットに貼り合わされる所定サイズの光学部材、および排除に係る光学部材を当該離型フィルム上に形成する切断装置と、
前記切断装置により形成された前記所定サイズの光学部材から離型フィルムを剥離する剥離装置と、
前記剥離装置により前記所定サイズの光学部材から離型フィルムを剥離しながら、または剥離した後に、当該所定サイズの光学部材を前記光学表示ユニットに貼り合せる貼合装置と、
粘着表面を備え、当該粘着表面に前記切断装置により形成された排除に係る光学部材を貼り合せることで、当該排除に係る光学部材を離型フィルムから排除する排除装置と、を有する構成である。
光学表示ユニットと、当該光学表示ユニットに貼り合せた所定サイズの光学部材とを有する光学表示装置の製造方法であって、
前記光学部材と当該光学部材に設けられた離型フィルムとを有する長尺の積層光学製品のうち、当該離型フィルムを残して当該積層光学製品を切断して、前記光学表示ユニットに貼り合わされる所定サイズの光学部材、または排除に係る光学部材を当該離型フィルム上に形成する切断工程と、
前記切断工程により形成された前記所定サイズの光学部材から離型フィルムを剥離する剥離工程と、
前記剥離工程により前記所定サイズの光学部材から離型フィルムを剥離しながら、または剥離した後に、当該所定サイズの光学部材を前記光学表示ユニットに貼り合せる貼合工程と、
粘着表面に前記切断工程により形成された排除に係る光学部材を貼り合せることで、当該排除に係る光学部材を離型フィルムから排除する排除工程と、を有する構成である。
前記排除に係る光学部材から離型フィルムを剥離する剥離手段と、
前記剥離手段によって離型フィルムが剥離された排除に係る光学部材を、前記排除用ローラ側に押圧する排除用押さえローラと、を有し、
前記排除用押さえローラで、前記離型フィルムが剥離された前記排除に係る光学部材の粘着剤層を前記排除用ローラに掛け渡されたテープ部材の表面に押圧し、当該排除に係る光学部材を当該テープ部材に貼り合わせて排除する構成が挙げられる。
F2 第2シート製品
F11 第1光学部材
F11a 第1偏光子
F11b 第1偏光子保護フィルム
F11c 第2偏光子保護フィルム
F12 第1離型フィルム
F13 表面保護部材
F14 第1弱粘着剤層
F15 第1粘着剤層
F21 第2光学部材
F21a 第2偏光子
F21b 第3偏光子保護フィルム
F21c 第4偏光子保護フィルム
F22 第2離型フィルム
F23 表面保護部材
F24 第2弱粘着剤層
F25 第2粘着剤層
R 搬送手段
W 光学表示ユニット
W12 光学表示装置
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
192 排除用ローラ
194 排除用押さえローラ
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
292 排除用ローラ
294 排除用押さえローラ
本発明の実施形態1について以下に説明する。図1に光学表示装置の製造方法の一例のフローチャートを示す。図2に第1、第2積層光学製品F1、F2、第1、第2光学部材F11,F22、液晶セルW(光学表示ユニット)断面構成の模式図を示す。図3に、図1の実施形態1における光学表示装置の製造システムの平面配置図の一例を示す。図4~10Cは、実施形態1における光学表示装置の製造システムの一例について説明するための図である。この実施形態1は、光学部材を光学表示ユニットに貼り合わせる位置で、欠点が含まれていると判定された光学部材を排除する構成でもよく、当該貼り合わせ位置の上流側で排除する構成でもよい。また、欠点が含まれると判定された光学部材を排除する場合に限定されず、例えば、工程検査のサンプリング、品質検査のサンプリング等するために排除する場合も例示される。
光学表示ユニットに貼り合わされる光学部材は、偏光子フィルム、位相差フィルム、視角補償フィルム、輝度向上フィルム等、または、それらフィルムの2種以上の組み合わせ積層フィルムが例示される。これら光学部材の一方表面または両表面には、保護用の透明フィルムが積層される場合がある。以下において第1積層光学製品F1の構成について説明するが、第2積層光学製品F2も同様の構成である。なお、第1積層光学製品F1の構成と第2積層光学製品F2の構成は異なっていてもよい。
以下の各工程および各装置処理動作は、工場内から隔離された隔離構造50内において行なわれる。隔離構造50は、透明材料の壁と骨組み構造とで構成される。隔離構造50の天井には、送風装置40が設置される。送風装置40は、HEPAフィルタを備え、清浄度の高い空気を隔壁構造50内部に送風し、清浄空気の気流を発生する。隔壁構造50の壁面下部には、内部空気を外部に排出させるための空気排出開口部50aが設けられている。また、外部からの侵入物を防ぐために開口面にはフィルタを設けることもできる。この隔壁構造50、送風装置40によって、製造システム全体を清浄環境に維持でき、外部からの異物混入を好適に防ぐことができる。また、製造システムのみを隔壁構造50で外部から隔離しているために、工場全体をいわゆるクリーンルームにする必要がない。
