WO2015030066A1

WO2015030066A1 - Production method for laminated optical member

Info

Publication number: WO2015030066A1
Application number: PCT/JP2014/072465
Authority: WO
Inventors: 力也松本
Original assignee: 住友化学株式会社
Priority date: 2013-08-30
Filing date: 2014-08-27
Publication date: 2015-03-05
Also published as: JP2015049347A; TW201518812A

Abstract

A production method for laminated optical members formed by laminating an optical member on to an optical display device. The production method has: a laminated optical member formation step (S13) in which a belt-shaped optical member sheet is wound out from a starting material roll, the plurality of optical members obtained by cutting the optical member sheet are laminated on to a plurality of optical display components, and a plurality of laminated optical members are formed; and a first visual inspection step (S14) in which a visual inspection for defects is made for each of the plurality of laminated optical members. The laminated optical member formation step and the first visual inspection step are performed on the same production line.

Description

Method for producing optical member bonded body

The present invention relates to a method for producing an optical member bonded body.
This application claims priority based on Japanese Patent Application No. 2013-180587 filed on August 30, 2013, the contents of which are incorporated herein by reference.

As a method of bonding a polarizing plate (optical member) to a liquid crystal panel (optical display component), a bonding method called an RTP (Roll-to-Panel) method is known (for example, see Patent Document 1). This bonding method is a method in which a long polarizing plate unwound from an original fabric roll is cut into a predetermined size and directly bonded to a liquid crystal panel conveyed on the line.

When sticking a polarizing plate to a liquid crystal panel, there is a defect such as dust generated from operating equipment or dust generated due to workers entering the liquid crystal panel and the polarizing plate as a sticking foreign matter. May occur. Such a defective product can be detected by inspecting the product carried out of the production line. However, in this method, the inspection position of the defective product is separated from the production line, and the occurrence of the defective product is A time lag occurs between detection of a defective product. As a result, after the occurrence of defective products, measures such as line stoppage and cause removal are delayed.As a result, defective products will continue to be generated until defective products are detected, and a considerable number of defective products will be generated, increasing the production line yield. There is a problem of lowering.

Therefore, in the production system of Patent Document 1, an automatic optical inspection device (Automatic Optical Inspection) is installed on the production line to sequentially automatically inspect defects in the bonded body conveyed on the line. Various defect inspection apparatuses such as a transmission type and a reflection type are known as such defect inspection apparatuses, and these defect inspection apparatuses are appropriately selected and used according to the type of defect. In the production system of Patent Document 1, since the defect inspection apparatus is installed on the production line, the time lag as described above does not occur, and the production yield is improved.

Japanese Patent No. 46669070

In the automatic inspection using a defect inspection apparatus that is currently on the market, compared to the visual inspection, “missing” for determining a defective product as a non-defective product is likely to occur. Usually, in the defect inspection apparatus, the pass / fail judgment threshold is strictly set to suppress the occurrence of oversight. However, even in the automatic inspection using the defect inspection apparatus, there are cases where oversight may occur. Therefore, drastic improvement measures for increasing the accuracy of defect detection are required.

The aspect of the present invention has been made in view of such circumstances, and is capable of detecting a defect with sufficient accuracy in actual use and capable of stable production without impairing the production yield. It aims at providing the manufacturing method of a member bonding body.

In order to achieve the above object, the method for producing an optical member bonded body according to an aspect of the present invention employs the following configuration.
(1) The manufacturing method of the optical member bonding body which concerns on 1 aspect of this invention is a manufacturing method of the optical member bonding body formed by bonding an optical member to an optical display component, Comprising: A strip | belt-shaped optical member sheet | seat is used. The optical member bonding body which unwinds from a raw fabric roll, bonds the said some optical member obtained by cut | disconnecting the said optical member sheet | seat to the said some optical display component, and forms the said some optical member bonding body. A first visual inspection step for visually inspecting defects for each of the plurality of optical member bonded bodies, and the optical member bonded body forming step and the first visual inspection step are manufactured in the same manner. Do in line.

(2) The manufacturing method of the optical member bonding body which concerns on another one aspect | mode of this invention is a manufacturing method of the optical member bonding body formed by bonding an optical member to an optical display component, Comprising: A strip | belt-shaped optical member The sheet is unwound from the raw roll, and a plurality of sheet pieces obtained by cutting the optical member sheet are bonded to the plurality of optical display components to form a plurality of bonded bodies, and In the said bonding body, the detection process which detects the outer periphery of the bonding surface of the said sheet piece and the said optical display component, In the said bonding body, the said bonding surface from the said sheet piece bonded to the said optical display component. The excess part arrange | positioned on the outer side of the part corresponding to 1 is cut | disconnected along the said outer periphery, The optical member bonding body formation which forms the said optical member bonding body containing the said optical member of the magnitude | size corresponding to the said bonding surface is formed. A plurality of optical member pasting steps It has a first visual inspection step of visually inspecting defects for each body, a, and the optical member bonded body forming step and the first visual inspection step, performed in the same manufacturing line.

(3) In the aspect of (2), in the detection step, an outer peripheral edge of a bonding surface between the sheet piece and the optical display component may be detected for each of the plurality of optical display components.

(4) In the aspect according to any one of (1) to (3), the manufacturing method of the optical member bonded body includes the defective product with respect to the defective product detected in the first visual inspection step. Depending on the state of the defect, autoclave treatment for heating and pressurizing the defective product, or peeling the optical member from the optical member bonded body to expose the optical display component, and exposing the surface of the optical display component In addition, it has a regeneration process step of selecting and implementing either one of the rework processes of pasting the new optical member prepared in advance and forming the new optical member bonded body, The regeneration treatment step may be performed separately from the production line.

(5) In the aspect of said (4), the manufacturing method of the said optical member bonding body is a 2nd visual inspection process which visually inspects a defect about each of the said some optical member bonding body which passed through the said reproduction | regeneration process process. And the second visual inspection step may be performed separately from the production line.

(6) In the above aspect (5), the regeneration process may be performed again on the defective product detected in the second visual inspection process.

(7) In the aspect of any one of (1) to (6) above, in the first visual inspection step, a plurality of the optical member bonded bodies sequentially conveyed through the optical member bonded body forming step. A plurality of inspectors may share the visual inspection.

(8) In the aspect of the above (7), in the first visual inspection step, the plurality of optical member bonded bodies are distributed to a plurality of inspection lines, and the inspectors arranged on the plurality of inspection lines are visually observed. You may inspect.

(9) In the aspect of any one of (1) to (8) above, in the optical member bonding body forming step, the optical member bonding body in which the optical member is bonded to both surfaces of the optical display component. In the first visual inspection step, the optical member bonded body in which the optical member is bonded to both surfaces of the optical display component may be visually inspected.

According to the aspect of the present invention, it is possible to provide a method for producing an optical member bonded body capable of detecting a defect with an accuracy that is not excessive or insufficient in actual use and capable of stable production without impairing the production yield. it can.

It is a schematic block diagram about a film bonding system. It is explanatory drawing about the 1st inversion apparatus which a film bonding system has. It is a top view of a liquid crystal panel. FIG. 4 is a sectional view taken along line IV-IV in FIG. 3. It is a fragmentary sectional view of an optical member sheet. It is explanatory drawing about the manufacturing method of the optical member bonding body in 1st Embodiment. It is a schematic block diagram about the film bonding system of 2nd Embodiment. It is a schematic diagram of the 1st detection apparatus which detects the outer periphery of the bonding surface. It is a schematic diagram which shows the modification of a 1st detection apparatus. It is a top view which shows the position which detects the outer periphery of the bonding surface. It is a schematic diagram of the 2nd detection apparatus which detects the outer periphery of the bonding surface.

Hereinafter, the manufacturing method of the optical member bonding body which concerns on embodiment of this invention is demonstrated. 1 and 2 are explanatory views showing an optical member bonded body production system used for carrying out the method for manufacturing an optical member bonded body according to the present embodiment. FIG. 1: is a schematic block diagram about the film bonding system 1 which comprises a part of production system of an optical member bonding body, FIG. 2 is explanatory drawing about the 1st inversion apparatus 15 which the film bonding system 1 has. It is.

The film bonding system 1 manufactures an optical member bonding body by bonding a film-shaped optical member such as a polarizing film, an antireflection film, or a light diffusion film to a panel-shaped optical display component such as a liquid crystal panel or an organic EL panel. System. The film bonding system 1 is configured as a part of a production system that produces an optical display device including an optical display component and an optical member. In the film bonding system 1, the liquid crystal panel P is used as an optical display component.

In the following description, first, the liquid crystal panel P used in the film bonding system 1 is described, and then the film bonding system 1 is described in detail.

(LCD panel)
FIG. 3 is a plan view of the liquid crystal panel P. FIG. The liquid crystal panel P includes a first substrate P1 having a rectangular shape in plan view, a second substrate P2 having a relatively small rectangular shape disposed to face the first substrate P1, a first substrate P1, and a second substrate. And a liquid crystal layer P3 sealed between the substrate P2. The liquid crystal panel P has a rectangular shape that follows the outer peripheral shape of the first substrate P1 in a plan view, and has a display region P4 that is an area that fits inside the outer periphery of the liquid crystal layer P3 in a plan view.

4 is a cross-sectional view taken along the line IV-IV in FIG. On the front surface of the liquid crystal panel P and the back surface of the liquid crystal panel P, the first optical member F11 and the first optical member F11 cut out from the long strip-shaped first optical member sheet F1 and the long strip-shaped second optical member sheet F2 (see FIG. 1) Two optical members F12 are appropriately bonded. In the following description, the first optical member sheet F1 and the second optical member sheet F2 may be collectively referred to as “optical member sheet FX”. Further, the first optical member F11 and the second optical member F12 may be collectively referred to as “optical member F1X”.

In the present embodiment, the first optical member F11 as the polarizing film and the second optical member F12 as the polarizing film are bonded to the backlight side surface of the liquid crystal panel P and the display surface side surface of the liquid crystal panel P, respectively. Is done. In addition, the 3rd optical member as a brightness improvement film may be further bonded on the surface by the side of the backlight of liquid crystal panel P so that it may overlap with the 1st optical member F11.

