WO2009088013A1 - 光学表示ユニットの製造システムおよび搬送機構 - Google Patents
光学表示ユニットの製造システムおよび搬送機構 Download PDFInfo
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- WO2009088013A1 WO2009088013A1 PCT/JP2009/050075 JP2009050075W WO2009088013A1 WO 2009088013 A1 WO2009088013 A1 WO 2009088013A1 JP 2009050075 W JP2009050075 W JP 2009050075W WO 2009088013 A1 WO2009088013 A1 WO 2009088013A1
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- Prior art keywords
- optical film
- film
- optical
- pressure
- adhesive
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Classifications
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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
- B29D11/0074—Production of other optical elements not provided for in B29D11/00009- B29D11/0073
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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
- Y10T156/17—Surface bonding means and/or assemblymeans with work feeding or handling 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
- Y10T156/17—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
Definitions
- the present invention relates to a manufacturing system and a transport mechanism of an optical display unit in which an optical film is bonded to a display substrate via an adhesive layer.
- FIG. 11 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 roll material is slit into a predetermined size (a size according to the size of the display substrate) (# 2).
- the slit raw material is cut to a fixed length in accordance with the size of the display substrate 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 in accordance with quality standards that are stricter 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.
- a display substrate for example, a glass substrate unit in which a liquid crystal cell is sealed
- the display substrate is cleaned before the bonding step (# 13).
- the release film is peeled off from the sheet-like product leaving the pressure-sensitive adhesive layer, and the pressure-sensitive adhesive layer is bonded to one surface of the display substrate as a bonding surface. Further, it can be similarly bonded to the other surface of the display substrate.
- the optical film of the same structure may be bonded to each surface of a display substrate, and the optical film of a different structure may be bonded to each other.
- 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 display substrate.
- An optical film is newly bonded to the reworked display substrate (# 14).
- Patent Document 1 Japanese Patent Laid-Open No. 2007-140046
- 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 laminating process means for laminating the sheet-like product transferred by the transfer means and the display substrate which is a member of the optical display device.
- an adhesive layer for adhering the optical film to a display substrate is formed, and a release film is bonded to the adhesive layer, whereby the strip-shaped sheet product (sheet product) is formed. Is formed.
- the release film can be peeled from the optical film before or after the detection of the defect by the detection means.
- the release film bonded to the optical film via the pressure-sensitive adhesive layer is not cut, the optical film and the pressure-sensitive adhesive layer are cut, and before the bonding process to the display substrate, A method of peeling the release film from the optical film is conceivable.
- the optical film and the pressure-sensitive adhesive layer may be peeled off from the release film at the cut position.
- foreign matter may adhere to the pressure-sensitive adhesive layer, or the optical film may adhere to any part in the conveyance path via the pressure-sensitive adhesive layer.
- the present invention has been made in view of the above circumstances, and provides an optical display unit manufacturing system and a transport mechanism capable of satisfactorily preventing the optical film and the pressure-sensitive adhesive layer from peeling from the release film.
- the purpose is to do.
- An optical display unit manufacturing system is an optical display unit manufacturing system in which an optical film is bonded to a display substrate via an adhesive layer, and includes the optical film and the adhesive layer. And the conveyance apparatus which conveys the adhesive optical film of the shape corresponding to the said display substrate adhere
- the transport device is located on the side opposite to the optical film side with respect to the release film, and a transport direction changing device that changes the transport direction of the adhesive optical film; In the position where the transport direction of the adhesive optical film is changed, the adhesive optical film and the release film are sandwiched between the adhesive optical film and the release film with respect to the transport direction changing device. And an anti-peeling device that opposes at the above intervals and prevents the adhesive optical film from peeling from the release film.
- the pressure-sensitive adhesive optical film having a shape corresponding to the display substrate to be bonded is composed of the optical film and the pressure-sensitive adhesive layer, and the pressure-sensitive adhesive layer side is bonded to the long release film.
- the release film is peeled from the adhesive optical film immediately before the bonding process to the display substrate. That is, since the pressure-sensitive adhesive layer that is the bonding surface of the optical film can be configured not to be exposed until just before the bonding, it is possible to prevent foreign matters from being mixed into the bonding surface of the optical film.
- an adhesive optical film having a shape corresponding to a display substrate to be bonded can be transported using a release film as a carrier. Therefore, since the conveyance apparatus of an adhesion type optical film can be made into a simpler structure, the manufacturing cost of an optical display unit can be reduced.
- the adhesive optical film and the release film are sandwiched, and the distance between the transport direction change device and the total thickness of the adhesive optical film and the release film is greater than Since the peeling prevention device is provided so as to face each other, peeling of the adhesive optical film from the release film can be satisfactorily prevented.
- the transport direction changing device constitutes a transport path length changing device that changes a length of a transport path in which the adhesive optical film is transported. It is characterized by.
- the separation preventing device can be provided in the conveyance path length changing device that changes the path length of the conveyance path. In this way, at the position where the path length of the conveyance path changes, the adhesive optical film is easily peeled off from the release film, but by providing a peeling prevention device at the position, the peeling of the adhesive optical film is made better. Can be prevented.
- the transport direction changing device changes the transport direction of the adhesive optical film by 90 ° or more.
- the peeling prevention device can be provided at a position having a large change angle in the transport direction such that the transport direction of the adhesive optical film is changed by 90 ° or more.
- the adhesive optical film is easily peeled off from the release film.
- the adhesive optical film can be peeled off. This can be prevented better.
- a manufacturing system of an optical display unit according to a fourth aspect of the present invention is characterized in that the peeling prevention device is formed in a shape along a transport locus of the adhesive optical film.
- the peeling of the adhesive optical film can be effectively prevented by the peeling preventing device having a shape along the conveyance path of the adhesive optical film.
- the space formed between the peeling prevention device and the transport direction changing device is from the upstream side to the downstream side in the transport direction of the adhesive optical film. It is formed so that it may become small gradually.
- the space formed between the peeling prevention device and the transport direction changing device is formed so as to gradually decrease from the upstream side to the downstream side in the transport direction of the adhesive optical film. Therefore, even if the adhesive optical film is already peeled off from the release film before being transported into the space, the leading end of the peeled adhesive optical film can be guided well into the space. Can do. Thereby, it can prevent still more favorably that an adhesive optical film peels from a release film.
- the body is obtained by cutting the long adhesive optical film into a shape corresponding to the display substrate without cutting the release film.
- the long adhesive optical film is cut into a shape corresponding to the display substrate without cutting the release film in the sheet-like laminate, the adhesive released by using the release film as a carrier. Mold optical film can be conveyed. Therefore, since the conveyance apparatus of an adhesion type optical film can be made into a simpler structure, the manufacturing cost of an optical display unit can be reduced.
- An optical display unit manufacturing system is an optical display unit manufacturing system in which an optical film is bonded to a display substrate via an adhesive layer, and the optical film is interposed through the adhesive layer.
- a transport device that transports the adhesive sheet product from which the optical film and the pressure-sensitive adhesive layer have been cut, along a transport path having a bent portion or a curved portion, without cutting the release film bonded together.
- a pressing member provided at a position facing the bent portion or the curved portion in the conveyance path and configured to press the optical film peeled off from the release film toward the release film, and conveyed along the conveyance path
- a peeling device for peeling the release film from the pressure-sensitive adhesive sheet product, and the optical film from which the release film has been peeled, through the pressure-sensitive adhesive layer. And having an optical film bonding apparatus for bonding to the display substrate Te.
- the release film bonded to the optical film via the pressure-sensitive adhesive layer is not cut, and the pressure-sensitive adhesive sheet product in which the optical film and the pressure-sensitive adhesive layer are cut is along the conveyance path.
- the release film is peeled from the optical film immediately before being transferred and bonded to the display substrate. That is, since the pressure-sensitive adhesive layer that is the bonding surface of the optical film can be configured not to be exposed until just before the bonding, it is possible to prevent foreign matters from being mixed into the bonding surface of the optical film.
- the optical film and the pressure-sensitive adhesive layer are cut without cutting the release film, the cut optical film and the pressure-sensitive adhesive layer can be transported using the release film as a carrier. Therefore, since the optical film transport device can be made simpler, the manufacturing cost of the optical display unit can be reduced.
- the optical film peeled off from the release film can be pressed to the release film side by a pressing member provided at a position facing the bent portion or the curved portion in the conveyance path. Thereby, it can prevent favorably that an optical film peels from a release film.
- An optical display unit manufacturing system provides the optical film of the pressure-sensitive adhesive sheet product without cutting the release film bonded to the optical film via the pressure-sensitive adhesive layer, and It further has a cutting device for cutting the pressure-sensitive adhesive layer, and the pressing member is provided between the cutting device and the optical film laminating device in the transport path.
- the cutting device cuts the optical film and the pressure-sensitive adhesive layer without cutting the release film bonded to the optical film via the pressure-sensitive adhesive layer. Peeling from the release film can be satisfactorily prevented by the pressing member.
- An optical display unit manufacturing system further includes a displacement mechanism that is displaced in order to change the length of the transport path, and the displacement member is provided with the pressing member.
- the pressing member can be provided in the displacement mechanism that is displaced to change the length of the conveyance path.
