WO2015030113A1 - Film bonding device, optical-display-device production system, and optical-display-device production method - Google Patents

Abstract

This film bonding device is provided with a load setting mechanism (50) for setting loads to be applied to a film during film bonding. The load setting mechanism (50) includes: a first load adjustment unit (54a) for adjusting a first load (W1) to be applied downwards from above to one end side of a bonding roller (41); a second load adjustment unit (54b) for adjusting a second load (W2) to be applied upwards from below to the one end side of the bonding roller (41); a third load adjustment unit (55a) for adjusting a third load (W3) to be applied downwards from above to another end side of the bonding roller (41); and a fourth load adjustment unit (55b) for adjusting a fourth load (W4) to be applied upwards from below to the other end side of the bonding roller (41).

Description

Film laminating apparatus, optical display device production system, and optical display device production method

The present invention relates to a film laminating apparatus, an optical display device production system, and an optical display device production method.
This application claims priority based on Japanese Patent Application No. 2013-178231 for which it applied on August 29, 2013, and uses the content here.

In the recently developed FPR (Film Patterned Retarder) 3D (three-dimensional) liquid crystal display device, a 3D image can be viewed through polarized glasses while simultaneously displaying an image corresponding to the left eye and an image corresponding to the right eye. Is possible.

In such a 3D liquid crystal display device, an FPR film is bonded to the surface side of the liquid crystal display panel. The FPR film has a plurality of polarization pattern columns corresponding to a plurality of pixel columns of the liquid crystal display panel. The plurality of polarization pattern rows are configured by alternately arranging left-eye polarization pattern rows and right-eye polarization pattern rows having different polarization directions. The left-eye polarization pattern row is provided corresponding to a pixel row that forms an image corresponding to the left eye. The right-eye polarization pattern row is provided corresponding to the pixel row that forms an image corresponding to the right eye.

When bonding the FPR film to the liquid crystal display panel, after transferring the FPR film cut to the size of the liquid crystal display panel to the outer peripheral surface of the bonding roller, while rotating the bonding roller on the liquid crystal display panel The FPR film held on the outer peripheral surface of the bonding roller is transferred to the liquid crystal display panel.

At this time, it is necessary to bond the FPR film to the liquid crystal display panel with high accuracy so that each boundary line of the plurality of polarization pattern rows is located between each of the plurality of pixel rows. If this boundary line deviates from between the pixel columns, it causes crosstalk such as mixing the image of the opposite eye into the image of the left and right eyes.

Japanese Laid-Open Patent Publication No. 2-308217 Japanese Unexamined Patent Publication No. 2003-98520 Japanese Unexamined Patent Publication No. 2010-197434

In the film bonding apparatus, a load setting mechanism for setting a load applied to the FPR film on the liquid crystal display panel when the FPR film is bonded is provided. In the film laminating apparatus, by using this load setting mechanism, the load applied to one end side of the laminating roller and the load applied to the other end side of the laminating roller are adjusted, respectively, on the liquid crystal display panel. The load applied to the FPR film is made uniform in the width direction of the laminating roller.

However, in the conventional film laminating apparatus, even when the load applied to the FPR film on the liquid crystal display panel is made uniform in the width direction of the laminating roller, the linearity of the polarization pattern column with respect to the pixel column may be deteriorated. . When the linearity of the polarization pattern row deteriorates, the positional deviation of the polarization pattern row with respect to the pixel row increases as it goes from the bonding start end side to the bonding end side of the liquid crystal display panel and the FPR film. In this case, it is difficult to position each boundary line of the plurality of polarization pattern columns between the plurality of pixel columns.

The present invention relates to a film bonding apparatus capable of increasing the bonding accuracy of a film to a panel, an optical display device production system including such a film bonding apparatus, and an optical device using such a film bonding apparatus. An object is to provide a method for producing a display device.