FIG. 5 is a partial cross-sectional view of the optical member sheet FX. The optical member sheet FX includes a film-shaped optical member main body F1a, an adhesive layer F2a provided on the first surface (upper surface in FIG. 5) of the optical member main body F1a, and the optical member main body F1a. The separator sheet F3a is detachably laminated on one surface, and the surface protection film F4a is laminated on the second surface (lower surface in FIG. 5) of the optical member body F1a. Hereinafter, the part remove | excluding the separator sheet F3a from the optical member sheet | seat FX is called the bonding sheet | seat F5. For convenience of illustration, hatching of each layer in FIG. 5 is omitted.

The optical member body F1a is bonded to the sheet-like polarizer F6, the first film F7 bonded to the first surface of the polarizer F6 with an adhesive or the like, and the second surface of the polarizer F6 with an adhesive or the like. And a second film F8. The first film F7 and the second film F8 are protective films that protect the polarizer F6, for example.

The optical member body F1a may have a single-layer structure having a single optical layer, or may have a stacked structure in which a plurality of optical layers are stacked together. In addition to the polarizer F6, the optical layer may be a retardation film, a brightness enhancement film, or the like. At least one of the first film F7 and the second film F8 may be subjected to a surface treatment capable of obtaining an effect such as a hard coat treatment for protecting the outermost surface of the liquid crystal display element or an antiglare treatment. The optical member body F1a may not include at least one of the first film F7 and the second film F8. For example, when the 1st film F7 is abbreviate | omitted, it is good also as laminating | stacking the separator sheet F3a on the 1st surface of polarizer F6 so that separation | separation is possible via the adhesion layer F2a.

The optical member body F1a is cut out to a predetermined length, and then pasted over the entire display area P4 of the liquid crystal panel P and the peripheral area of the display area P4. At that time, the sheet piece obtained by cutting the adhesive layer F2a into the same predetermined length is left in the sheet piece cut out from the optical member body F1a, and the sheet piece of the optical member body F1a is the sheet piece of the adhesive layer F2a. It is bonded to the liquid crystal panel P.

The separator sheet F3a protects the adhesive layer F2a and the optical member body F1a until the separator sheet F3a is separated from the adhesive layer F2a.

The surface protective film F4a is cut out together with the optical member main body F1a and bonded to the liquid crystal panel P. The surface protective film F4a is disposed on the side opposite to the liquid crystal panel P with respect to the optical member body F1a to protect the optical member body F1a. The surface protective film F4a is separated from the optical member main body F1a at a predetermined timing. In addition, the structure which does not contain the surface protection film F4a may be sufficient as the optical member sheet | seat FX. The structure which is not isolate | separated from the optical member main body F1a may be sufficient as the surface protection film F4a.

From such an optical member sheet FX, the optical member F1X is formed by cutting the bonding sheet F5 in the production line as will be described later.

(Film bonding system)
Hereinafter, the film bonding system 1 will be described with reference to FIGS. In the drawing, the right side indicates the upstream side in the transport direction of the liquid crystal panel P (hereinafter referred to as the panel transport upstream side). The left side in the figure shows the downstream side in the transport direction of the liquid crystal panel P (hereinafter referred to as the panel transport downstream side).

The film bonding system 1 sequentially performs a predetermined process on the liquid crystal panel P while transporting the liquid crystal panel P from the start position to the final position of the bonding process using, for example, a driving roller conveyor 5. The liquid crystal panel P is conveyed on the roller conveyor 5 with its front and back surfaces being horizontal.

In the following description, the entire process performed by the flow operation on the liquid crystal panel P from the start position to the end position of the bonding process may be referred to as a “production line”. The production line mainly refers to a flow operation performed on the roller conveyor 5, and the operation performed on the production line is referred to as “operation in the production line”. In the present embodiment, the production line includes a cleaning process (not shown) of the liquid crystal panel P provided on the upstream side of the bonding process.

Further, the liquid crystal panel P conveyed on the roller conveyor 5 is taken out from the start position to the end position of the bonding process, and the liquid crystal panel P is processed at a position different from the roller conveyor 5, and then the processed liquid crystal Even when the panel P is returned to the roller conveyor 5, the panel P is handled as a part of the production line if no stagnation occurs in the flow operation.

Also, the work performed separately from the flow work on the roller conveyor 5 is referred to as “outside the production line”. Outside the production line, the work can be performed over the necessary time regardless of the conveying speed of the roller conveyor 5.

The roller conveyor 5 is divided into an upstream conveyor 6 and a downstream conveyor 7 with a first reversing device 15 described in detail later as a boundary. For example, the liquid crystal panel P is transported in the direction in which the short side of the display area P4 is along the transport direction in the upstream conveyor 6, and is transported in the direction in which the long side of the display area P4 is along the transport direction in the downstream conveyor 7. Is done. An optical member obtained by cutting the belt-shaped optical member sheet FX is bonded to the front surface of the liquid crystal panel P and the back surface of the liquid crystal panel P. Each part of the film bonding system 1 is comprehensively controlled by the control part 20 as an electronic control apparatus.

The film bonding system 1 includes a first suction device 11 that sucks the liquid crystal panel P transported to the end position of the upstream process and transports the liquid crystal panel P to the start position of the upstream conveyor 6 and aligns the liquid crystal panel P. The first dust collector 12 provided on the downstream side of the panel transport, the first bonding device 13 provided on the downstream side of the panel transport with respect to the first dust collector 12, and the panel transport with respect to the first pasting device 13. The first deviation inspection device 14 provided on the downstream side, and the liquid crystal panel P provided on the downstream side of the panel conveyance with respect to the first deviation inspection device 14 and reaching the end position of the upstream conveyor 6, the initial position of the downstream conveyor 7 And a first reversing device 15 that conveys the

In addition, the film bonding system 1 includes a second dust collector 16 provided on the downstream side of the panel transport from the initial position of the downstream conveyor 7 and a second dust collector provided on the downstream side of the panel transport from the second dust collector 16. A bonding device 17, a second displacement inspection device 18 provided on the panel conveyance downstream side with respect to the second bonding device 17, and a second reversing device 19 provided on the panel conveyance downstream side with respect to the second displacement inspection device 18. It is equipped with.

Moreover, the defect inspection position which performs visual inspection (1st visual inspection process) of a defect about the optical member bonding body which bonded the optical member on both surfaces of liquid crystal panel P in the panel conveyance downstream rather than the 2nd inversion apparatus 19. 21 is set.

(First adsorption device)
The first suction device 11 holds the liquid crystal panel P and freely conveys it in the vertical and horizontal directions and aligns the liquid crystal panel P. For example, the first suction device 11 is provided in the panel holding portion 11a. And an alignment camera 11b for detecting the alignment reference.

The panel holding unit 11a holds the upper surface of the liquid crystal panel P transported to the end position of the upstream process by vacuum suction, and transports the liquid crystal panel P in a horizontal state to the starting position of the bonding process (upstream conveyor 6). At that position, the suction is released and the liquid crystal panel P is delivered to the upstream conveyor 6.

Alignment camera 11b images the alignment mark, tip shape, and the like of liquid crystal panel P when, for example, liquid crystal panel P held by panel holding portion 11a is placed on upstream conveyor 6. The imaging data of the alignment camera 11b is transmitted to the control unit 20, and the control unit 20 operates the panel holding unit 11a based on the imaging data. Thereby, alignment of liquid crystal panel P with respect to the upstream conveyor 6 is performed. At this time, positioning of the liquid crystal panel P with respect to the upstream conveyor 6 in the horizontal direction (conveyor width direction) perpendicular to the transport direction, and positioning of the liquid crystal panel P with respect to the upstream conveyor 6 in the rotational direction around the vertical axis Is done.

(First dust collector)
The 1st dust collector 12 is provided in the panel conveyance upstream of the 1st bonding apparatus 13 in proximity to the bonding position of the 1st bonding apparatus 13. The first dust collector 12 removes static electricity and collects dust on the lower surface side of the liquid crystal panel P immediately before being introduced into the bonding position.

(First bonding device)
The 1st bonding apparatus 13 is a 1st optical member along the longitudinal direction of the 1st optical member sheet | seat F1, unwinding the 1st optical member sheet | seat F1 from the original fabric roll R1 in which the 1st optical member sheet | seat F1 was wound. A conveyance device 22 that conveys the sheet F1 and a pressure roll 23 that bonds the optical member separated by the conveyance device 22 from the first optical member sheet F1 to the lower surface of the liquid crystal panel P that the upstream conveyor 6 conveys. .

In the present embodiment, the first optical member sheet F1 is configured to have a width corresponding to the width of the liquid crystal panel P. “Having a width corresponding to the width of the liquid crystal panel P” means that the sheet piece of the bonding sheet obtained by half-cutting the first optical member sheet F1 in the sheet width direction is the size of the display area P4 of the liquid crystal panel P. That is, the size of the substrate of the liquid crystal panel P to which the sheet piece is bonded (the size excluding the functional part such as the electronic component mounting portion on the substrate).

Specifically, the width (length in the short direction) of the first optical member sheet F1 is the same as or wider than the long side of the display area P4 of the liquid crystal panel P, and the liquid crystal on which the sheet piece is bonded. In the substrate of the panel P, it is the same as or narrower than the side corresponding to the long side of the display area P4. The 1st bonding apparatus 13 is the liquid crystal panel P by which the bonding sheet F5 of the 1st optical member sheet | seat F1 is the same as or longer than the short side of the display area P4 of liquid crystal panel P, and a sheet piece is bonded. A sheet piece of the bonding sheet F5 is formed by cutting with a length equal to or shorter than the side corresponding to the short side of the display region P4 in the substrate of the substrate, and on the lower surface of the liquid crystal panel P introduced into the bonding position. On the other hand, the sheet piece of the bonding sheet F5 cut into a predetermined size is bonded.

The “sheet piece of the bonding sheet F5” produced in the first bonding apparatus 13 corresponds to the optical member bonded to the liquid crystal panel P. The optical member produced as described above has such a size that the peripheral edge can be accommodated in the frame G when the liquid crystal panel P is overlapped.