- the optical film is easily peeled from the release film at the position where the path length of the transport path changes, peeling of the optical film can be prevented better by providing a pressing member at the position. .
- the traveling direction of the pressure-sensitive adhesive sheet product conveyed along the conveyance path is changed by 90 ° or more in the bent portion or the curved portion.
- the pressing member can be provided at a position facing a bent portion or a curved portion having a large angle such that the traveling direction of the adhesive sheet product is changed by 90 ° or more.
- the optical film is easily peeled off from the release film at the position where the traveling direction of the pressure sensitive adhesive sheet product is greatly changed.
- the peeling of the optical film can be prevented more favorably. be able to.
- An optical display unit manufacturing system is characterized in that the pressing member is formed in a bent shape or a curved shape corresponding to the opposed bent portion or the curved portion.
- the pressing member since the pressing member is formed in a bent shape or a curved shape corresponding to the opposing bent portion or curved portion, the optical film is peeled from the release film at any portion of the bent portion or curved portion. Even in this case, the pressing member can satisfactorily press the release film.
- a space is formed between the pressure-sensitive adhesive sheet product conveyed along the conveyance path and the pressing member, and the pressing member includes The upstream end of the adhesive sheet product in the transport direction is formed such that the space gradually increases toward the upstream side in the transport direction.
- the upstream end of the pressure-sensitive adhesive sheet product in the conveyance direction of the presser member is formed between the pressure-sensitive adhesive sheet product conveyed along the conveyance path toward the upstream side in the conveyance direction.
- the formed space is formed so as to gradually increase. Therefore, even if the optical film is already peeled off from the release film before being transported into the space, the tip of the peeled optical film can be guided well into the space. Thereby, it can prevent still more favorably that an optical film peels from a release film.
- the transport mechanism for the pressure-sensitive adhesive optical film according to the thirteenth aspect of the present invention comprises the optical film and the pressure-sensitive adhesive layer in order to produce an optical display unit in which the optical film is bonded to the display substrate via the pressure-sensitive adhesive layer. And a pressure-sensitive adhesive optical film transport mechanism for transporting a pressure-sensitive adhesive optical film having a shape corresponding to the display substrate to be bonded, wherein the pressure-sensitive adhesive optical film has a long release layer on the pressure-sensitive adhesive layer side.
- the adhesive optical film is sandwiched between the adhesive optical film and the release film with respect to the transport direction changing device.
- Opposed by Lum and total thickness or spacing of the release film characterized by comprising the a peeling preventing apparatus for preventing separation from the release film of the pressure-sensitive adhesive optical film.
- the transport direction changing device constitutes a transport path length changing device that changes the length of the transport path along which the pressure-sensitive adhesive optical film is transported. It is characterized by that.
- the adhesive optical film transport mechanism according to the fifteenth aspect of the present invention is characterized in that the transport direction changing device changes the transport direction of the adhesive optical film by 90 ° or more.
- the adhesive optical film transport mechanism according to the sixteenth aspect of the present invention is characterized in that the peeling preventing device is formed in a shape along the transport locus of the adhesive optical film.
- the space formed between the peeling prevention device and the transport direction changing device is from the upstream side to the downstream side in the transport direction of the adhesive optical film. It is formed so that it may become small gradually toward this.
- a pressure-sensitive adhesive sheet product in which a release film is bonded to an optical film bonded to a display substrate via a pressure-sensitive adhesive layer.
- a conveyance device; and a pressing member that is provided at a position facing the bent portion or the curved portion in the conveyance path and that presses the optical film peeled from the release film toward the release film.
- FIG. 1 Flowchart of manufacturing method of optical display unit of embodiment 1
- FIG. 2 The figure for demonstrating the manufacturing system of Embodiment 1.
- FIG. 2 The figure for demonstrating the manufacturing system of Embodiment 2.
- FIG. The figure which showed the concrete structure of the vicinity of the 1st bonding apparatus.
- the figure for demonstrating an example of the laminated structure of a 1st, 2nd optical film The principal part enlarged view which showed an example of the structure of the pressing member
- the principal part enlarged view which showed the structure of the peeling prevention apparatus which concerns on a 1st modification.
- the principal part enlarged view which showed the structure of the peeling prevention apparatus which concerns on a 2nd modification.
- FIG. 1 shows a flowchart of a method for manufacturing the optical display unit of the first embodiment.
- FIG. 3 shows the configuration and plan layout of the optical display unit manufacturing system in the first embodiment.
- the manufacturing system of the first embodiment includes first and second pre-inspection peeling devices 13 and 23 and first and second release film sticking devices 15 and 25 in the configuration of the manufacturing system of the second embodiment to be described later. There is no configuration example. Further, as another embodiment of the manufacturing system of the first embodiment, a configuration that does not include the first and second defect inspection apparatuses 14 and 24 can be exemplified.
- Examples of the display substrate used in the present invention include a glass substrate unit of a liquid crystal cell, an organic EL light emitting unit, and the like.
- optical film examples of the optical film provided in the optical display unit of the present invention include a polarizer film, a retardation film, a viewing angle compensation film, a brightness enhancement film, and a combination laminated film of two or more of these films. These optical films may have a protective transparent film (for example, a polarizer protective film described later) laminated on the surface thereof. Further, an adhesive layer is formed on one surface of the optical film so as to be attached to the display substrate, and a release film for protecting the adhesive layer is provided. Further, a surface protective film may be provided on the other surface of the optical film via an adhesive layer. Specific configurations of these films will be described later.
- the said release film peels from the adhesive layer formed in the one surface of the said optical film to which it adheres, and the said surface protection film peels from the said optical film with the said adhesive layer to which it adheres .
- the optical film on which the pressure-sensitive adhesive layer is laminated may be referred to as a pressure-sensitive adhesive optical film, and a release film (or a surface protective film and a pressure-sensitive adhesive layer that adheres this to the optical film) is further laminated thereon.
- the optical film made may be referred to as a sheet product.
- the first sheet product F1 has a configuration in which a first optical film F11 and a first release film F12 are laminated via a first pressure-sensitive adhesive layer F14.
- the laminated structure of the 1st sheet product which has the 1st surface protection film F13 further is shown.
- 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 an adhesive layer (not shown) having the other side. 2 film 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 display substrate via the first pressure-sensitive adhesive layer F14 (at this time, the first release film F12 is peeled off).
- 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 1st 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 processes are carried out in an isolation structure isolated from the factory, and the cleanliness is maintained.
- the cleanliness is maintained in the bonding step of bonding the optical film to the display substrate.
- the first sheet material F1 is fed out from the first roll stock prepared and installed, and conveyed to the downstream side of the optical display unit manufacturing system of the present invention.
- 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 1st conveying apparatus 12 makes the 1st adhesive type optical film which consists of the 1st optical film F11 and the 1st adhesive layer F14 into the 1st release film F12 which has the 1st adhesive layer F14 side long. It is transported in a bonded state.
- the first sheet product F1 is inspected for defects using the first defect inspection device 14.
- the defect inspection method here, for example, there is a method of taking an image of transmitted light and / or reflected light on both surfaces of the first sheet product F1 and performing image processing.
- the inspection polarizing film is arranged so as to be crossed Nicol with the polarization axis of the first sheet product F1 (sometimes referred to as 0 degree crossing) for inspection.
- 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 inspection method is not limited to the image capturing and image processing method using the CCD camera, and a method capable of determining the intensity of transmitted light and reflected light, wavelength change, and the like can be employed.
- foreign matter inside the first sheet product F1 can be detected.
- adhered foreign matter on the surface of the first sheet product F1 can be detected.
- mainly surface foreign matter, dirt, internal foreign matter, etc. can be detected as bright spots.
- 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 first 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. That is, in the long first sheet product F1, portions other than the first release film F12 are sequentially cut into a shape corresponding to the display substrate W, whereby a plurality of first shapes having a shape corresponding to the display substrate W are obtained.
- the pressure-sensitive adhesive optical film is obtained in a configuration in which the surface is protected by the first surface protective film F13 bonded through the pressure-sensitive adhesive layer F15.
- the cutting means include a laser device, a cutter, and other known cutting means.
- the cutting is performed so as to avoid the defect.
- the yield of the 1st adhesion type optical film in the 1st sheet product F1 improves significantly.
- the first pressure-sensitive adhesive optical film in the first sheet product F1 including the defect is excluded by a first rejection device 19 to be described later, and is not attached to the display substrate W.
- steps of the first roll original fabric preparation step, the first inspection step, the first cutting step, the first optical film laminating step, and the washing step are preferably continuous production lines.
- the first adhesive optical film with a surface protective film is bonded to one surface of the display substrate W.
- the manufacturing process of bonding the adhesive layer F25 to be bonded will be described.
- Second roll original fabric preparation step (FIG. 1, S11).
- 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 has a configuration in which a second optical film F21 and a second release film F22 are laminated via a second pressure-sensitive adhesive layer F24.
- the laminated structure of the 2nd sheet product which has the 2nd surface protection film F23 further is shown.
- 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 third film F21b having an adhesive layer (not shown) on the other side. 4 film 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 display substrate via the second pressure-sensitive adhesive layer F24 (at this time, the second release film F22 is peeled off).