(1)第1ロール原反準備工程(S1)。長尺の第1積層光学製品F1を第1ロール原反として準備する。第1ロール原反の幅は、光学表示ユニットの貼り合わせサイズに依存している。
図5A~5Cおよび図7~9は、排除装置の構成例について説明するための図である。第1排除装置19の構成は、ここで例示する構成に制限されず、これら構成の各種変形例も適用でき、この変形例は本発明の技術的思想の範囲に含まれる。
第1積層光学製品F1を排除する第1排除装置19について説明する。図5Aに示す第1排除装置19の動作を図6を用いて説明する。この実施例1の第1排除装置19は、光学表示ユニットWと光学部材F11の貼り合わせ位置で、排除に係る光学部材F11を排除する構成である。排除用ローラ192は、弾性ローラ(例えば、シリコンゴム製)でもよく、金属製ローラでもよい。
(2)次いで、テープ191が掛け渡された排除用ローラ192は案内ローラ182の定位置である貼り合わせ位置に移動する。
(3)押さえローラ181は垂直下方に移動する。
(4)押さえローラ181は、剥離機構171によって離型フィルムF12aが剥離された排除に係る光学部材F11の粘着剤層F14面を排除用ローラ192側へ押さえつけて、排除に係る光学部材F11をテープ191に貼り付ける。テープ191とともに排除に係る光学部材F11を巻き取りローラ193に巻き取る。
(5)排除後、押さえローラ181は上昇し、排除用ローラ192は原位置に復帰し、案内ローラ182は原位置に復帰する。以上の動作は、制御装置1によって制御される。
図5Bに示す実施例2の第1排除装置19は、光学表示ユニットWと光学部材F11との貼り合わせ位置より上流側で、排除に係る光学部材F11を排除する構成である。この構成の場合、光学表示ユニットWと光学部材F11との貼り合わせ処理を長時間中断させることがないため、実施例1の構成よりも生産性が高い。図5Bに示す実施例2の第1排除装置19の動作を図7を用いて説明する。
(2)排除用押さえローラ194が、排除位置である貼り合わせ位置に移動する。
(3)排除用押さえローラ194は、排除に係る第1光学部材F11の粘着剤層F14面を排除用ローラ192側へ押さえつけて、第1光学部材F11をテープ191に貼り付ける。テープ191とともに第1光学部材F11を巻き取りローラ193に巻き取る。
(4)排除後、排出用押さえローラ194は上昇し、剥離機構195は原位置に復帰する。以上の動作は、制御装置1によって制御される。
図5Cに示す実施例3の第1排除装置19は、光学表示ユニットWと光学部材F11との貼り合わせ位置より上流側で、排除に係る光学部材F11を排除する構成である。この構成の場合、光学表示ユニットWと光学部材との貼り合わせ処理を長時間中断させることがないため、実施例1の構成よりも生産性が高い。図5Cに示す実施例3の第1排除装置19の動作を図8を用いて説明する。第1排除装置19は、粘着テープ191と、粘着テープ191が掛け渡された排除用ローラ192と、粘着テープ191を巻き取る巻取りローラ193とで構成される。実施例3は、実施例2のように剥離機構195、押さえローラ194、アキュムレート装置Aを備えていないため、装置を簡単に構成できる。その動作は以下のとおりである。
(2)排除用ローラ192は、第1光学部材F11をローラ121側に押さえつけて、排除に係る第1光学部材F11を粘着テープ191に貼り付ける。そして、粘着テープ191とともに第1光学部材F11を巻き取りローラ193に巻き取る。
(3)排除後、排除用ローラ192は原位置に復帰する。以上の排除処理中に光学表示ユニットWと第1光学部材F11との貼り合わせ処理は中断しないように動作されている。以上の動作は、制御装置1によって制御される。
以下では、別の製造システムについて図11~14Cを用いて説明する。図11の第1積層光学製品F1は、離型フィルムF12を上面にして搬送されている。第1検査前剥離装置13、第1欠点検査装置14、第1離型フィルム貼合装置15、および第1切断装置16のそれぞれの構成および機能は上記と同様であるが、離型フィルムF12、F12aの位置によって、それらの配置が異なっている。
Claims (7)
- 光学表示ユニットと、当該光学表示ユニットに貼り合せた所定サイズの光学部材とを有する光学表示装置の製造システムであって、
前記光学部材と当該光学部材に設けられた離型フィルムとを有する長尺の積層光学製品のうち、当該離型フィルムを残して当該光学部材を切断して、前記光学表示ユニットに貼り合わされる所定サイズの光学部材、および排除に係る光学部材を当該離型フィルム上に形成する切断装置と、