The conveying device 22 is a device that conveys the bonding sheet F5 using the separator sheet F3a as a carrier. The conveying device 22 holds a raw fabric roll R1 around which the belt-shaped first optical member sheet F1 is wound, and rolls out the first optical member sheet F1 along the longitudinal direction of the first optical member sheet F1. A plurality of guide rollers 22b for winding the first optical member sheet F1 to guide the first optical member sheet F1 unwound from the raw roll R1 along a predetermined transport path, and a first optical on the transport path A cutting device 22c for half-cutting the member sheet F1 and a first optical member sheet F1 that has been half-cut are wound at an acute angle to separate the optical member from the separator sheet F3a, and this optical member is supplied to the bonding position. A knife edge 22d that winds and a separator roll R2 that winds up the separator sheet F3a that has become independent after passing through the knife edge 22d. And a Ri section 22e.

In the present embodiment, the “half cut” means that the separator sheet F3a remains in a predetermined thickness so that the separator sheet F3a is not broken by a tension acting during conveyance of the first optical member sheet F1. Indicates that the first optical member sheet F1 is cut from the opposite side to the vicinity of the boundary surface between the adhesive layer F2a and the separator sheet F3a. A cutting blade or a laser device can be used to form the cut.

The roll holding unit 22a positioned at the start point of the transport device 22 and the winding unit 22e positioned at the end point of the transport device 22 are driven in synchronization with each other, for example. Thereby, the winding part 22e winds up the separator sheet F3a having passed through the knife edge 22d while the roll holding part 22a feeds the first optical member sheet F1 in the transport direction of the first optical member sheet F1. Hereinafter, the upstream side in the transport direction of the first optical member sheet F1 (separator sheet F3a) in the transport device 22 is referred to as a sheet transport upstream side, and the downstream side in the transport direction is referred to as a sheet transport downstream side.

Each guide roller 22b changes the traveling direction of the first optical member sheet F1 being conveyed along the conveyance path. At least some of the plurality of guide rollers 22b are movable in order to adjust the tension of the first optical member sheet F1 being conveyed.

When the first optical member sheet F1 is fed out by a predetermined length, the cutting device 22c has one thickness direction of the first optical member sheet F1 over the entire width in the width direction orthogonal to the longitudinal direction of the first optical member sheet F1. Cut the part (half cut).

The cutting device 22c performs cutting so that the first optical member sheet F1 (separator sheet F3a) is not broken by a tension acting during conveyance of the first optical member sheet F1 (so that a predetermined thickness remains on the separator sheet F3a). The advancing / retreating position of the blade is adjusted, and half cutting is performed to the vicinity of the interface between the adhesive layer F2a and the separator sheet F3a.

The first optical member sheet F1 after the half cut is cut along the entire width in the width direction of the first optical member sheet F1 by cutting the bonding sheet F5 in the thickness direction of the first optical member sheet F1. Is formed. A plurality of score lines are formed so as to be aligned in the longitudinal direction of the belt-shaped first optical member sheet F1. For example, in the case of the bonding process which conveys liquid crystal panel P of the same size, a plurality of score lines are formed at equal intervals in the longitudinal direction of the first optical member sheet F1. The first optical member sheet F1 is divided into a plurality of sections in the longitudinal direction by a plurality of cut lines. Each section sandwiched between a pair of cut lines adjacent in the longitudinal direction in the first optical member sheet F1 is a sheet piece in the bonding sheet F5.

The knife edge 22d is disposed below the upstream conveyor 6 and extends at least over the entire width of the first optical member sheet F1 in the width direction of the first optical member sheet F1. The knife edge 22d winds the first optical member sheet F1 so as to be in sliding contact with the separator sheet F3a of the first optical member sheet F1 after the half cut.

The knife edge 22d is in an inclined position as viewed from the width direction of the first optical member sheet F1 (the width direction of the upstream conveyor 6) (that is, has a predetermined angle with respect to the transport direction of the liquid crystal panel P). A first surface disposed; a second surface disposed at an acute angle with respect to the first surface when viewed from the width direction of the first optical member sheet F1 above the first surface; and the first surface and the second surface. And an intersecting tip.

The knife edge 22d winds the first optical member sheet F1 at an acute angle around the tip of the knife edge 22d. The first optical member sheet F1 separates the sheet piece (optical member) of the bonding sheet F5 from the separator sheet F3a when turning back at an acute angle at the tip of the knife edge 22d. The tip end of the knife edge 22d is arranged close to the panel conveyance upstream side of the pinching roll 23. The optical member separated from the separator sheet F3a by the knife edge 22d is introduced between the pair of bonding rollers 23a of the pinching roll 23 while overlapping with the lower surface of the liquid crystal panel P conveyed by the upstream conveyor 6.

The pinching roll 23 has a pair of laminating rollers 23a arranged in parallel with each other in the axial direction. A predetermined gap is formed between the pair of bonding rollers 23 a, and the inside of this gap is the bonding position of the first bonding device 13. In the gap, the liquid crystal panel P and the optical member are overlapped and introduced. The liquid crystal panel P and the optical member are sent out to the downstream side of the panel conveyance while being pressed between the pair of bonding rollers 23a. Thereby, an optical member is integrally bonded to the lower surface of the liquid crystal panel P. Hereinafter, the panel after this bonding is called single-sided bonding panel (optical member bonding body) P11.

(First displacement inspection device)
The 1st shift | offset | difference test | inspection apparatus 14 is whether the position with respect to liquid crystal panel P of the optical member bonded by the 1st bonding apparatus 13 in the single-sided bonding panel P11 is appropriate (whether a position shift exists in a tolerance range). Inspect. The first misalignment inspection apparatus 14 includes, for example, a pair of cameras 14a that capture an image of the edge of the optical member on the upstream side of the single-sided bonding panel P11 and the edge of the optical member on the downstream side of the single-sided bonding panel P11. Have. Imaging data from each camera 14a is transmitted to the control unit 20, and it is determined based on this imaging data whether or not the relative positions of the optical member and the liquid crystal panel P are appropriate. The single-sided bonding panel P11 whose relative position is determined to be inappropriate is discharged out of the system (outside the production line) by a not-shown dispensing means.

(First reversing device)
The first reversing device 15 shown in FIG. 2 includes, for example, a rotation shaft 15a inclined at 45 ° in a plan view with respect to the transport direction of the liquid crystal panel P, and the end position of the upstream conveyor 6 via the rotation shaft 15a. And a reversing arm 15b supported between the initial positions of the downstream conveyor 7. The reversing arm 15b holds the single-sided bonding panel P11 that has reached the end position of the upstream conveyor 6 via the first deviation inspection device 14 by suction or pinching, and rotates 180 ° around the rotation shaft 15a. Thereby, the reversing arm 15b reverses the front and back of the single-sided bonding panel P11 and, for example, transfers the single-sided bonding panel P11 that has been transferred in parallel with the short side of the display area P4 in parallel with the long side of the display area P4. Turn around as you do.

In the above inversion, the polarization axis direction of the optical member F1X bonded to the surface of the liquid crystal panel P and the polarization axis direction of the optical member F1X bonded to the back surface of the liquid crystal panel P are arranged at right angles to each other. Done in case. The upstream conveyor 6 and the downstream conveyor 7 both have the direction from the right side to the left side of the drawing as the transport direction of the liquid crystal panel P. However, the upstream conveyor 6 and the downstream conveyor pass through the first reversing device 15. 7 is offset by a predetermined amount in plan view.

In the case of simply reversing the front and back of the liquid crystal panel P, for example, a reversing device having a reversing arm having a rotation axis parallel to the transport direction may be used. In this case, if the sheet conveying direction of the first laminating device 13 and the sheet conveying direction of the second laminating device 17 are arranged at right angles to each other in a plan view, the liquid crystal panel P and the back surface of the liquid crystal panel P are mutually attached. The optical member F1X whose polarization axis direction is a right angle can be bonded.

The reversing arm 15b has the same alignment function as the panel holding part 11a of the first suction device 11. The first reversing device 15 is provided with an alignment camera 15 c similar to the alignment camera 11 b of the first suction device 11.

(Second dust collector)
Returning to FIG. 1, the second dust collecting device 16 is provided in the vicinity of the bonding position of the second bonding device 17 on the panel conveyance upstream side of the second bonding device 17. The second dust collector 16 removes static electricity and collects dust on the lower surface side of the single-sided bonding panel P11 immediately before being introduced into the bonding position.

(Second bonding device)
The 2nd bonding apparatus 17 is provided with the conveying apparatus 22 and the pinching roll 23 similar to the 1st bonding apparatus 13. FIG. In the 2nd bonding apparatus 17, the optical member formed by cutting the 2nd optical member sheet | seat F2 into a predetermined size is performed with respect to the lower surface of the single-sided bonding panel P11 introduced into the bonding position. .

In the present embodiment, like the first optical member sheet F1 described above, the second optical member sheet F2 is configured to have a width corresponding to the width of the liquid crystal panel P. Specifically, the width (length in the short direction) of the second optical member sheet F2 is the same as or wider than the short side of the display region P4 of the liquid crystal panel P, and the liquid crystal on which the sheet piece is bonded. In the substrate of the panel P, the side corresponding to the short side of the display region P4 is the same as or narrower than the side. The 2nd bonding apparatus 17 is the liquid crystal panel P by which the bonding sheet F5 of the 2nd optical member sheet | seat F2 is the same as or longer than the long side of the display area P4 of liquid crystal panel P, and a sheet piece is bonded. A sheet piece of the bonding sheet F5 is formed by cutting with a length equal to or shorter than the side corresponding to the long side of the display region P4 on the substrate of the liquid crystal panel P introduced into the bonding position. On the other hand, the sheet piece of the bonding sheet F5 cut into a predetermined size is bonded.

The “sheet piece of the bonding sheet F5” produced in the second bonding apparatus 17 corresponds to the optical member bonded to the liquid crystal panel P. The optical member produced as described above has such a size that the peripheral edge can be accommodated in the frame G when the liquid crystal panel P is overlapped.

In the gap between the pair of bonding rollers 23a of the pinching roll 23 (the bonding position of the second bonding device 17), the single-sided bonding panel P11 and the optical member are introduced in an overlapping state, and the single-sided bonding panel An optical member is integrally bonded to the lower surface of P11. Hereinafter, the panel after this bonding is called double-sided bonding panel (optical member bonding body) P12.