- 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 2nd surface protection film F23 is provided through the 3rd film F21b and the adhesive layer F25. Specific configurations of the third and fourth films F21b and F21c will be described later.
- the second sheet material F2 is fed out from the prepared and installed second roll, and conveyed to the downstream side of the optical display unit manufacturing system of the present invention.
- 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.
- the 2nd conveying apparatus 22 makes the 2nd adhesive type optical film which consists of the 2nd optical film F21 and the 2nd adhesive layer F24 into the long 2nd release film F22 to the 2nd adhesive layer F24 side. It is transported in a bonded state.
- 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 second 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. That is, in the long second sheet product F2, portions other than the second release film F22 are sequentially cut into a shape corresponding to the display substrate W, whereby a plurality of second shapes having a shape corresponding to the display substrate W are obtained.
- the pressure-sensitive adhesive optical film is obtained in a configuration in which the surface is protected by the second surface protective film F23 bonded through the pressure-sensitive adhesive layer F25.
- the cutting means include a laser device, a cutter, and other known cutting means.
- the second adhesive optical film in the second sheet product F2 including the defects is configured to be excluded by a second rejection device 29 described later and not attached to the display substrate W.
- Second optical film bonding step (FIG. 1, S15). Then, after the 2nd cutting process, while removing the 2nd mold release film F22 using the 2nd peeling device 27, the surface protection film from which the 2nd mold release film F22 was removed using the 2nd pasting device 28 The attached second pressure-sensitive adhesive optical film is bonded to a surface different from the surface where the first optical film F11 of the display substrate W is bonded to the second pressure-sensitive adhesive layer F24.
- the display substrate W is rotated 90 degrees by the transport direction switching mechanism of the transport mechanism, and the first optical film F11 and the second optical film F21 are in a crossed Nicols relationship. It may be.
- the second adhesive optical film with the surface protective film and the display substrate W are sandwiched between rolls and pressure bonded.
- the inspection apparatus inspects the optical display unit W12 in which an adhesive optical film (or further including a surface protective film and an adhesive layer that adheres the surface protective film to the optical film) is attached to both surfaces of the display substrate W.
- the inspection method include a method of taking an image of transmitted light and / or reflected light on both surfaces of the optical display unit W12 and performing image processing.
- inspection polarizing film is illustrated similarly to the said 1st and 2nd test process. 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 non-defective product of the optical display unit W12 is determined based on the defect information obtained by the inspection apparatus.
- the optical display unit W12 determined to be non-defective is conveyed to the next mounting process.
- a rework process is performed, and the first adhesive optical film is newly affixed to the collected display substrate W, and then inspected. In this case, the process is shifted to the rework process or disposed of again.
- An optical display unit can be suitably manufactured.
- defect information (defect coordinates, defect type, size, etc.) of the first and second sheet products is coded in a predetermined pitch unit (for example, 1000 mm). It may be attached as information (for example, QR code, barcode, etc.). That is, it is a case where the defect inspection of the adhesive optical film is performed in the manufacturing process of the sheet product, and the obtained defect information is attached to the sheet product as code information.
- the code information is read and analyzed at a stage prior to cutting, and cut into a predetermined size in the first and second cutting steps (sometimes referred to as skip cut) so as to avoid the defective portion. Then, the portion including the defect is removed or bonded to a member that is not a display substrate, and a non-defective sheet product that has been cut into a predetermined size is bonded to the display substrate. Thereby, the yield of the optical display unit is greatly improved.
- a sheet product having a configuration in which an adhesive optical film originally formed in a shape corresponding to the display substrate W is bonded to a long release film on the adhesive layer side is provided.
- the form used as a 1st roll original fabric and a 2nd roll original fabric can be mentioned.
- the first and second cutting steps described above are not necessary.
- the adhesive optical film originally formed in a shape corresponding to the display substrate W does not include a defect, the first and second inspection steps can be omitted.
- FIG. 2 shows a flowchart of the manufacturing method of the optical display unit of the second embodiment.
- FIG. 4 shows the configuration and plan layout of the optical display unit manufacturing system according to the second embodiment. A process similar to that of the first embodiment will be briefly described.
- First roll original fabric preparation step (FIG. 2, S1).
- a long first sheet product F1 is prepared as a first roll material.
- the laminated structure of the first sheet product F1 is the same as that of the first embodiment shown in FIG.
- the first pre-inspection peeling device 13 peels the first release film F12 from the first sheet product F1 being conveyed. Details of the peeling mechanism will be described later.
- the first defect inspection device 14 inspects defects after removing the first release film F12 from the first sheet material F1. There is no need to consider the retardation or the like inherent in the first release film F12, and the defect inspection of the first adhesive optical film composed of the first optical film F11 and the first adhesive layer F14 can be performed.
- the method of defect inspection is as described above.
- the first adhesive optical film including the defects is configured to be excluded together with the first release film F12 by the first exclusion device 19 described later and not attached to the display substrate W.
- the 1st mold release film bonding apparatus 15 bonds the 1st mold release film F12 to the 1st optical film F11 via the 1st adhesive layer F14 after a 1st fault inspection process. In order to maintain flatness, it is preferable to perform the bonding so that bubbles such as bubbles do not occur. The detail of the 1st release film bonding apparatus 15 is mentioned later.
- the first peeling device 17 peels the first release film F12.
- the 1st bonding apparatus 18 bonds the 1st adhesion type optical film with a surface protection film with which the 1st release film F12 was peeled off to the display board
- the first adhesive optical film and the display substrate W are sandwiched by a roll and bonded.
- Second roll original fabric preparation step (FIG. 2, S11).
- a long second sheet product F2 is prepared as a second roll material.
- the laminated structure of the second sheet product F2 has the configuration shown in FIG.
- Second inspection step (FIG. 2, S34).
- the second defect inspection device 24 inspects defects after removing the second release film F22 from the second sheet material F2. There is no need to consider the retardation or the like inherent in the second release film F22, and the defect inspection of the second adhesive optical film composed of the second optical film F21 and the second adhesive layer F24 can be performed.
- the method of defect inspection is as described above.
- the second adhesive optical film including the defects is configured to be excluded together with the second release film F22 by a second exclusion device 29 described later and not attached to the display substrate.
- the 2nd release film bonding apparatus 25 bonds the 2nd release film F22 (refer FIG. 7) to the 2nd optical film F21 via the 2nd adhesive layer F24 after a 2nd fault test process. In order to maintain flatness, it is preferable to perform the bonding so that bubbles such as bubbles do not occur. The detail of the 2nd release film bonding apparatus 25 is mentioned later.
- Second cutting step (FIG. 2, S36).
- the second cutting device 26 does not cut the second release film F22, but the second surface protective film F23, the adhesive layer F25, the second optical film F21, and the second adhesive.
- the agent layer F24 is cut into a predetermined size.
- the cutting means include a laser device, a cutter, and other known cutting means.
- Second optical film bonding step (FIG. 2, S37).
- the second peeling device 27 peels the second release film F22.
- substrate W sticks the 2nd adhesive type optical film with the surface protection film from which the 2nd release film F22 was peeled by the 2nd adhesive layer F24. Affix to a different surface from the mated surface.
- substrate W may be rotated 90 degree
- the second adhesive optical film and the display substrate W are sandwiched by a roll and bonded.
- the optical display unit W12 in which the first optical film F11 is bonded to one surface of the display substrate W, the second optical film F21 is bonded to the other surface, and the optical films are provided on both surfaces can be manufactured.
- the non-defective product of the optical display unit W12 is determined.
- the optical display unit W12 determined to be non-defective is conveyed to the next mounting process.
- a rework process is performed, and the first adhesive optical film is newly affixed to the collected display substrate W, and then inspected. In this case, the process is shifted to the rework process or disposed of again.
- An optical display unit can be suitably manufactured.
- the isolation structure is composed of a transparent material wall and a framework structure.
- a blower is installed on the ceiling of the isolation structure.
- the blower device includes a HEPA filter and blows air with high cleanness into the partition wall structure.
- An air discharge opening for discharging the internal air to the outside is provided at the bottom of the wall surface of the partition wall structure.
- a filter can be provided on the opening surface to prevent intruders from the outside.
- the polishing cleaning apparatus will be described.
- the display substrate W is taken out from the storage box and placed on the transport mechanism.
- the conveyance is stopped and the end portion of the display substrate W is held by the holding means.
- the polishing means is brought into contact with the upper surface of the display substrate W from vertically above, and the polishing means is brought into contact with the lower surface of the display substrate from vertically below.
- the respective polishing means are rotated on both surfaces of the display substrate W. As a result, the adhered foreign substances on both surfaces of the display substrate W are removed. Examples of the adhering foreign matter include glass fine pieces, fiber pieces, and the like.
- the display substrate W that has been polished and cleaned is transferred to a water bath by a transfer mechanism, and is washed with water here. Pure water flows inside the bath. Both surfaces of the display substrate W conveyed from the water bath are washed with pure water flowing out from the flowing water pipe. Next, the display substrate W is drained by the blowing of clean air by a drying device. Subsequently, the display board
- substrate W is conveyed by the 1st bonding apparatus. As another embodiment, it is possible to wash with an aqueous ethanol solution instead of pure water. In another embodiment, the water bath can be omitted.