前記切断装置により形成された前記所定サイズの光学部材から離型フィルムを剥離する剥離装置と、
前記剥離装置により前記所定サイズの光学部材から離型フィルムを剥離しながら、または剥離した後に、当該所定サイズの光学部材を前記光学表示ユニットに貼り合せる貼合装置と、
粘着表面を備え、当該粘着表面に前記切断装置により形成された排除に係る光学部材を貼り合せることで、当該排除に係る光学部材を離型フィルムから排除する排除装置とを有する光学表示装置の製造システム。 - 前記排除装置は、粘着テープが掛け渡された回転可能な排除用ローラを備え、当該粘着テープの粘着表面に、前記切断装置により形成された排除に係る光学部材を貼り合せて、当該排除に係る光学部材を前記離型フィルムから排除する請求項1に記載の光学表示装置の製造システム。
- 前記積層光学製品の欠点検査をする検査装置をさらに有し、
前記所定サイズの光学部材は、前記検査装置による欠点検査で良品判定されたものであり、
前記排除に係る光学部材は、前記検査装置による欠点検査で不良品判定されたものである請求項1または2に記載の光学表示装置の製造システム。 - 前記排除装置は、前記排除に係る光学部材の離型フィルム貼合面とは反対側の面を前記粘着テープの粘着表面に貼り合せて、当該排除に係る光学部材を前記離型フィルムから排除する請求項2に記載の光学表示装置の製造システム。
- 前記排除装置は、前記積層光学製品の搬送過程であって、前記貼合装置より上流の搬送位置で、前記排除に係る光学部材を排除する請求項4に記載の光学表示装置の製造システム。
- 前記排除装置は、前記積層光学製品を搬送する搬送手段のロール部材に位置する前記排除に係る光学部材に、前記排除用ローラに掛け渡された粘着テープの粘着表面を押圧し、当該排除に係る光学部材を当該粘着テープに貼り合わせて排除する請求項5に記載の光学表示装置の製造システム。
- 光学表示ユニットと、当該光学表示ユニットに貼り合せた所定サイズの光学部材とを有する光学表示装置の製造方法であって、
前記光学部材と当該光学部材に設けられた離型フィルムとを有する長尺の積層光学製品のうち、当該離型フィルムを残して当該光学部材を切断して、前記光学表示ユニットに貼り合わされる所定サイズの光学部材、および排除に係る光学部材を当該離型フィルム上に形成する切断工程と、
前記切断工程により形成された前記所定サイズの光学部材から離型フィルムを剥離する剥離工程と、
前記剥離工程により前記所定サイズの光学部材から離型フィルムを剥離しながら、または剥離した後に、当該所定サイズの光学部材を前記光学表示ユニットに貼り合せる貼合工程と、
粘着表面に前記切断工程により形成された排除に係る光学部材を貼り合せることで、当該排除に係る光学部材を離型フィルムから排除する排除工程と、を有する光学表示装置の製造方法。
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Also Published As
Publication number | Publication date |
---|---|
CN101911156B (zh) | 2012-10-03 |
TWI358687B (ja) | 2012-02-21 |
JP4724742B2 (ja) | 2011-07-13 |
KR20100103638A (ko) | 2010-09-27 |
EP2237249A1 (en) | 2010-10-06 |
KR101529757B1 (ko) | 2015-06-17 |
JP2009186994A (ja) | 2009-08-20 |
US8500937B2 (en) | 2013-08-06 |
JP4759091B2 (ja) | 2011-08-31 |
US20110061801A1 (en) | 2011-03-17 |
TW200951903A (en) | 2009-12-16 |
TW201037651A (en) | 2010-10-16 |
CN101893782B (zh) | 2013-04-03 |
KR20110086189A (ko) | 2011-07-27 |
JP2010191479A (ja) | 2010-09-02 |
CN101911156A (zh) | 2010-12-08 |
KR101099944B1 (ko) | 2011-12-28 |
KR20100103517A (ko) | 2010-09-27 |
CN101893782A (zh) | 2010-11-24 |
EP2319689A2 (en) | 2011-05-11 |
US20100288432A1 (en) | 2010-11-18 |
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