Whether the position with respect to liquid crystal panel P of the optical member bonded by the 2nd bonding apparatus 17 in the 2nd bonding panel P12 is the 2nd shift inspection apparatus 18 is appropriate (whether a position shift exists in a tolerance range). Inspect. The second misalignment inspection apparatus 18 includes, for example, a pair of cameras 18a that capture an image of the edge of the optical member on the upstream side of the double-sided bonding panel P12 and the edge of the optical member on the downstream side of the double-sided bonding panel P12. Have. Imaging data from each camera 18a is transmitted to the control unit 20, and based on this imaging data, it is determined whether or not the relative positions of the optical member and the liquid crystal panel P are appropriate. The double-sided bonding panel P12 determined to have an inappropriate relative position is discharged out of the system by a not-shown payout means.

(Second reversing device)
The second reversing device 19 reverses the front and back of the liquid crystal panel P (double-sided bonding panel P12) with the backlight side facing upward via the first reversing device 15 and the liquid crystal is the same as when carrying into the film bonding system 1. The display surface side of the panel P is turned upward.

(Defect inspection position)
At the defect inspection position 21, the presence or absence of a defect is visually inspected for the double-sided bonded panel P12 with the display surface facing upward through the second reversing device 19.

Here, in the manufacturing method of the optical member bonding body of the present embodiment, the “defect” that is the inspection target is a defect that is present in the display area of the double-sided bonding panel P12 and can be optically inspected. In the display device manufactured using the composite panel P12, this indicates a display defect.

Examples of such defects include (1) defects that the liquid crystal panel P itself has, (2) defects that the optical member itself has, and (3) defects that occur on the bonding surface between the liquid crystal panel P and the optical member.

“(1) Defects of the liquid crystal panel P itself” include, for example, that the liquid crystal of the liquid crystal panel P is not aligned as designed due to disturbance of the liquid crystal alignment film of the liquid crystal panel P. When the liquid crystal panel P has such a defect, for example, even if a pair of polarizing plates are accurately bonded to crossed Nicols and the liquid crystal panel P is designed to be normally black, from one side of the double-sided bonded panel P12 When light is irradiated, light leakage occurs, so that defects can be confirmed as bright spots. In visual inspection, light is irradiated from the 1st surface side of the double-sided bonding panel P12, and an inspector observes and judges the presence or absence of a bright spot from the 2nd surface side of the double-sided bonding panel P12. Moreover, also when the liquid crystal panel P is damaged during conveyance, it is mentioned as a defect which (1) liquid crystal panel P itself has.

“(2) Defects of the optical member itself” can include deformations such as scratches and dents formed on the surface of the optical member F1X. In the visual inspection, the inspector observes and judges the presence or absence of scratches or dents.

“(3) Defect generated on the bonding surface between the liquid crystal panel P and the optical member” inserts dust and dust (hereinafter, collectively referred to as “foreign matter”) into the bonding surface between the liquid crystal panel P and the optical member. And defects due to air bubbles being formed between the bonding surfaces. A bonding surface is a bonding surface of liquid crystal panel P and the 1st optical member F11 shown in FIG. 4, and a bonding surface of liquid crystal panel P and the 2nd optical member F12. In the visual inspection, an inspector observes and determines the presence or absence of foreign matter or bubbles.

Since the defect inspection position 21 is set on the downstream conveyor 7, the double-sided bonded panels P12 can be inspected in real time on the production line. For this reason, when defective products are found, the production line is stopped before many defective products are manufactured, and the occurrence position of defective products and measures against the occurrence of defective products can be quickly implemented.

In addition, since the inspector conducts visual inspection, compared with the case of automation using a measuring device, there are false reports (determining a non-defective product as a non-defective product) and oversight (determining a non-defective product as a non-defective product). The result of defect inspection is stable.

In the defect inspection, the line conveyance speed of the double-sided bonding panel P12 is usually higher than the time (speed) required for the inspector to visually inspect one double-sided bonding panel P12. Therefore, it is possible to arrange a plurality of inspectors at the defect inspection position 21 and perform visual inspection by sharing them.

A plurality of inspectors may be arranged in a line in the extending direction of the downstream conveyor 7 for inspection. After setting up a plurality of inspection lines, an inspector is arranged on the plurality of inspection lines, and the double-sided bonding panel P12 conveyed is distributed to each inspection line, so that inspection can be performed on each inspection line. Good.

About the double-sided bonding panel P12 which was inspected at the defect inspection position 21 and no defect was found, it is transported to the downstream side by the downstream conveyor 7 and is carried out of the production line of the film bonding system 1.

Also, defective products that have been inspected at the defect inspection position 21 and found to be defective can be removed from the production line without being returned to the downstream conveyor 7 and subjected to the following regeneration processing outside the production line (offline).

(Reproduction processing)
For defective products, first, the type and state of the found defect are confirmed, and it is determined whether or not the defect can be eliminated by performing subsequent processing. Next, one of the following two processes is selected according to the state of the defect, and the process is performed.

Of the “(2) Defects of the optical member itself”, the defects are small deformations of the optical member itself and “(3) Defects occurring on the bonding surface between the liquid crystal panel P and the optical member”. In the case where the air bubbles are sandwiched between the optical member and the optical member and the air bubbles are very small, an autoclave treatment is performed to heat and press the defective product.

“Autoclave treatment” refers to exposing a defective product to be treated to a temperature higher than room temperature in a pressurized environment higher than atmospheric pressure and holding it for a certain period of time. As an example, the processing condition is a pressure condition of 0.294 MPa or more and 0.785 MPa or less (3 kgf / cm ² or more and 8 kgf / cm ² or less), and holding at a temperature condition of 40 ° C. or more and 80 ° C. or less for 30 seconds or more and 25 minutes or less. Time is mentioned.

The pressure conditions can than 0.392MPa (4kgf / cm ² or more) 0.588MPa or less (6 kgf / cm ² or less).
The temperature condition can be 50 ° C. or higher and 70 ° C. or lower.
The holding time can be 1 minute or more and 5 minutes or less.
The upper limit value and the lower limit value of the processing conditions can be arbitrarily combined.
In addition, said numerical value is an example and is not limited to this.

Also, “holding time” refers to the time from when the pressure in the chamber 101 becomes equal to or higher than the set values for pressure and temperature until either one of the pressure or temperature falls below the set value. Therefore, even if one or both of the pressure and temperature fluctuate, if the pressure and temperature are equal to or higher than a set value, the processing time under that condition is included in the holding time.

When the defect of the defective product is a small deformation of the optical member itself, when the autoclave treatment is performed, the optical member is softened and easily deformed by heat. Thereby, it can be expected that a small deformation causing the defect disappears.

Moreover, when the defect which a defective article has is the bubble which pinched | interposed air on the bonding surface and was produced, the saturated solubility of the air in the sheet piece of the adhesion layer F2a (refer FIG. 5) which an optical member has with heat and pressure. Therefore, the air forming the bubbles melts into the sheet piece of the adhesive layer F2a. Thereby, it can be expected that bubbles disappear.

Further, since the air dissolved in the sheet piece of the adhesive layer F2a diffuses into the sheet piece of the adhesive layer F2a, even if the defective product is returned to room temperature under atmospheric pressure after the autoclave treatment, the position where the lost bubbles existed In addition, it can be expected that air will not aggregate again and bubbles will not be regenerated.

Therefore, when it is judged that the defect of the defective product is a minute one and disappears by autoclaving, the defective product is subjected to autoclaving to eliminate the defect.

On the other hand, the defect that the defective product has is a large deformation of the optical member itself among “(2) Defects of the optical member itself” or “(3) Defects that occur on the bonding surface of the liquid crystal panel P and the optical member. ”In the case where the air bubbles are sandwiched between the liquid crystal panel P and the optical member and are large, or if the defect is caused by the foreign matter sandwiched in the pasting surface, the above autoclave In the process, it is expected that defects will not disappear.

In that case, the optical member is peeled from the defective product to expose the liquid crystal panel P, a new sheet piece is bonded to the exposed liquid crystal panel P, and a rework process is performed to form a new double-sided bonded panel P12. .

In addition, the defect that the defective product has is “(1) the defect that the liquid crystal panel P itself has” such as damage to the liquid crystal panel P, and if it is determined that it cannot be regenerated by the autoclave process or the rework process, the defective product is discarded. To do.

Such a regeneration processing step is performed separately from the above production line (offline processing). Therefore, it is possible to spend a sufficient amount of time for each process, and reduction of waste products can be expected.

About the double-sided bonding panel P12 which passed through the reproduction | regeneration processing process, the presence or absence of a defect is test | inspected in the visual inspection (2nd visual inspection process) isolate | separated from the above-mentioned manufacturing line. If a defect is not found, it will be carried out to the next process as a finished product double-sided bonding panel P12.

Also, in the second visual inspection process, if a defect is found and determined as a defective product, the process is returned to the above-described regeneration processing process again to attempt regeneration.

(Manufacturing method of an optical member bonding body)
Drawing 6 is an explanatory view about a manufacturing method of an optical member pasting object in this embodiment, and is a flow figure showing a manufacturing process mentioned above. Hereinafter, the manufacturing flow will be described using the reference numerals shown in FIG. 1 as appropriate.

In the flowchart, the process indicated by reference sign S1 indicates a process performed within the manufacturing line, and the process indicated by reference sign S2 indicates a process performed outside the manufacturing line.

(Optical member bonding body formation process)
First, in the manufacture of the double-sided bonded panel P12, the liquid crystal panel P is carried into the production line (step S11), and dirt such as dust and dust adhering to the surface of the liquid crystal panel P is washed (step S12).

Next, in the above-described film bonding system 1, the first optical member sheet F1 and the second optical member sheet F2 are unwound from the raw roll R1, respectively, while the first optical member sheet F1 and the second optical member sheet F2 are unwound. Each of the first optical member F11 and the second optical member F12 is formed by cutting to a length corresponding to the long side or the short side of the display region P4. Here, “cut to the length corresponding to the long side or the short side of the display region P4” means that the size of the sheet piece obtained by cutting is equal to or larger than the size of the display region P4 of the liquid crystal panel P. And the long side of the display area P4 is not larger than the size of the substrate of the optical display component to which the sheet piece is bonded (the size excluding the functional part such as the electronic component mounting portion on the substrate). The length or sheet piece corresponding to the long side of the display region P4 of the substrate of the liquid crystal panel P to which the sheet piece is pasted is longer than the length or the length of the short side of the display region P4. This means that the substrate of the liquid crystal panel P is cut with a length equal to or shorter than the length corresponding to the short side of the display region P4.