- FIG. 5 is a diagram illustrating a specific configuration in the vicinity of the first bonding apparatus 18. Although only the structure of the vicinity of the 1st bonding apparatus 18 is shown by FIG. 5, the vicinity of the 2nd bonding apparatus 28 is also the same structure.
- the first roll of the long first sheet product F1 is installed on a roller gantry 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 includes a large number of transport rollers, and the first sheet product F1 is transported along a transport path 12A formed by these transport rollers.
- the conveyance path 12 ⁇ / b> A extends from the first roll material to the first sticking device 18.
- the first transport device 12 is controlled by the control device 1.
- the first pre-inspection peeling device 13 has a configuration in which the first release film F12 is peeled from the first sheet product F1 conveyed along the conveying path 12A and wound on a roll.
- the winding speed on the roll is controlled by the control device 1.
- the first release film F12 is peeled off by wrapping the first release film F12 around the knife edge portion and reversely transporting the first release film F12. It is comprised so that the 1st sheet product F1 after peeling the release film F12 may be conveyed in a conveyance direction.
- the first defect inspection apparatus 14 performs defect inspection after the first release film F12 is peeled off.
- the first defect inspection device 14 detects the defect by analyzing the image data picked up 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.
- the 1st release film bonding apparatus 15 bonds the 1st release film F12 to the 1st adhesive layer F14 of the film after a 1st fault test
- the first release film F12 is unwound from the roll raw material of the first release film F12, and the first release film F12, the first surface protection film F13, the adhesive layer F15, the first with one or a plurality of roller pairs. It is sandwiched together with the optical film F11 and the first pressure-sensitive adhesive layer F14, and is bonded by applying a predetermined pressure with the roller pair.
- the rotation speed, pressure control, and conveyance control of the roller pair are controlled by the control device 1.
- the first cutting device 16 does not cut the first release film F12 after bonding the first release film F12, but the first optical film F11, the first surface protective film F13, and the first pressure-sensitive adhesive layer. F14 and the pressure-sensitive adhesive layer F15 are 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 material F1 is horizontally moved so as to scan the laser in the width direction, and the first optical film F11, the first pressure-sensitive adhesive layer F14, and the first surface protection film F13 are left with the lowermost first release film F12 being left.
- the pressure-sensitive adhesive layer F15 is cut at a predetermined pitch in the transport 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 of the transport mechanism is moved 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 1st bonding apparatus 18 is the 1st adhesive layer F14 with the 1st adhesive type optical film with the surface protection film from which the 1st release film F12 was peeled after the cutting process by the said 1st cutting apparatus 16 by the 1st adhesive layer F14. Affixed to the display substrate W.
- the conveyance path 12A of the first sheet product F1 is above the conveyance path of the display substrate W. The flow of clean air from the blower is blocked by the first sheet product F1, and the wind force is weak on the upper surface of the display substrate W.
- the pressing roller 181 and the guide roller 182 bond the film from which the first release film F12 has been peeled off from the first sheet product F1 while being pressed against the display substrate W surface.
- 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 with a sharp tip, and the first release film F12 is wound around the knife edge portion and reversed and transferred.
- the first adhesive optical film with the surface protective film after peeling the first release film F12 is sent to the display substrate W surface.
- the first release film F12 peels off the first pressure-sensitive adhesive optical film with the surface protective film in a state where a tension of 150 N / m or more and 1000 N / m or less is applied to the first release film F12.
- the bonding accuracy of the first pressure-sensitive adhesive optical film with the surface protective film can be improved by performing the time from when the contact is made to the display substrate W surface within 3 seconds.
- the tension is less than 150 N / m, the delivery position of the first adhesive optical film with the surface protective film is not stable, and if it is greater than 1000 N / m, the first release film F12 may be stretched and broken. If the time until it is longer than 3 seconds, the end of the first pressure-sensitive adhesive optical film with the surface protective film peeled off from the first release film F12 may be bent to generate folds or bubbles. .
- the peeled first release mold F12 is wound around a roll 172. The winding control of the roll 172 is controlled by the control device 1.
- 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 display substrate W is cleaned by various cleaning apparatuses and is transferred by the transfer mechanism.
- the conveyance control of the conveyance mechanism is also controlled by the control device 1.
- the guide roller moves vertically downward.
- the roller around which the adhesive tape is stretched moves to a fixed position of the guide roller.
- the pressing roller By moving the pressing roller vertically downward, the first sheet product F1 including the defect is pressed against the adhesive tape, the first sheet product F1 is attached to the adhesive tape, and the first sheet product F1 including the defect together with the adhesive tape is a roller. Take up around.
- the display substrate W on which the first adhesive optical film with the surface protective film is bonded is transported to the downstream side, and the second adhesive optical film with the surface protective film is bonded thereto.
- the description of the same device configuration will be briefly described.
- the display substrate W is rotated by 90 ° by the transfer direction switching mechanism of the transfer mechanism, and then the surface protection is performed.
- a second adhesive optical film with a film is attached.
- each step is processed with the second sheet product F2 inverted (with the second release film F22 on the upper surface),
- the optical film F21 is configured to be bonded from the lower side of the display substrate W.
- the second roll raw material 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 conveying device 22 includes a large number of conveying rollers, and the second sheet product F2 is conveyed along a conveying path formed by these conveying rollers. The said conveyance path is extended from the 2nd roll original fabric to the 2nd sticking apparatus 28.
- FIG. The second transport device 22 is controlled by the control device 1.
- the second pre-inspection peeling device 23 has a configuration in which the second release film F22 is peeled from the second sheet product F2 conveyed along the conveyance path and wound on a roll.
- the winding speed on the roll is controlled by the control device 1.
- the tip has a sharp knife edge portion, and the second release film F22 is wound around the knife edge portion and transferred in reverse, whereby the second release film F22 is peeled off and the second release film F22 is peeled off. It is comprised so that the 2nd adhesion type optical film with a surface protection film after peeling release film F22 may be conveyed in a conveyance direction.
- the second defect inspection device 24 performs defect inspection after the second release film F22 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 second release film laminating apparatus 25 bonds the second release film F22 to the second adhesive layer F24 of the film after the second defect inspection.
- the second release film F22 is unwound from the original roll of the second release film F22, and the second release film F22, the second surface protective film F23, the adhesive layer F25, the second, with one or a plurality of roller pairs. It is sandwiched together with the optical film F21 and the second pressure-sensitive adhesive layer F24, and is bonded by applying a predetermined pressure with the roller pair.
- the rotation speed, pressure control, and conveyance control of the roller pair are controlled by the control device 1.
- the second cutting device 26 after bonding the second release film F22, without cutting the second release film F22, the second optical film F21, the second surface protection film F23, the second pressure-sensitive adhesive layer F24 and the adhesive layer F25 are cut into predetermined sizes.
- 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.
- the second sheet product F2 is horizontally moved so as to scan the laser in the width direction, and the second optical film F21, the second pressure-sensitive adhesive layer F24, and the second surface protective film F23 are left, leaving the lowermost second release film F22.
- the adhesive layer F25 is cut at a predetermined pitch in the transport direction.
- the accumulation device of the transport mechanism is moved 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 is the 2nd adhesive layer F24 with the 2nd adhesive type optical film with the surface protection film from which the 2nd release film F22 was peeled after the cutting process by the said 2nd cutting apparatus 26. Affixed to the display substrate W.
- the second optical film F21 is bonded to the display substrate W surface while being pressed by a pressing roller and a guide roller.
- the control device 1 controls the pressing pressure and driving operation of the pressing roller and the guide roller.
- a knife edge portion having a sharp tip is provided, and the second release film F22 is transferred by inverting and transferring the second release film F22 around the knife edge portion. While peeling, it is comprised so that the 2nd adhesion type optical film with a surface protection film after peeling the 2nd release film F22 may be sent out to the display substrate W surface. At this time, the second release film F22 peels off the second pressure-sensitive adhesive optical film with the surface protective film and / or the tension applied to the second release film F22 from 150 N / m to 1000 N / m.
- the bonding accuracy of the second pressure-sensitive adhesive optical film with the surface protective film can be improved by performing the time from when the contact is made to the display substrate W surface within 3 seconds. If the tension is less than 150 N / m, the delivery position of the second adhesive optical film with the surface protective film is not stable, and if it is greater than 1000 N / m, the second release film F22 may be stretched and broken. If the time until it is longer than 3 seconds, the end of the second adhesive optical film with the surface protective film peeled off from the second release film F22 may be bent and folds or bubbles may be generated. . The peeled second release film F22 is wound up on a roll. The roll winding control is controlled by the control device 1.
- the laminating mechanism is composed of a pressing roller and a guide roller arranged opposite to it.
- the guide roller is composed of a rubber roller that is rotationally driven by a motor, and is arranged to be movable up and down.
- a pressing roller made of a metal roller that is rotationally driven by a motor is disposed directly below it.
- the pressing roller is moved to a lower position so as to open a roller interval.
- the guide roller and the pressing roller may both be rubber rollers or metal rollers.
- the second rejection apparatus 29 that excludes the second sheet material F2 including the defects.
- the guide roller moves vertically upward.
- the roller around which the adhesive tape is stretched moves to a fixed position of the guide roller.
- the pressing roller By moving the pressing roller vertically upward, the second sheet product F2 including the defect is pressed against the adhesive tape, the second sheet product F2 is attached to the adhesive tape, and the second sheet product F2 including the defect is rolled with the adhesive tape. Take up around.
- the optical display unit W12 to which the first and second sheet products are bonded is conveyed to an inspection apparatus.
- the inspection apparatus performs 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 by the half mirror, and the reflected light image is captured as image data by the CCD camera.
- Another 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 inspection of the opposite surface of the optical display unit W12 is similarly performed using a light source and a CCD camera. The defect is subjected to image processing analysis from these image data, and a non-defective product is determined.
- the operation timing of each apparatus is calculated by, for example, a method of detecting by arranging a sensor at a predetermined position, or by detecting a rotary member of the transfer apparatus or the transfer mechanism 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 first adhesive optical film with the surface protective film is attached from the upper surface of the display substrate W
- the second adhesive optical film with the surface protective film is attached from the lower surface of the display substrate W.
- the first sheet product F1 is conveyed with the first release film F12 as an upper surface.
- the configuration and function of the first pre-inspection peeling device 13, the first defect inspection device 14, the first release film laminating device 15, and the first cutting device 16 are the same as above, but the first release film These arrangements differ depending on the position of F12.
- each of the first peeling device 17, the first bonding device 18, and the first excluding device 19 are the same as those described above, but their arrangement differs depending on the position of the first release film F12. ing. Accordingly, since the first sheet product F1 is conveyed below the display substrate W, the cleanliness of the upper surface side of the display substrate W can be maintained high. Further, the first sheet product F1 has a low degree of cleanness around the first sheet product F1, but the first release film F12 that is peeled off is formed on the upper surface side, so even if floating substances adhere to the first release film F12. There are few problems of foreign matter adhering at the time of bonding.
- the second sheet product F2 is conveyed with the second release film F22 as the bottom surface.
- the second pre-inspection peeling device 23, the second defect inspection device 24, the second release film laminating device 25, and the second cutting device 26 have the same configuration and function as described above, but the second release film. These arrangements differ depending on the position of F22.
- each of the second peeling device 27, the second bonding device 28, and the second excluding device 29 are the same as those described above, but their arrangement differs depending on the position of the second release film F22. ing. With this arrangement, the cleanliness on the upper surface side of the display substrate W can be maintained high. Moreover, the cleanliness around the second sheet product F2 can be maintained high.
- the automatic inspection apparatus is an apparatus that automatically inspects defects (also referred to as defects) of a sheet product.
- the automatic inspection apparatus emits light, and the reflected light image and the transmitted light image are image sensors such as a line sensor or a two-dimensional TV camera The defect detection is performed based on the acquired image data. Further, the image data is acquired in a state where the inspection polarizing filter is interposed in the optical path between the light source and the imaging unit.
- the polarization axis (for example, the polarization absorption axis) of the polarizing filter for inspection is arranged to be in a state (crossed Nicols) orthogonal to the polarization axis (for example, the polarization absorption axis) of the polarizing plate to be inspected.
- crossed Nicols a black image is input from the imaging unit if there is no defect, but if there is a defect, that part will not be black (recognized as a bright spot). Therefore, a defect can be detected by setting an appropriate threshold value. In such bright spot detection, defects such as surface deposits and internal foreign matter are detected as bright spots.
- the method (half-cut method) for cutting other members of the sheet product without cutting the release film has been described.
- the optical film and the pressure-sensitive adhesive layer are cut without cutting the release film bonded to the optical film via the pressure-sensitive adhesive layer, and before the bonding process to the display substrate.
- the release film can be peeled from the optical film. That is, since the pressure-sensitive adhesive layer that is the bonding surface of the optical film can be configured not to be exposed until just before the bonding, it is possible to prevent foreign matters from being mixed into the bonding surface of the optical film.
- the cut optical film and the pressure-sensitive adhesive layer can be conveyed using the release film as a carrier. Therefore, since the optical film transport device can have a simpler configuration, the manufacturing cost of the optical display unit can be further reduced.
- the first sheet product F1 is not cut by the first cutting device 16 without cutting the first release film F12 bonded to the first optical film F11 via the first pressure-sensitive adhesive layer F14.
- the first optical film F11, the first surface protective film F13, the first pressure-sensitive adhesive layer F14, and the pressure-sensitive adhesive layer F15 are cut, they are transported along the transport path 12A by the first transport device 12.
- the second sheet product F2 is not cut by the second cutting device 26 without cutting the second release film F22 bonded to the second optical film F21 via the second pressure-sensitive adhesive layer F24.
- the optical film F21, the second surface protective film F23, the second pressure-sensitive adhesive layer F24, and the pressure-sensitive adhesive layer F25 are cut, they are transported along the transport path 22A by the second transport device 22.
- the conveyance paths 12A and 22A have a plurality of curved portions. More specifically, at least some of the conveyance rollers are provided by appropriately arranging the plurality of conveyance rollers provided in each of the conveyance paths 12A and 22A according to the arrangement position of each device, not on a straight line.
- the conveying paths 12A and 22A are curved along the outer peripheral surface of the. In such curved portions of the conveyance paths 12A and 22A, the traveling directions of the first sheet product F1 and the second sheet product F2 to be conveyed are changed.
- the release films F12 and F22 bonded to the optical films F11 and F21 through the adhesive layers F14 and F24 are not cut, and the portions other than the release films F12 and F22, that is, the optical films F11, F22, F21, surface protective films F13 and F23, pressure-sensitive adhesive layers F14 and F24, and pressure-sensitive adhesive layers F15 and F25 (hereinafter referred to as “film main body”) are cut along the conveyance paths 12A and 22A.
- the film main body easily peels from the release films F12 and F22 in the curved portions of the transport paths 12A and 22A.
- One or more pressing members 200 are provided. These holding members 200 are provided at positions facing the curved portions in the transport paths 12A and 22A, and press the film body peeled off from the release films F12 and F22 toward the release films F12 and F22.
- the position of the pressing member 200 provided between the cutting devices 16 and 26 and the downstream accumulating device A is the conveyance roller initially arranged on the downstream side of the cutting devices 16 and 26 or the conveying paths 12A and 22A.
- the position is opposed to the conveying roller that is first arranged on the downstream side of the cutting devices 16 and 26.
- the sheet products F1 and F2 immediately after being cut by the cutting devices 16 and 26 are particularly easily peeled off from the release films F12 and F22. Therefore, the film body is formed of the release films F12 and F22 by the above-described configuration. Can be satisfactorily prevented from peeling off.
- the position of the pressing member 200 provided in the accumulating device A is opposed to the conveying roller that is initially arranged on the upstream side or the downstream side of the displacement roller A1 provided in the accumulating device A that is displaced in the vertical direction. It is preferable that it is a position to do.
- One or a plurality of the displacement rollers A1 are provided in the accumulating device A. When the displacement rollers A1 are displaced in the vertical direction, the path lengths of the conveying paths 12A and 22A are changed, and the sheet is formed on the downstream side. When the products F1 and F2 are sucked by the holding table, the continuous conveyance of the downstream and upstream sheet products F1 and F2 can be prevented from being stopped.
- the accumulation apparatus A constitutes a conveyance path length changing apparatus that changes the path length of the conveyance path through which the sheet products F1 and F2 are conveyed.
- the film main body is easy to peel off from the release films F12 and F22.
- Peeling can be prevented better.
- the traveling direction of the sheet products F1 and F2 conveyed along the conveying paths 12A and 22A is changed by 90 ° or more. It is preferable that it is a position facing the conveyance roller.
- the film main body is peeled off from the release films F12 and F22, and the film main body is bonded to the display substrate W while applying a relatively large tension to the film main body.
- seat products F1 and F2 conveyed between the side bonding apparatuses 18 and 28 are easy to peel a film main body from the release films F12 and F22. Therefore, by providing the pressing member 200 between the accumulating device A and the laminating devices 18 and 28 on the downstream side, it is possible to satisfactorily prevent the film body from being peeled off from the release films F12 and F22.
- FIG. 7 is an enlarged view of a main part showing an example of the configuration of the pressing member 200.
- the pressing member 200 is provided at a position facing the conveyance roller R1 forming the curved portion of the conveyance path 12A of the first sheet product F1 or the conveyance path 22A of the second sheet product F2. It has been.
- the conveyance roller R1 is located on the opposite side to the film body F side with respect to the release films F12 and F22, and constitutes a conveyance direction changing device that changes the conveyance direction (traveling direction) of the sheet products F1 and F2. is doing.
- the sheet products F1 and F2 conveyed along the conveying paths 12A and 22A are conveyed so that the release films F12 and F22 abut on the conveying roller R1, and at the curved portion formed by the conveying roller R1.
- the traveling direction is changed by 90 ° or more, for example, 180 °.
- the film main body F is a release film at a curved portion having a large angle such that the traveling direction of the sheet products F1 and F2 is changed by 90 ° or more, that is, at a position where the traveling direction of the sheet products F1 and F2 varies greatly.
- peeling of the film main body F can be prevented more favorably by providing the pressing member 200 at the position.
- the traveling direction of the sheet products F1 and F2 conveyed along the conveying paths 12A and 22A is not limited to the configuration in which the curved portion is changed by 90 ° or more, and is larger than 0 ° and smaller than 90 °. The configuration may be changed within a range.