Thereafter, the first optical member F11 is bonded to the first surface of the liquid crystal panel P, and the second optical member F12 is bonded to the second surface of the liquid crystal panel P to form a double-sided bonding panel P12 (step S13).

(First visual inspection process)
Then, about the obtained double-sided bonding panel P12, the visual inspection of a defect is performed in a manufacturing line (inline) (step S14).
In this embodiment, a 1st visual inspection process is performed in the manufacturing line continuous with the optical member bonding body formation process. In other words, the optical member bonded body forming step and the first visual inspection step are performed on the same production line. In other words, the optical member bonded body forming step and the first visual inspection step are performed in the production line (inline).

As a result of the visual inspection, the double-sided bonded panel P12 determined to be non-defective is, for example, collected for a plurality of sheets and then carried out for the next process (step S15).

(Regeneration process)
On the other hand, as for the double-sided bonded panel P12 determined as a defective product having defects as a result of visual inspection, the type and state of the found defects are confirmed outside the production line (offline), and the subsequent processing is performed to obtain defects. It is determined whether or not it can be lost (step S21).

When the defect of the defective product is a small object that is a small deformation of the optical member itself or air bubbles that are sandwiched between the liquid crystal panel P and the optical member (“defect / small” in the flow diagram) And an autoclave process is performed (step S22).

On the other hand, when the defect of the defective product is a large object that is a large deformation of the optical member itself or air bubbles that are sandwiched between the liquid crystal panel P and the optical member (in the flow diagram, “defect / medium And rework processing is performed (step S23).

In addition, if it is determined that the defect of the defective product is one that cannot be regenerated by the autoclave process or the rework process, such as damage to the liquid crystal panel P (denoted as “defect / large” in the flow diagram), discard it. .

Next, a visual inspection for defects is performed on the double-sided bonded panel P12 that has been subjected to autoclave processing or rework processing (second visual inspection step, step S24).

If a defect is not found, it will be carried out to the next process as a finished product double-sided bonding panel P12. If a defect is found and determined as a defective product, the process returns to step S21 again, and reproduction is attempted again through the reproduction process.
The manufacturing method of the optical member bonding body of this embodiment is performed as mentioned above.

According to the manufacturing method of the optical member bonding body as described above, the inspector sequentially inspects the optical member bonding body conveyed on the line by visual inspection. In visual inspection by an inspector, there is less possibility of overkill compared to the case of performing defect inspection with a commercially available optical automatic inspection device, and the accuracy of defect inspection is at an appropriate level according to actual use. Kept.

Also, since inspectors are arranged on the production line and the products are inspected sequentially, the occurrence of defective products on the production line can be detected in a short time from the occurrence of defective products. Therefore, the generation of defective products can be suppressed, and the manufacturing yield can be improved.

Therefore, according to the manufacturing method of the optical member bonding body of the present embodiment, the optical member bonding that enables defect detection with accuracy with no excess or deficiency in actual use and that can be stably manufactured without impairing the manufacturing yield. A method for producing a coalescence is provided.

The present invention is not limited to the above embodiment. For example, in the above embodiment, the case where the polarizing film is bonded to the liquid crystal panel has been described. However, the optical display component to which the optical member is bonded is not limited to the liquid crystal panel, and can be an organic EL panel, and the optical member to be bonded. Is not limited to a polarizing film, and can be an antireflection film, a light diffusion film, or the like.

In this embodiment, the visual inspection is performed after the optical member is bonded to both surfaces of the liquid crystal panel P. However, the visual inspection can also be performed after the optical member is bonded to one surface.

In the present embodiment, the defective product detected in the second visual inspection process is subjected to the regeneration process again. However, if the regeneration process is performed a plurality of times, the heat history increases and the optical member is attached. Since the quality of coalescence is likely to deteriorate, defective products detected in the second visual inspection process may be discarded.

However, from the viewpoint of improving yield, it is better to have fewer waste products. For example, an upper limit value that can be applied to the regeneration process step is set in advance, and defective products that have passed the regeneration process step a set number of times. It is good practice to discard them.

[Second Embodiment]
Drawing 7 is an explanatory view showing the production system of other optical member bonding objects used for implementation of the manufacturing method of the optical member bonding object concerning this embodiment. FIG. 7: is a schematic block diagram about the film bonding system 2 which comprises a part of production system of an optical member bonding body, and is a figure corresponding to FIG. In FIG. 7, for convenience of illustration, the film bonding system 2 is described in two upper and lower stages. In the following description, detailed description of contents common to the above description is omitted.

In the film bonding system 2 shown in FIG. 7, the width | variety (length of a transversal direction) of the strip | belt-shaped 1st optical member sheet | seat F1 is wider than the long side of the display area P4 of liquid crystal panel P. FIG. In addition, the width (length in the short direction) of the band-shaped second optical member sheet F2 is wider than the short side of the display region P4 of the liquid crystal panel P.

In such a film bonding system 2, the bonding sheet F5 of the belt-shaped first optical member sheet F1 is cut out with a length longer than the short side of the display region P4 of the liquid crystal panel P to produce the first sheet piece F1m. Then, the liquid crystal panel P is bonded to the liquid crystal panel P during the conveyance of the liquid crystal panel P using the roller conveyor 5. Similarly, the bonding sheet F5 of the band-shaped second optical member sheet F2 is cut out with a length longer than the long side of the display area P4 of the liquid crystal panel P to produce a second sheet piece F2m, and the roller conveyor 5 is used. The liquid crystal panel P is bonded to the liquid crystal panel P while it is being transported. In the following description, the first sheet piece F1m and the second sheet piece F2m may be collectively referred to as “sheet piece FXm”.

After that, the first optical member F11 is formed by separating the excess portion of the first sheet piece F1m located outside the display area P4 of the liquid crystal panel P when being bonded to the liquid crystal panel P from the first sheet piece F1m. Moreover, the 2nd optical member F12 is formed by cut | disconnecting the excess part of the 2nd sheet piece F2m located outside the display area P4 of the liquid crystal panel P from the 2nd sheet piece F2m when it bonds to the liquid crystal panel P. Each part of the film bonding system 2 is comprehensively controlled by a control unit (not shown).

The film bonding system 2 includes a first suction device 11 that sucks the liquid crystal panel P transported to the carry-out end of the preceding step and transports it to the carry-in end of the upstream conveyor 6 and performs alignment (positioning) of the liquid crystal panel P. The 1st dust collector 12 provided in the panel conveyance downstream of the 1st adsorption | suction apparatus 11, the 1st bonding apparatus 13 provided in a panel conveyance downstream rather than the 1st dust collector 12, and the 1st bonding apparatus The first reversing device 31A disposed on the panel transport downstream side with respect to 13, the first cutting device 32A disposed on the panel transport downstream side with respect to the first reversing device 31A, and the panel transport downstream with respect to the first cutting device 32A. A recovery device (not shown) disposed at the first recovery position 33A on the side, and a first swivel device 34 disposed on the downstream side of the panel transport with respect to the recovery device.

Moreover, the film bonding system 2 is arrange | positioned in the panel conveyance downstream rather than the 2nd dust collector 16 and the 2nd dust collector 16 arrange | positioned in the panel conveyance downstream rather than the carrying-in end of the downstream conveyor 7. FIG. The 2nd bonding apparatus 17, the 2nd inversion apparatus 31B arrange | positioned in the panel conveyance downstream rather than the 2nd bonding apparatus 17, and the 2nd cutting apparatus arrange | positioned in the panel conveyance downstream rather than the 2nd inversion apparatus 31B. 32B, a collection device (not shown) disposed at the second collection position 33B on the downstream side of the panel conveyance with respect to the second cutting device 32B, and a second turning device 35 disposed on the downstream side of the conveyance of the panel with respect to the collection device. It is equipped with.

Further, on the downstream side of the panel transport with respect to the second turning device 35, a defect inspection position 21 for performing a visual inspection for defects is set for the optical member bonded body in which the optical member is bonded to both surfaces of the liquid crystal panel P.

Further, as will be described in detail later, a detection device used for setting a cut position in the first cutting device 32A is provided on the panel conveyance upstream side of the first cutting device 32A. A detection device used for setting a cut position in the second cutting device 32B is provided on the upstream side of the second cutting device 32B on the panel conveyance.

(First bonding device)
The 1st bonding apparatus 13 bonds the sheet piece (1st sheet piece F1m) of the bonding sheet | seat F5 cut into the predetermined size with respect to the lower surface of liquid crystal panel P introduced into the bonding position.

The 1st bonding apparatus 13 is a 1st optical member along the longitudinal direction of the 1st optical member sheet | seat F1, unwinding the 1st optical member sheet | seat F1 from the original fabric roll R1 in which the 1st optical member sheet | seat F1 was wound. A conveying device 22 that conveys the sheet F1, and a pressure roll that bonds the first sheet piece F1m separated by the conveying device 22 from the first optical member sheet F1 to the lower surface of the liquid crystal panel P conveyed by the upstream conveyor 6. 23.

The conveying device 22 is a device that conveys the bonding sheet F5 using the separator sheet F3a as a carrier. The transport device 22 includes a roll holding unit 22a, a plurality of guide rollers 22b, a cutting device 22c that performs a half cut on the first optical member sheet F1 on the transport path, and a first optical member sheet F1 that has been subjected to a half cut. It has a knife edge 22d that feeds the first sheet piece F1m to the bonding position while peeling off the first sheet piece F1m from the separator sheet F3a by winding at an acute angle, and a winding part 22e.

The first optical member sheet F1 has a width wider than the width of the liquid crystal panel P in a plan view in a horizontal direction (sheet width direction) orthogonal to the transport direction of the first optical member sheet F1.

The cutting device 22c is configured such that the length of the display area P4 in the length direction perpendicular to the sheet width direction of the first optical member sheet F1 (the length of either the long side of the display area P4 or the short side of the display area P4, In the embodiment, every time a length longer than the short side length of the display area P4 is extended, the first optical member sheet F1 is half-cut across the entire width along the sheet width direction. Thereby, the 1st sheet piece F1m larger than the display area P4 of liquid crystal panel P is formed from the bonding sheet | seat F5 which the 1st optical member sheet | seat F1 has.