- the pressing member 200 is formed in a curved shape (arc shape) corresponding to the curved portions of the transport paths 12A and 22A, that is, the outer peripheral surface of the transport roller R1.
- the pressing member 200 is formed in a shape along the transport locus of the adhesive optical film (first adhesive optical film or second adhesive optical film) included in the sheet products F1 and F2. More specifically, the pressing member 200 is opposed to the outer peripheral surface of the conveying roller R1 forming the curved portion with an interval larger than the thickness of the sheet products F1 and F2 being conveyed.
- the presser member 200 sandwiches the sheet products F1 and F2 at the position where the transport direction of the sheet products F1 and F2 is changed, and the pressure-sensitive adhesive optical film with respect to the transport roller R1 (transport direction changing device).
- the peeling prevention apparatus which opposes with the space
- the distance between the pressing member 200 and the outer peripheral surface of the conveying roller R1 is the total thickness of the adhesive optical film and the release films F12 and F22 (in the case of including a surface protective film and an adhesive layer that adheres this to the optical film) It is preferable that the distance exceeds the total thickness including Accordingly, a space 202 is formed between the sheet products F1 and F2 conveyed along the conveying paths 12A and 22A and the pressing member 200, and the sheet products F1 and F2 are pressed by the space 202 by the pressing member 200. It can be conveyed without rubbing.
- the presser member 200 is formed in a curved shape corresponding to the opposing curved portion, the presser member 200 can be pressed even when the film body F is peeled off from the release films F12 and F22 at any part of the curved portion.
- the member 200 can favorably press the release films F12 and F22.
- the upstream and downstream ends of the holding member 200 in the conveying direction of the sheet products F1 and F2 are formed in a shape that is bent away from the conveying roller R1 toward the tip.
- the end of the holding member 200 on the upstream side in the transport direction is such that the space 202 gradually increases toward the upstream side in the transport direction (from the upstream side in the transport direction toward the downstream side).
- the end of the holding member 200 on the downstream side in the transport direction is formed so that the space 202 gradually increases toward the downstream side in the transport direction. Yes.
- the present invention is not limited to this configuration, and only one of the upstream end and the downstream end of the holding member 200 in the transport direction may be bent as described above, or both end portions may be The configuration may not be a bent shape as described above.
- the film body F when the end of the holding member 200 on the upstream side in the transport direction is bent, the film body F is released from the release film F12 before being transported into the space 202. , F22, even if it has already peeled off, the leading end of the peeled film body F can be guided well into the space 202. Thereby, it can prevent further more favorably that the film main body F peels from the release films F12 and F22.
- the outer diameter of the conveying roller R1 facing the pressing member 200 is formed to be 200 mm.
- the transport roller R1 is preferably formed such that its outer diameter is, for example, about 1.5 to 2 times larger than that of the transport roller without the pressing member 200.
- the surfaces of the release films F12 and F22 on which the pressure-sensitive adhesive layers F14 and F24 are formed are processed so as to be more difficult to peel. It is also possible. In this case, when the sheet products F1 and F2 are bonded to the display substrate W, when the release films F12 and F22 are peeled from the film body F, the adhesive layers F14 and F24 do not adhere to the release films F12 and F22 side. It is necessary to process to the extent.
- the conveyance paths 12 ⁇ / b> A and 22 ⁇ / b> A have bent portions.
- the pressing member 200 may be provided at a position facing the bent portion. In this case, the pressing member 200 may be formed in a bent shape corresponding to the bent portion.
- the pressing member 200 is provided at the position facing the curved portion formed by the conveyance roller R ⁇ b> 1 in the conveyance paths 12 ⁇ / b> A and 22 ⁇ / b> A has been described.
- the pressing member 200 may be provided at a position facing the curved portion or the bent portion of the conveyance paths 12A and 22A formed by a member other than the conveyance roller R1.
- the pressing member 200 is not limited to the arc shape as shown in FIG. 7, and can be formed in various other shapes.
- the pressing member 200 is merely an example of a peeling prevention device, and the present invention can be applied to an optical display unit manufacturing system including various peeling prevention devices other than the pressing member 200.
- the pressure-sensitive adhesive layer F15 is peeled off from the surface protective films F13 and F23.
- F25 can be applied to the case where the optical films F11 and F21 are peeled off. That is, when the surface protective films F13 and F23 are used as the release films in the present invention, the optical members F11 and F21 that are peeled off from the surface protective films F13 and F23 while leaving the adhesive layers F15 and F25 are pressed. By pressing to the surface protective films F13 and F23 side, it is possible to satisfactorily prevent the optical films F11 and F21 from being separated from the surface protective films F13 and F23.
- FIG. 8 is an enlarged view of a main part showing the configuration of the peeling preventing apparatus 210 according to the first modification.
- it functions as a pressing member at a position facing the conveying roller R1 forming the curved portion of the conveying path 12A of the first sheet product F1 or the conveying path 22A of the second sheet product F2.
- a peeling preventing apparatus 210 having a plurality of roll bars 211 is provided.
- the plurality of roll bars 211 are arranged in an arc shape along the shape of the curved portion, that is, the conveyance direction of the sheet products F1 and F2, and each of the above-mentioned adhesive type optical elements with respect to the conveyance roller R1 (conveyance direction changing device).
- the film (the first adhesive type optical film or the second adhesive type optical film) and the release films F12 and F22 are opposed to each other at an interval equal to or greater than the total thickness. That is, the plurality of roll bars 211 are arranged in a shape along the transport locus of the adhesive optical film included in the sheet products F1 and F2, and the adhesive optical film is peeled from the release films F12 and F22. To prevent.
- the distance between the roll bar 211 and the outer peripheral surface of the transport roller R1 is the total thickness of the adhesive optical film and the release films F12 and F22 (in the case of including a surface protective film and an adhesive layer that adheres this to the optical film) It is preferable that the distance exceeds the total thickness including
- the roll bar 211 is arranged such that its axis extends in a direction orthogonal to the conveying direction of the sheet products F1, F2.
- the roll bar 211 may be configured to be rotatable about its axis or may be configured not to rotate.
- the roll bar 211 may be configured to be driven by driving means such as a motor, or may be configured to be rotatable without being driven by the driving means. There may be.
- the roll bar 211 is not limited to a configuration in which a plurality of roll bars 211 are provided.
- FIG. 9 is an enlarged view of a main part showing the configuration of the peeling preventing apparatus 220 according to the second modification.
- it functions as a pressing member at a position facing the conveying roller R1 forming the curved portion of the conveying path 12A of the first sheet product F1 or the conveying path 22A of the second sheet product F2.
- a flexible annular sheet 221 is provided.
- the annular sheet 221 is wound around a plurality of rollers 222 each having an axis extending in a direction orthogonal to the conveying direction of the sheet products F1 and F2, and the annular sheet 221 and the plurality of rollers 222 constitute a peeling prevention device 220. is doing.
- the region close to the conveyance roller R1 in the annular sheet 221 is in contact with the sheet products F1 and F2 conveyed along the conveyance paths 12A and 22A, thereby forming the curved portion, that is, in the conveyance direction of the sheet products F1 and F2.
- the area close to the transport roller R1 in the annular sheet 221 is the above adhesive optical film (first adhesive optical film or second adhesive optical film) with respect to the transport roller R1 (transport direction changing device) and It is opposed to the release films F12 and F22 at an interval equal to or greater than the total thickness.
- the area close to the conveyance roller R1 in the annular sheet 221 has a shape along the conveyance locus of the adhesive optical film included in the sheet products F1 and F2, and the release film F12 of the adhesive optical film. , Prevents peeling from F22.
- the interval between the annular sheet 221 and the outer peripheral surface of the conveying roller R1 is the total thickness of the adhesive optical film and the release films F12 and F22 (in the case of including a surface protective film and an adhesive layer that adheres this to the optical film) It is preferable that the distance exceeds the total thickness including
- the plurality of rollers 222 are configured to be rotatable about their respective axes.
- the plurality of rollers 222 may be configured such that at least one of them is driven by a driving means such as a motor, or all the rollers 222 are rotatable without being driven by the driving means. Also good.
- FIG. 10 is an enlarged view showing a main part of the configuration of the peeling preventing apparatus 230 according to the third modification.
- it functions as a pressing member at a position facing the conveyance roller R1 forming the curved portion of the conveyance path 12A of the first sheet product F1 or the conveyance path 22A of the second sheet product F2.
- An anti-separation device 230 having an air injection device 231 is provided.
- the air injection device 231 is formed in an arc shape along the shape of the curved portion, that is, the conveyance direction of the sheet products F1, F2. 1 adhesive type optical film or 2nd adhesive type optical film) and release films F12 and F22 are opposed to each other at an interval equal to or greater than the total thickness. That is, the air injection device 231 is arranged in a shape along the transport locus of the adhesive optical film included in the sheet products F1 and F2.
- the air injection device 231 releases the pressure-sensitive adhesive optical film by injecting air at a high pressure from the opposite side of the conveyance roller R1 to the sheet products F1 and F2 conveyed through the conveyance paths 12A and 22A. The peeling from the films F12 and F22 is prevented.