The first optical member sheet F1 after the half cut is formed with a cut line in which at least the optical member main body F1a and the surface protection film F4a are cut in the thickness direction over the entire width in the width direction of the first optical member sheet F1. The The cut lines are formed at intervals having a length corresponding to the short side length of the display region P4 in the longitudinal direction of the belt-shaped first optical member sheet F1. The first optical member sheet F1 is divided into a plurality of sections in the longitudinal direction by the plurality of score lines. In the 1st optical member sheet | seat F1, each division part pinched | interposed into a pair of cutting line adjacent in a longitudinal direction turns into 1st sheet piece F1m.

The size of the first sheet piece F1m can be larger than the liquid crystal panel P, for example. In the first sheet piece F1m, the size of the portion that protrudes outside the liquid crystal panel P (the size of the surplus portion of the first sheet piece F1m) is appropriately set according to the size of the liquid crystal panel P. For example, when the first sheet piece F1m is applied to a medium to small size liquid crystal panel P of 5 to 10 inches, one side of the first sheet piece F1m and one side of the liquid crystal panel P at each side of the first sheet piece F1m Is set to a length in the range of 2 mm to 5 mm.
In addition, said numerical value is an example and is not limited to this.

The knife edge 22d is disposed below the upstream conveyor 6 and extends over at least the entire width in the width direction of the first optical member sheet F1. The first optical member sheet F1 is wound around the knife edge 22d so that the separator sheet F3a of the first optical member sheet F1 after the half cut comes into sliding contact with the knife edge 22d.
The first optical member sheet F1 peels the separator sheet F3a from the first sheet piece F1m when the traveling direction changes so as to be bent at an acute angle at the tip of the knife edge 22d. The front end portion of the knife edge 22d is disposed close to the upstream side of the sandwiching roll 23 in the panel conveyance, and the first sheet piece F1m peeled from the separator sheet F3a by the knife edge 22d is transferred to the upstream conveyor 6 by the liquid crystal panel P. It is introduced between the pair of laminating rollers 23 a of the pinching roll 23 while overlapping with the lower surface of.

The pinching roll 23 has a pair of laminating rollers 23a arranged in parallel with each other in the axial direction. A predetermined gap is formed between the pair of bonding rollers 23 a, and the position of this gap becomes the bonding position of the first bonding device 13. The liquid crystal panel P and the first sheet piece F1m are introduced into the gap between the pair of bonding rollers 23a so that the liquid crystal panel P and the first sheet piece F1m are sandwiched between the pair of bonding rollers 23a. It is sent out downstream. Thereby, the 1st sheet piece F1m is integrally bonded by the lower surface of liquid crystal panel P, and it becomes 1st optical member bonding body (bonding body) PA1.

(First reversing device)
31 A of 1st inversion apparatuses convey the 1st optical member bonding body PA1 to the cutting position of the 1st cutting device 32A, reverse the front and back of 1st optical member bonding body PA1 at the time of this conveyance, and 1st of liquid crystal panel P The sheet piece F1m is transferred to the first cutting device 32A in a state where the upper surface is the bonded surface.

(First cutting device)
32 A of 1st cutting devices cut off the surplus part arranged outside the part corresponding to the pasting surface of liquid crystal panel P and the 1st sheet piece F1m from the 1st sheet piece F1m pasted on liquid crystal panel P, The 1st optical member F11 (refer FIG. 4) of the magnitude | size corresponding to the bonding surface of liquid crystal panel P and 1st sheet piece F1m is formed. The first optical member is placed on one of the front surface of the liquid crystal panel P and the back surface of the liquid crystal panel P by separating the excess portion of the first sheet piece F1m from the first optical member bonding body PA1 by the first cutting device 32A. 2nd optical member bonding body PA2 formed by F11 being bonded is formed.
The configuration of the first cutting device 32A will be described in detail later.

(Recovery device)
A collection device (not shown) disposed at the first collection position 33A holds, for example, an excess portion cut by the first cutting device 32A and peels off from the first optical member F11 formed by the first cutting device 32A. Then, the unnecessary surplus part is collected. After the recovery process of the surplus portion, the second optical member bonding body PA2 moves in the direction of the first turning device 34. Note that the recovery device may not be used as long as the cut surplus portion is removed by free fall during cutting by the first cutting device 32A.

(First turning device)
The first swivel device 34 holds the second optical member bonding body PA2 that has reached the carry-out end of the upstream conveyor 6 via the first cutting device 32A by suction or pinching, and the second optical member bonding body PA2 is displayed. The second optical member bonding body PA2 is turned so as to be conveyed in the direction along the long side of the region P4. Thereby, the polarizing axis of the polarizing film bonded to the surface of the liquid crystal panel P and the polarizing axis of the polarizing film bonded to the back surface of the liquid crystal panel P become perpendicular to each other.

The first turning device 34 includes an alignment camera 34c similar to the alignment camera 11b of the first suction device 11, and has the same alignment function as the panel holding portion 11a of the first suction device 11.

(Second bonding device)
The 2nd bonding apparatus 17 is the bonding of the sheet piece (2nd sheet piece F2m) of the bonding sheet | seat F5 cut into predetermined size with respect to the lower surface of 2nd optical member bonding body PA2 introduced into the bonding position. Do a match. The 2nd bonding apparatus 17 is provided with the conveying apparatus 22 and the pinching roll 23 similar to the 1st bonding apparatus 13. FIG.

The cutting device 22c of the 2nd bonding apparatus 17 is the length of the display area P4 in the length direction in which the 2nd optical member sheet | seat F2 used with the 2nd bonding apparatus 17 orthogonally crosses the sheet width direction (the long side of the display area P4). And the length of one of the short sides of the display area P4, which is longer than the length of the long side of the display area P4 in this embodiment), is extended over the entire width along the sheet width direction. 2. Half cut is applied to the optical member sheet F2. Thereby, the 2nd sheet piece F2m larger than the display area P4 of liquid crystal panel P is formed from the bonding sheet | seat F5 which the 2nd optical member sheet | seat F2 has.

Cut lines are formed in the second optical member sheet F2 after the half cut at intervals having a length corresponding to the long side length of the display region P4 in the longitudinal direction of the band-shaped second optical member sheet F2. The second optical member sheet F2 is divided into a plurality of sections in the longitudinal direction by the plurality of score lines. In the 2nd optical member sheet | seat F2, each division part pinched | interposed into a pair of cutting line adjacent in a longitudinal direction turns into 2nd sheet piece F2m.

The size of the second sheet piece F2m can be made larger than the liquid crystal panel P, for example. In the second sheet piece F2m, the size of the portion that protrudes outside the liquid crystal panel P (the size of the surplus portion of the second sheet piece F2m) is appropriately set according to the size of the liquid crystal panel P. For example, when the second sheet piece F2m is applied to a medium-to-small size liquid crystal panel P of 5 inches to 10 inches, one side of the second sheet piece F2m and one side of the liquid crystal panel P at each side of the second sheet piece F2m Is set to a length in the range of 2 mm to 5 mm.
In addition, said numerical value is an example and is not limited to this.

The pinching roll 23 has a pair of bonding rollers 23a arranged in parallel with each other in the axial direction. A predetermined gap is formed between the pair of bonding rollers 23a. It becomes the bonding position of the combination device 17. In the gap, the second optical member bonding body PA2 and the second sheet piece F2m are introduced in an overlapping state, and the second optical member bonding body PA2 and the second sheet piece F2m are sandwiched between the pair of bonding rollers 23a. It is sent out to the panel conveyance downstream side while being pressed. Thereby, 2nd sheet piece F2m is integrally bonded by the lower surface (surface on the opposite side to the surface where 1st optical member F11 of 2nd optical member bonding body PA2 was bonded) of 2nd optical member bonding body PA2. It becomes a 3rd optical member bonding body (bonding body) PA3.

(Second reversing device)
The second reversing device 31B conveys the third optical member bonding body PA3 to the cutting position of the second cutting device 32B, reverses the front and back of the third optical member bonding body PA3 during the conveyance, and the second of the liquid crystal panel P. The sheet piece F2m is transferred to the second cutting device 32B in a state where the surface on which the sheet piece F2m is bonded is used as the upper surface.

(Second cutting device)
The 2nd cutting device 32B is the surplus arrange | positioned on the outer side of the part corresponding to the bonding surface of liquid crystal panel P and 2nd sheet piece F2m from 2nd sheet piece F2m bonded by 3rd optical member bonding body PA3. A part is cut | disconnected and the 2nd optical member F12 (refer FIG. 4) of the magnitude | size corresponding to the bonding surface of liquid crystal panel P and the 2nd sheet piece F2m is formed. The second cutting device 32B separates the excess portion of the second sheet piece F2m from the third optical member bonding body PA3, so that the second surface is either the front surface of the liquid crystal panel P or the back surface of the liquid crystal panel P. 4th optical member bonding body (1st optical member F11 is bonded and formed in the 1st surface which is either the surface of liquid crystal panel P, or the back surface of liquid crystal panel P, and optical member F12 is bonded. Optical member bonding body) PA4 is formed.

The first cutting device 32A and the second cutting device 32B are, for example, CO ₂ laser cutters. The first cutting device 32A separates the surplus portion arranged outside the portion corresponding to the bonding surface of the liquid crystal panel P and the first sheet piece F1m from the first sheet piece F1m, and the liquid crystal panel P and the first sheet The 1st optical member F11 of the magnitude | size corresponding to the bonding surface with piece F1m is formed. The second cutting device 32B separates the surplus portion arranged outside the portion corresponding to the bonding surface of the liquid crystal panel P and the second sheet piece F2m from the second sheet piece F2m, and the liquid crystal panel P and the second sheet The 2nd optical member F12 of the magnitude | size corresponding to the bonding surface with piece F2m is formed.

The cutting device 32 (the first cutting device 32A and the second cutting device 32B may be collectively referred to as “cutting device 32”) is bonded to the liquid crystal panel P and the liquid crystal panel P detected by the detection device described later. The sheet piece FXm bonded to the liquid crystal panel P is cut endlessly along the outer peripheral edge of the bonded surface of the sheet piece FXm. Outside the display area P4, there is provided a frame portion G (see FIG. 4) having a predetermined width for arranging a sealant or the like for joining the first substrate P1 of the liquid crystal panel P and the second substrate P2 of the liquid crystal panel P. The sheet piece FXm is cut by the cutting device 32 within the width of the frame portion G.

Such detection of the outer periphery of the bonding surface and cutting with a cutting device are performed in detail as follows.

FIG. 8 is a schematic diagram of the first detection device 61 that detects the outer peripheral edge of the bonding surface. The 1st detection apparatus 61 with which the film bonding system 2 of this embodiment is provided is the bonding surface (henceforth, 1st bonding surface (below) of liquid crystal panel P and 1st sheet piece F1m in 1st optical member bonding body PA1. Bonding surface) may be referred to as SA1.) An imaging device 63 that captures an image of the outer peripheral edge ED, an illumination light source 64 that illuminates the outer peripheral edge ED, an image that is captured by the imaging device 63, and an image And a control unit 65 that performs calculation for detecting the outer peripheral edge ED.

Such a first detection device 61 is provided on the upstream side of the panel conveyance of the first cutting device 32A in FIG. 7, and is provided between the first reversing device 31A and the first cutting device 32A.

The imaging device 63 is fixed and arranged inside the first bonding surface SA1 with respect to the outer peripheral edge ED, and the normal line of the first bonding surface SA1 and the normal line of the imaging surface 63a of the imaging device 63 are arranged. The posture is inclined so as to form an angle θ (hereinafter referred to as an inclination angle θ of the imaging device 63). The imaging device 63 directs the imaging surface 63a to the outer peripheral edge ED, and captures an image of the outer peripheral edge ED from the side on which the first sheet piece F1m is bonded in the first optical member bonding body PA1.

The inclination angle θ of the imaging device 63 can be set so that the outer peripheral edge of the first substrate P1 constituting the first bonding surface SA1 can be reliably imaged. For example, in the case where the liquid crystal panel P is formed by so-called multiple chamfering that divides the mother panel into a plurality of liquid crystal panels, the first substrate P1 constituting the liquid crystal panel P and the second substrate P2 constituting the liquid crystal panel P. And the end surface of the second substrate P2 may be shifted outward from the end surface of the first substrate P1. In such a case, the inclination angle θ of the imaging device 63 can be set so that the outer peripheral edge of the second substrate P2 does not enter the imaging field of the imaging device 63.

In such a case, the inclination angle θ of the imaging device 63 is adapted to the distance between the first bonding surface SA1 and the center of the imaging surface 63a of the imaging device 63 (hereinafter referred to as the height H of the imaging device 63). Can be set to. For example, when the height H of the imaging device 63 is 50 mm or more and 100 mm or less, the inclination angle θ of the imaging device 63 can be set to an angle in the range of 5 ° or more and 20 ° or less. However, when the deviation amount is empirically known, the height H of the imaging device 63 and the inclination angle θ of the imaging device 63 can be obtained based on the deviation amount. In the present embodiment, the height H of the imaging device 63 is set to 78 mm, and the inclination angle θ of the imaging device 63 is set to 10 °.
In addition, said numerical value is an example and is not limited to this.

The inclination angle θ of the imaging device 63 may be 0 °. FIG. 9 is a schematic diagram illustrating a modification of the first detection device 61, and is an example in the case where the inclination angle θ of the imaging device 63 is 0 °. In this case, each of the imaging device 63 and the illumination light source 64 may be disposed at a position overlapping the outer peripheral edge ED along the normal direction of the first bonding surface SA1.

The distance between the first bonding surface SA1 and the center of the imaging surface 63a of the imaging device 63 (hereinafter referred to as the height H1 of the imaging device 63) is easy to detect the outer peripheral edge ED of the first bonding surface SA1. Can be set to position. For example, the height H1 of the imaging device 63 can be set in the range of 50 mm or more and 320 mm or less.
In addition, said numerical value is an example and is not limited to this.

The illumination light source 64 is fixed and arranged on the side opposite to the side on which the first sheet piece F1m is bonded in the first optical member bonded body PA1. The illumination light source 64 is arrange | positioned rather than the outer periphery ED on the outer side of 1st bonding surface SA1. In the present embodiment, the optical axis of the illumination light source 64 and the normal line of the imaging surface 63a of the imaging device 63 are parallel.

In addition, the illumination light source 64 may be arrange | positioned at the side (namely, the same side as the imaging device 63) by which the 1st sheet piece F1m in 1st optical member bonding body PA1 was bonded.

If the outer peripheral edge ED imaged by the imaging device 63 is illuminated by the illumination light emitted from the illumination light source 64, the optical axis of the illumination light source 64 and the normal line of the imaging surface 63a of the imaging device 63 intersect. It may be.

FIG. 10 is a plan view showing a position for detecting the outer peripheral edge of the bonding surface. Inspection area | region CA is set on the conveyance path | route of 1st optical member bonding body PA1 shown to a figure. Inspection area | region CA is set in the position corresponding to the outer periphery ED of 1st bonding surface SA1 in the liquid crystal panel P conveyed. In the figure, the inspection area CA is set at four locations corresponding to the four corners of the rectangular first bonding surface SA1 in plan view, and the corners of the first bonding surface SA1 are detected as the outer peripheral edge ED. It is the composition to do. In the figure, among the outer peripheral edges of the first bonding surface SA1, the hook-shaped part corresponding to the corner is shown as the outer peripheral edge ED.

8 detects the outer periphery ED in the four inspection areas CA. Specifically, the imaging device 63 and the illumination light source 64 are arranged in each inspection area CA, and the first detection device 61 has a corner portion of the first bonding surface SA1 for each liquid crystal panel P to be transported. And the outer peripheral edge ED is detected based on the imaging data. Data of the detected outer peripheral edge ED is stored in the control unit 65 shown in FIG.

In addition, if the outer periphery of 1st bonding surface SA1 is detectable, the setting position of inspection area | region CA is not restricted to this. For example, each inspection area | region CA may be arrange | positioned in the position corresponding to a part (for example, center part of each side) of each edge | side of 1st bonding surface SA1. In this case, it becomes the structure which detects each edge | side (four sides) of 1st bonding surface SA1 as an outer periphery.

In addition, the imaging device 63 and the illumination light source 64 are not limited to the configuration arranged in each inspection area CA, and are configured to be able to move along a movement path set along the outer peripheral edge ED of the first bonding surface SA1. It may be. In this case, the imaging device 63 and the illumination light source 64 are configured to detect the outer peripheral edge ED when the imaging device 63 and the illumination light source 64 are positioned in each inspection area CA, so that one imaging device 63 and one illumination light source 64 are provided. In this case, the outer periphery ED can be detected.

The cutting position for the first sheet piece F1m by the first cutting device 32A is set based on the detection result of the outer peripheral edge ED of the first bonding surface SA1.

For example, the control unit 65 shown in FIG. 8 is configured such that the first optical member F11 is outside the liquid crystal panel P (the outside of the first bonding surface SA1) based on the stored data of the outer peripheral edge ED of the first bonding surface SA1. ), The cut position of the first sheet piece F1m can be set so as not to protrude. Further, the setting of the cut position is not necessarily performed by the control unit 65 of the first detection device 61, and may be performed by using a calculation unit separately using the data of the outer peripheral edge ED detected by the first detection device 61. I do not care.

The first cutting device 32A cuts the first sheet piece F1m at the cutting position set by the control unit 65.

Returning to FIG. 7, the first cutting device 32 </ b> A includes a portion corresponding to the first bonding surface SA <b> 1 in the first sheet piece F <b> 1 m bonded to the liquid crystal panel P and an extra portion outside the first bonding surface SA <b> 1. Are cut along a cut position set based on the detected outer peripheral edge ED, and a first optical member F11 (see FIG. 4) having a size corresponding to the first bonding surface SA1 is cut out. Thereby, 2nd optical member bonding body PA2 by which the 1st optical member F11 overlapped and bonded on the upper surface of liquid crystal panel P is formed.

Here, the “part corresponding to the first bonding surface SA1” means the outer peripheral shape (contour shape in plan view) of the liquid crystal panel P that is equal to or larger than the size of the display area of the liquid crystal panel P facing the first sheet piece F1m. ) And a region that avoids a functional part such as an electric component mounting portion in the liquid crystal panel P.

In the present embodiment, the surplus portion is laser-cut along the outer peripheral edge of the liquid crystal panel P at three sides excluding the functional portion in the liquid crystal panel P having a rectangular shape in plan view, and the liquid crystal panel P at one side corresponding to the functional portion. It is possible to adopt a configuration in which the surplus portion is laser-cut at a position that appropriately enters the display region P4 side from the outer peripheral edge. For example, when the first substrate P1 is a TFT substrate, it is possible to adopt a configuration in which a cut is made at a position shifted by a predetermined amount from the outer peripheral edge of the liquid crystal panel P to the display region P4 side so as to exclude the functional portion on one side corresponding to the functional portion.

FIG. 11 is a schematic diagram of the second detection device 62 that detects the outer peripheral edge of the bonding surface. The 2nd detection apparatus 62 with which the film bonding system 2 of this embodiment is provided is the bonding surface (henceforth the 2nd bonding surface (below) of liquid crystal panel P and 2nd sheet piece F2m in 3rd optical member bonding body PA3. The image pickup device 63 that picks up the image of the outer peripheral edge ED of the bonding surface) SA2), the illumination light source 64 that illuminates the outer peripheral edge ED, and the image picked up by the image pickup device 63 are stored in the image. And a control unit 65 that performs calculation for detecting the outer peripheral edge ED. The second detection device 62 has the same configuration as the first detection device 61 described above.

Such a second detection device 62 is provided on the upstream side of the panel conveyance of the second cutting device 32B in FIG. 7, and is provided between the second reversing device 31B and the second cutting device 32B. The 2nd detection apparatus 62 detects the outer periphery ED of 2nd bonding surface SA2 similarly to the above-mentioned 1st detection apparatus 61 in the test | inspection area | region set on the conveyance path | route of 3rd optical member bonding body PA3. .