- the distance between the air injection device 231 and the outer peripheral surface of the transport roller R1 is the total thickness of the adhesive optical film and the release films F12 and F22 (in the case of including a surface protective film and an adhesive layer that adheres this to the optical film). It is preferable that the distance exceeds the total thickness including them.
- the configuration is not limited to the configuration in which air is injected as in the air injection device 231, and the peeling of the adhesive optical film from the release films F ⁇ b> 12 and F ⁇ b> 22 is prevented by injecting gas other than air.
- Such a configuration may be adopted.
- a polarizing plate will be described as an example of an optical film.
- a TAC (triacetylcellulose) film (polarizer protective film) is bonded to one side of a polyvinyl alcohol film (polarizer) manufactured in advance, and a PET (polyethylene terephthalate) film is bonded to the other side. It is obtained by combining.
- the roll of the polarizing plate is manufactured by the following manufacturing process.
- A a step of obtaining a polarizer.
- a polarizer is obtained by drying a polyvinyl alcohol (PVA) film subjected to dyeing / crosslinking and stretching treatment.
- B The process of manufacturing a polarizing plate.
- a TAC film is bonded to one side of a polarizer via an adhesive, and a PET film is bonded to the other side and dried to produce a polarizing plate.
- Anti-glare treatment may be applied in advance to the PET film on the viewing side of the display device.
- C The process of bonding a release film (separator) and a protective film together.
- a separator is bonded to the TAC film surface of the polarizing plate via a strong adhesive, and a surface protective film is bonded to the PET film surface via a weak adhesive.
- a strong adhesive is applied to the separator in advance, and a weak adhesive is applied to the surface protective film.
- the strong adhesive applied to the separator is transferred to the TAC film after peeling the separator.
- the weak adhesive applied to the surface protective film remains formed on the surface protective film even when the surface protective film is peeled off, and is not substantially transferred to the PET film.
- a long sheet product is manufactured, wound into a roll, and provided to the post-process.
- a predetermined inspection is performed by an inspector for each process.
- the inspector visually confirms defects (foreign matter, dirt, twist, etc.) during the conveyance of the PVA original fabric.
- the inspector visually observes a defect (foreign matter, dirt, nick, twist, Check for kinks.
- a defect inspection device (a well-known device that photographs foreign matter, dirt, etc. with a camera, and processes the image to determine the defect) automatically inspects the original polarizing plate after bonding and confirms the defect on the monitor. .
- step (C) when the obtained belt-shaped sheet product is rolled up, the inspector visually observes a defect (foreign matter, dirt, twist, etc.) at the start and end of winding of the roll.
- the sheet product is rated (good, defective, whether shipment is possible) by confirming this and evaluating this defect.
- (D) a slit process of the roll material Since the roll material is wide, the roll material is slit to a predetermined size in accordance with the size of the optical display unit as the final product. Depending on the width of the roll, the slit process is omitted.
- a roll type automatic inspection device and / or a visual inspection by an inspector is performed as a visual inspection of a long sheet product.
- the roll type automatic inspection device is a known device that takes a winding defect, an appearance defect, and the like with a camera, and performs image processing to determine a defect.
- the manufactured roll material is packed and transported to the next process place.
- the bonding process with the display substrate is performed at the same place, it is transported to the next process in simple packaging or as it is.
- optical display device examples include liquid crystal display devices, organic EL display devices, and image display devices such as PDPs (corresponding to optical display devices).
- a liquid crystal display device is generally formed by appropriately assembling components such as a liquid crystal cell (corresponding to a display substrate), an optical film, and an illumination system as necessary, and incorporating a drive circuit.
- a liquid crystal cell corresponding to a display substrate
- an optical film corresponding to a display substrate
- an illumination system as necessary
- incorporating a drive circuit there is no limitation in particular except the point which uses an optical film, and it can apply according to the former.
- 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 can be installed on one side or both sides of the liquid crystal cell.
- they may be the same or different.
- a liquid crystal display device for example, a single layer or a suitable part such as a diffusing plate, an antiglare layer, an antireflection film, a protective plate, a prism array, a lens array sheet, a light diffusing plate, a backlight, etc. Two or more layers can be arranged.
- the liquid crystal display device can be formed as an optical film having an appropriate structure according to the conventional transmission type or reflective type in which an optical film is disposed on one side or both sides of a liquid crystal cell, or a transmissive / reflective type. Accordingly, 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.
- the conveyance mechanism for the adhesive sheet product is incorporated in a part of the manufacturing system for the optical display unit.
- the conveyance mechanism for the adhesive sheet product is a component for manufacturing the optical display unit.
- the configuration may be separated from the system. That is, the present invention can be applied not only to a manufacturing system of an optical display unit but also to various transport mechanisms that transport an adhesive sheet product used in the optical display unit.
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- Engineering & Computer Science (AREA)
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- Manufacturing & Machinery (AREA)
- Ophthalmology & Optometry (AREA)