The cutting position of the second sheet piece F2m by the second cutting device 32B is set based on the detection result of the outer peripheral edge ED of the second bonding surface SA2.

For example, the control unit 65 shown in FIG. 11 is configured such that the second optical member F12 is outside the liquid crystal panel P (the outside of the second bonding surface SA2) based on the stored data of the outer peripheral edge ED of the second bonding surface SA2. ), The cut position of the second sheet piece F2m can be set so as not to protrude. Further, the setting of the cut position is not necessarily performed by the control unit 65 of the second detection device 62, and may be performed by using a calculation unit separately using the data of the outer peripheral edge ED detected by the second detection device 62. I do not care.

The second cutting device 32B cuts the second sheet piece F2m at the cutting position set by the control unit 65.

The 2nd cutting device 32B detects the part corresponding to 2nd bonding surface SA2 among the 2nd sheet pieces F2m bonded by liquid crystal panel P, and the excess part of the outer side of 2nd bonding surface SA2. The second optical member F12 (see FIG. 4) having a size corresponding to the second bonding surface SA2 is cut out along the outer peripheral edge ED. Thereby, 4th optical member bonding body PA4 by which the 2nd optical member F12 was bonded on the upper surface of 2nd optical member bonding body PA2 is formed.

Here, the “part corresponding to the second bonding surface SA2” means the outer peripheral shape (contour shape in plan view) of the liquid crystal panel P that is equal to or larger than the size of the display area of the opposing liquid crystal panel P in the second sheet piece F2m. ) And a region that avoids a functional part such as an electric component mounting portion in the liquid crystal panel P.

Thus, in the cutting device 32, the outer periphery of the bonding surface is detected for each of the plurality of liquid crystal panels P using the detection device, and the sheets bonded to the individual liquid crystal panels P based on the detected outer periphery. The cutting position of the piece FXm is set. As a result, an optical member having a desired size can be separated regardless of individual differences in the sizes of the liquid crystal panel P and the sheet piece FXm. For this reason, quality variations due to individual differences in the sizes of the liquid crystal panel P and the sheet piece FXm can be eliminated, and the frame area around the display area can be reduced to enlarge the display area and downsize the device.

In the above embodiment, the CO ₂ laser is used as an example of the cutting device 32, but the cutting device 32 is not limited to this. It is also possible to use other cutting means such as a cutting blade as the cutting device 32.

(Recovery device)
A collection device (not shown) disposed at the second collection position 33B holds, for example, an excess portion cut by the second cutting device 32B and peels off from the second optical member F12 formed by the second cutting device 32B. Then, the unnecessary surplus part is collected. 4th optical member bonding body PA4 moves to the direction of the 2nd turning apparatus 35 after the collection process of a surplus part. Note that the recovery device may not be used as long as the cut surplus portion is removed by free fall at the time of cutting by the second cutting device 32B.

(Second turning device)
The 2nd turning apparatus 35 turns 4th optical member bonding body PA4 so that 4th optical member bonding body PA4 may be conveyed in the direction in alignment with the short side of display area P4.

Then, similarly to the first embodiment, the defect of the fourth optical member bonding body PA4 is visually inspected at the defect inspection position 21 set on the downstream side of the second turning device 35. About handling of the 4th optical member bonding body PA4 after visual inspection (unloading from a production line, and regeneration processing outside a production line), it is the same as that of a 1st embodiment.

(Manufacturing method of an optical member bonding body)
With reference to FIG. 6, the manufacturing method of the optical member bonding body in 2nd Embodiment is demonstrated.

First, in manufacturing the double-sided bonded panel P12, the liquid crystal panel P is carried into the production line (step S11), and dirt such as dust and dust adhering to the surface of the liquid crystal panel P is washed (step S12).

Next, in the above-described film bonding system 2, the first optical member sheet F1 is cut while being unwound from the raw roll R1, and is larger than the display region P4 (for example, larger than the liquid crystal panel P), the first sheet piece F1m. Form. Then, the 1st sheet piece F1m is bonded together to liquid crystal panel P, and 1st optical member bonding body PA1 is formed.

Then, in 1st optical member bonding body PA1, the outer periphery of the bonding surface of 1st sheet piece F1m and liquid crystal panel P is detected, and the excess part of 1st sheet piece F1m is cut along the detected outer periphery. The 2nd optical member bonding body PA2 is formed.

Similarly, the second optical member sheet F2 is cut while being unwound from the original roll R1, and a second sheet piece F2m larger than the display region P4 (for example, larger than the liquid crystal panel P) is formed, and the second optical member affixed The third optical member bonded body PA3 is formed by bonding to the combined PA2.

Then, in 3rd optical member bonding body PA3, the outer periphery of the bonding surface of 2nd sheet piece F2m and liquid crystal panel P is detected, The excess part of 2nd sheet piece F2m is cut along the detected outer periphery. And 4th optical member bonding body PA4 is formed (step S13).

Thereafter, Steps S14, S15, and S21 to S24 are performed on the obtained fourth optical member bonding body PA4 in the same manner as in the first embodiment.
The manufacturing method of the optical member bonding body of this embodiment is performed as mentioned above.

Also by the manufacturing method of the optical member bonding body as described above, as in the first embodiment, it is possible to detect defects with accuracy without excess or deficiency on actual use, and stable manufacturing without impairing the manufacturing yield. A manufacturing method of a possible optical member pasting object is provided.

In addition, in this embodiment, in the 1st bonding apparatus 13 or the 2nd bonding apparatus 17, liquid crystal panel P or 1st while peeling the produced 1st sheet piece F1m and 2nd sheet piece F2m from the separator sheet F3a. Although it was set as the structure bonded directly to 2 optical member bonding body PA2, it is not restricted to this. In the bonding apparatus, the produced first sheet piece F1m and the second sheet piece F2m are attached and held, and have a bonding head that is transported and bonded onto the liquid crystal panel P or the second optical member bonding body PA2. It doesn't matter.

The preferred embodiments according to the present invention have been described above with reference to the accompanying drawings, but the present invention is not limited to these examples. Various shapes, combinations, and the like of the constituent members shown in the above-described examples are examples, and various modifications can be made based on design requirements and the like without departing from the gist of the present invention.

ED ... outer peripheral edge, F1X ... optical member, F11 ... first optical member (optical member), F12 ... second optical member (optical member), FX ... optical member sheet, F1 ... first optical member sheet (optical member sheet) F2 ... second optical member sheet (optical member sheet), P4 ... display region, R1 ... raw roll, FXm ... sheet piece, F1m ... first sheet piece (sheet piece), F2m ... second sheet piece (sheet piece) ), P ... liquid crystal panel (optical display component), P11 ... single-sided bonding panel (optical member bonding body), P12 ... double-sided bonding panel (optical member bonding body), PA1 ... first optical member bonding body (bonding body). PA3 ... 3rd optical member bonding body (bonding body), PA4 ... 4th optical member bonding body (optical member bonding body).

Claims

It is a manufacturing method of an optical member bonding body formed by bonding an optical member to an optical display component,
A plurality of optical members obtained by unwinding a belt-shaped optical member sheet from a raw fabric roll and cutting the optical member sheet are bonded to a plurality of the optical display components, and a plurality of the optical member bonded bodies are bonded. An optical member bonding body forming step to be formed;
A first visual inspection step for visually inspecting defects for each of the plurality of optical member bonded bodies,
The manufacturing method of the optical member bonding body which performs the said optical member bonding body formation process and a said 1st visual inspection process with the same manufacturing line.
It is a manufacturing method of an optical member bonding body formed by bonding an optical member to an optical display component,
A bonded body forming a plurality of bonded bodies by unwinding a belt-shaped optical member sheet from a raw roll and cutting a plurality of sheet pieces obtained by cutting the optical member sheet to the plurality of optical display components. Forming process;
In the bonding body, a detection step of detecting the outer peripheral edge of the bonding surface of the sheet piece and the optical display component;
In the said bonding body, the excess part arrange | positioned outside the part corresponding to the said bonding surface from the said sheet piece bonded to the said optical display component is cut | disconnected along the said outer periphery, and it respond | corresponds to the said bonding surface. An optical member bonding body forming step of forming the optical member bonding body including the optical member of a size to be
A first visual inspection step for visually inspecting defects for each of the plurality of optical member bonded bodies,
The manufacturing method of the optical member bonding body which performs the said optical member bonding body formation process and a said 1st visual inspection process with the same manufacturing line.
The manufacturing method of the optical member bonding body of Claim 2 which detects the outer periphery of the bonding surface of the said sheet piece and the said optical display component for every several said optical display components in the said detection process.
About the inferior goods detected at the said 1st visual inspection process, the said optical member is peeled from the autoclave process which heat-presses the said inferior goods according to the state of the defect which the said inferior goods have, or the said optical member bonding body. Then, the optical display component is exposed, and a new optical member prepared in advance is bonded to the exposed surface of the optical display component to form a new optical member bonded body. Having a regeneration process step of selecting and implementing either one of the regeneration processes;
The manufacturing method of the optical member bonding body of any one of Claim 1 to 3 which performs the said reproduction | regeneration processing process separately from the said manufacturing line.
For each of the plurality of optical member bonded bodies that have undergone the regeneration treatment step, it has a second visual inspection step for visually inspecting defects,
The manufacturing method of the optical member bonding body of Claim 4 which performs a said 2nd visual inspection process separately from the said manufacturing line.
The manufacturing method of the optical member bonding body according to claim 5, wherein the regeneration process is performed again on the defective product detected in the second visual inspection process.
The said 1st visual inspection process WHEREIN: A some inspector shares a plurality of said optical member bonding bodies sequentially conveyed through the said optical member bonding body formation process, and visually inspects any one of Claim 1 to 6. The manufacturing method of the optical member bonding body of description.
The optical member bonding body according to claim 7, wherein in the first visual inspection step, the plurality of optical member bonding bodies are distributed to a plurality of inspection lines, and the inspectors arranged on the plurality of inspection lines perform visual inspection. Manufacturing method.
In the said optical member bonding body formation process, the said optical member bonding body which bonded the said optical member on both surfaces of the said optical display component is formed,
The optical member bonding body according to any one of claims 1 to 8, wherein in the first visual inspection step, the optical member bonding body in which the optical member is bonded to both surfaces of the optical display component is visually inspected. Production method.