- Mechanical Engineering (AREA)
- Liquid Crystal (AREA)
- Devices For Indicating Variable Information By Combining Individual Elements (AREA)
- Polarising Elements (AREA)
- Registering, Tensioning, Guiding Webs, And Rollers Therefor (AREA)
- Adhesive Tapes (AREA)
Abstract
Description
本発明の実施形態1について以下に説明する。図1に実施形態1の光学表示ユニットの製造方法のフローチャートを示す。図3に実施形態1における光学表示ユニットの製造システムの構成および平面配置図を示す。実施形態1の製造システムは、後述する実施形態2の製造システムの構成の内、第1・第2検査前剥離装置13・23、第1・第2離型フィルム貼付装置15・25を備えていない構成例である。また、実施形態1の製造システムの別実施形態として、第1・第2欠点検査装置14・24を備えていない構成も例示できる。
まず、本発明に用いられる表示基板は、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。
本発明の光学表示ユニットに設けられる光学フィルムは、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、それらフィルムの2以上の組み合わせ積層フィルム等が例示される。これら光学フィルムは、その表面に保護用の透明フィルム(例えば、後述の偏光子保護フィルム等)が積層されたものである場合がある。また、光学フィルムの一方表面には、表示基板に貼り付けられるように、粘着剤層が形成され、この粘着剤層を保護するための離型フィルムが設けられる。また、光学フィルムのその他方表面には、粘着剤層を介して表面保護フィルムが設けられる場合がある。これらフィルムの具体的構成は後述する。なお、前記離型フィルムは、それが接着する前記光学フィルムの一方表面に形成される粘着剤層から剥離し、前記表面保護フィルムは、それが接着する前記粘着剤層とともに前記光学フィルムから剥離する。以下において、粘着剤層が積層された光学フィルムを粘着型光学フィルムと称することがあり、これにさらに離型フィルム(または、さらに表面保護フィルム及びこれを光学フィルムに接着する粘着剤層)が積層された光学フィルムをシート製品と称することがある。
(1)第1ロール原反準備工程(図1、S1)。長尺の第1シート製品を第1ロール原反として準備する。第1ロール原反の幅は、表示基板の貼り合わせサイズに依存している。図6に示すように、第1シート製品F1は、第1光学フィルムF11と、第1離型フィルムF12とが、第1粘着剤層F14を介して積層された構成を有する。図6では、さらに第1表面保護フィルムF13を有する第1シート製品の積層構造を示す。例えば、第1光学フィルムF11は、第1偏光子F11aと、その一方面に接着剤層(不図示)を介した第1フィルムF11bと、その他方面に接着剤層(不図示)を介した第2フィルムF11cとで構成されている。
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、バーコード等)として付されている場合がある。すなわち、シート製品の製造工程において粘着型光学フィルムの欠点検査を行い、得られた欠点情報がコード情報としてシート製品に付されている場合である。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、欠点を含む部分は除去あるいは表示基板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製品を表示基板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。
本発明の実施形態2について以下に説明する。図2に実施形態2の光学表示ユニットの製造方法のフローチャートを示す。図4に実施形態2における光学表示ユニットの製造システムの構成および平面配置図を示す。実施形態1と同様の処理についは簡単に説明する。
以下に、実施形態2の製造方法を実現する好適な製造システムの一例について説明する。
そこで、以下では、清浄空気の滞留を抑え、清浄度が高く維持された状態で表面保護フィルム付の第1粘着型光学フィルムを表示基板Wに貼り合わせることができる製造システムについて説明する。
欠点検査は公知の欠点検査方法が適用できる。自動検査装置は、シート製品の欠点(欠陥とも称される)を自動で検査する装置であり、光を照射し、その反射光像や透過光像をラインセンサーや2次元TVカメラなどの撮像部を介して取得し、取得された画像データに基づいて、欠点検出を行う。また、光源と撮像部の間の光路中に検査用偏光フィルタを介在させた状態で画像データを取得する。通常、この検査用偏光フィルタの偏光軸(例えば、偏光吸収軸)は、検査対象である偏光板の偏光軸(例えば、偏光吸収軸)と直交する状態(クロスニコル)となるように配置される。クロスニコルに配置することで、仮に欠点が存在しなければ撮像部から全面黒の画像が入力されるが、欠点が存在すれば、その部分が黒にならない(輝点として認識される)。従って、適宜のしきい値を設定することで、欠点を検出することができる。このような輝点検出では、表面付着物、内部の異物等の欠点が輝点として検出される。また、この輝点検出のほかに、対象物に対して透過光画像をCCD撮像し画像解析することで異物検出する方法もある。また、対象物に対して反射光画像をCCD撮像し画像解析することで表面付着異物を検出する方法もある。
まず、光学フィルムの一例として偏光板について説明する。偏光板は、予め製造しておいたポリビニルアルコール系フィルム(偏光子)の片面に例えばTAC(トリアセチルセルロース)フィルム(偏光子保護フィルム)を貼り合わせ、他方面にPET(ポリエチレンテレフタレート)フィルムを貼り合せることで得られる。
偏光板のロール原反は、例えば、以下の製造工程で製造される。前工程として、(A)偏光子を得る工程。ここでは、染色・架橋及び延伸処理を施したポリビニルアルコール(PVA)フィルムを乾燥して偏光子を得る。(B)偏光板を製造する工程。ここでは、偏光子の片面に接着剤を介してTACフィルムを貼り合わせ、その他面に、PETフィルムを貼り合せ、乾燥して偏光板を製造する。表示装置の視認側となるPETフィルムにはアンチグレア処理が予め施されていてもよい。(C)離型フィルム(セパレータ)及び保護フィルムを貼り合わせる工程。偏光板のTACフィルム面に強粘着剤を介してセパレータを、PETフィルム面に弱粘着剤を介して表面保護フィルムを貼り合わせる。ここで、セパレータには予め強粘着剤が塗工され、表面保護フィルムには弱粘着剤が塗工されている。セパレータに塗工された強粘着剤は、セパレータを剥離後、TACフィルムに転写される。また、表面保護フィルムに塗工された弱粘着剤は、表面保護フィルムを剥離しても表面保護フィルムに形成されたままであり、PETフィルムに実質的に転写されない。以上の前工程では、長尺のシート製品が製造され、ロール状に巻き取られ、後工程に提供される。
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 第1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 第2表面保護フィルム
F24 第2粘着剤層
W 表示基板
Claims (18)
- 表示基板に粘着剤層を介して光学フィルムが接着された光学表示ユニットの製造システムであって、
前記光学フィルム及び前記粘着剤層からなり、かつ、接着される前記表示基板に対応する形状の粘着型光学フィルムを、その粘着剤層側を長尺の離型フィルムに接着させた状態で搬送する搬送装置と、
搬送される前記粘着型光学フィルムを前記離型フィルムから剥離する剥離装置と、
前記離型フィルムから剥離された前記粘着型光学フィルムを、その粘着剤層側を前記表示基板に貼り合せる光学フィルム貼合装置とを備え、
前記搬送装置には、
前記離型フィルムに対して前記光学フィルム側とは反対側に位置し、前記粘着型光学フィルムの搬送方向を変更する搬送方向変更装置と、
前記粘着型光学フィルムの搬送方向が変更される位置において、前記粘着型光学フィルム及び前記離型フィルムを挟んで、前記搬送方向変更装置に対して前記粘着型光学フィルム及び前記離型フィルムの合計厚み以上の間隔で対向し、前記粘着型光学フィルムの前記離型フィルムからの剥離を防止する剥離防止装置とが含まれることを特徴とする光学表示ユニットの製造システム。 - 前記搬送方向変更装置が、前記粘着型光学フィルムが搬送される搬送路の路長を変更する搬送路長変更装置を構成していることを特徴とする請求項1に記載の光学表示ユニットの製造システム。
- 前記搬送方向変更装置が、前記粘着型光学フィルムの搬送方向を90°以上変更することを特徴とする請求項1又は2に記載の光学表示ユニットの製造システム。
- 前記剥離防止装置が、前記粘着型光学フィルムの搬送軌跡に沿った形状に形成されていることを特徴とする請求項1~3のいずれかに記載の光学表示ユニットの製造システム。
- 前記剥離防止装置と前記搬送方向変更装置との間に形成される空間が、前記粘着型光学フィルムの搬送方向の上流側から下流側に向かって徐々に小さくなるように形成されていることを特徴とする請求項4に記載の光学表示ユニットの製造システム。
- 前記表示基板に対応する形状の粘着型光学フィルムが、長尺の前記粘着型光学フィルム及び長尺の前記離型フィルムからなるシート状積層体を、前記離型フィルムを切断せずに前記長尺の粘着型光学フィルムを前記表示基板に対応する形状に切断することにより得られることを特徴とする請求項1~5のいずれかに記載の光学表示ユニットの製造システム。
- 表示基板に粘着剤層を介して光学フィルムが接着された光学表示ユニットの製造システムであって、
前記光学フィルムに前記粘着剤層を介して貼り合せられた離型フィルムが切断されずに、前記光学フィルムおよび前記粘着剤層が切断された粘着型シート製品を、屈曲部または湾曲部を有する搬送路に沿って搬送する搬送装置と、
前記搬送路における前記屈曲部または前記湾曲部に対向する位置に設けられ、前記離型フィルムから剥離する前記光学フィルムを前記離型フィルム側へ押さえるための押え部材と、
前記搬送路に沿って搬送される前記粘着型シート製品から前記離型フィルムを剥離する剥離装置と、
前記離型フィルムが剥離された前記光学フィルムを、前記粘着剤層を介して前記表示基板に貼り合せる光学フィルム貼合装置とを有することを特徴とする光学表示ユニットの製造システム。 - 前記光学フィルムに前記粘着剤層を介して貼り合せられた前記離型フィルムを切断せずに、前記粘着型シート製品の前記光学フィルムおよび前記粘着剤層を切断する切断装置をさらに有し、
前記搬送路における前記切断装置と前記光学フィルム貼合装置の間に、前記押え部材が設けられていることを特徴とする請求項7に記載の光学表示ユニットの製造システム。 - 前記搬送路の路長を変更するために変位する変位機構をさらに有し、
前記変位機構に前記押え部材が設けられていることを特徴とする請求項7または8に記載の光学表示ユニットの製造システム。 - 前記搬送路に沿って搬送される前記粘着型シート製品の進行方向が、前記屈曲部または前記湾曲部において90°以上変更されることを特徴とする請求項7~9のいずれかに記載の光学表示ユニットの製造システム。
- 前記押え部材が、対向する前記屈曲部または前記湾曲部に対応する屈曲形状または湾曲形状に形成されていることを特徴とする請求項7~10のいずれかに記載の光学表示ユニットの製造システム。
- 前記搬送路に沿って搬送される前記粘着型シート製品と前記押え部材との間には空間が形成されており、前記押え部材における前記粘着型シート製品の搬送方向の上流側の端部は、前記搬送方向の上流側に向かって前記空間が徐々に大きくなるように形成されていることを特徴とする請求項11に記載の光学表示ユニットの製造システム。
- 表示基板に粘着剤層を介して光学フィルムが接着された光学表示ユニットを製造するために、前記光学フィルム及び前記粘着剤層からなり、かつ、接着される前記表示基板に対応する形状の粘着型光学フィルムを搬送する粘着型光学フィルムの搬送機構であって、
前記粘着型光学フィルムを、その粘着剤層側を長尺の離型フィルムに接着させた状態で搬送するものであり、
前記離型フィルムに対して前記光学フィルム側とは反対側に位置し、前記粘着型光学フィルムの搬送方向を変更する搬送方向変更装置と、
前記粘着型光学フィルムの搬送方向が変更される位置において、前記粘着型光学フィルム及び前記離型フィルムを挟んで、前記搬送方向変更装置に対して前記粘着型光学フィルム及び前記離型フィルムの合計厚み以上の間隔で対向し、前記粘着型光学フィルムの前記離型フィルムからの剥離を防止する剥離防止装置とを備えたことを特徴とする粘着型光学フィルムの搬送機構。 - 前記搬送方向変更装置が、前記粘着型光学フィルムが搬送される搬送路の路長を変更する搬送路長変更装置を構成していることを特徴とする請求項13に記載の粘着型光学フィルムの搬送機構。
- 前記搬送方向変更装置が、前記粘着型光学フィルムの搬送方向を90°以上変更することを特徴とする請求項13又は14に記載の粘着型光学フィルムの搬送機構。
- 前記剥離防止装置が、前記粘着型光学フィルムの搬送軌跡に沿った形状に形成されていることを特徴とする請求項13~15のいずれかに記載の粘着型光学フィルムの搬送機構。
- 前記剥離防止装置と前記搬送方向変更装置との間に形成される空間が、前記粘着型光学フィルムの搬送方向の上流側から下流側に向かって徐々に小さくなるように形成されていることを特徴とする請求項16に記載の粘着型光学フィルムの搬送機構。
- 表示基板に粘着剤層を介して接着される光学フィルムに前記粘着剤層を介して離型フィルムが貼り合せられた粘着型シート製品の搬送機構であって、
前記離型フィルムが切断されずに、前記光学フィルムおよび前記粘着剤層が切断された前記粘着型シート製品を、屈曲部または湾曲部を有する搬送路に沿って搬送する搬送装置と、
前記搬送路における前記屈曲部または前記湾曲部に対向する位置に設けられ、前記離型フィルムから剥離する前記光学フィルムを前記離型フィルム側へ押さえるための押え部材とを有することを特徴とする粘着型シート製品の搬送機構。
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