According to the 1st aspect of this invention, it is a film bonding apparatus which bonds a film to a panel, Comprising: It has a stage which has the mounting surface in which the said panel is mounted, and a holding surface holding the said film. The film held on the holding surface is rotated while the bonding roller is rotated on the panel by moving the bonding roller relative to the bonding roller and the panel on the placement surface. A moving operation mechanism for transferring to the panel, and a load setting mechanism that is disposed on one end side and the other end side of the laminating roller and sets a load applied to the film on the panel at the time of laminating the film, The load setting mechanism includes: a first load adjusting unit that adjusts a first load that is applied to one end side of the laminating roller from above to below; and a lower end on one end side of the laminating roller. Upward A second load adjusting unit that adjusts a second load applied; a third load adjusting unit that adjusts a third load that is applied to the other end side of the laminating roller from above to below; And a fourth load adjusting unit that adjusts a fourth load that is applied to the other end side of the laminating roller from the lower side toward the upper side, to provide a film laminating device.

In the first aspect, in the load setting mechanism, a load applied to one end side of the bonding roller when the first load and the third load are set to be equal values, and the bonding The configuration may be such that the second load and the fourth load are set to unequal values so as to cancel the difference from the load applied to the other end of the combined roller.

Moreover, in the first aspect, the load setting mechanism includes the first load adjustment unit and the second load adjustment unit, and supports one end side of the bonding roller so as to be movable in the vertical direction. A second support mechanism that includes a first support mechanism, the third load adjustment unit, and the fourth load adjustment unit, and supports the other end side of the bonding roller in a vertically movable manner; The structure which has this may be sufficient.

In the first aspect, the first support mechanism and the second support mechanism may be air cylinder mechanisms.

Moreover, in the said 1st aspect, it is equipped with the rotational drive mechanism which rotationally drives the said bonding roller, and the said rotational drive mechanism is provided in the one side of the one end side and the other end side of the said bonding roller. It may be.

Moreover, according to the 2nd aspect of this invention, it is a production system of the optical display device formed by bonding an optical film to an optical display panel, Comprising: Film bonding which bonds the said optical film to the said optical display panel An optical display device production system is provided, comprising an apparatus, wherein the film laminating apparatus is the film laminating apparatus according to any of the first aspects.

Moreover, according to the 3rd aspect of this invention, it is a production method of the optical display device formed by bonding an optical film to an optical display panel, Comprising: Film bonding which bonds the said optical film to the said optical display panel A method for producing an optical display device comprising the steps of: using the film bonding apparatus according to any one of the first aspects in the film bonding step.

In the third aspect, the optical display panel is an image display panel having a plurality of pixel columns, and the optical film has a patterning position having a plurality of polarization pattern columns corresponding to the plurality of pixel columns. It is a phase difference film, and in the film laminating step, the patterned phase difference film is affixed to the image display panel so that each boundary line of the plurality of polarization pattern rows is located between each of the plurality of pixel rows. The method of combining may be used.

As mentioned above, according to this invention, the bonding precision of the film with respect to the panel of a film bonding apparatus can be improved. Therefore, in the production system of the optical display device provided with such a film bonding apparatus, and the production method of the optical display device using such a film bonding apparatus, the bonding accuracy of the optical film with respect to the optical display panel is increased. By increasing it, it becomes possible to produce an optical display device with excellent display quality.

It is a top view which shows the structure of a liquid crystal display panel. FIG. 2 is a cross-sectional view of the liquid crystal display panel taken along a cutting line AA shown in FIG. It is sectional drawing of the optical sheet which comprises an optical film. It is a top view which shows the structure of a film bonding system. It is a side view which shows the structure of a film bonding system. It is a side view which shows the structure of a film bonding apparatus. It is a side view for demonstrating operation | movement until the bonding roller hold | maintains an optical film from the half cut of a film bonding apparatus. It is a plane schematic diagram for demonstrating alignment adjustment with the liquid crystal display panel of a film bonding apparatus, and an optical film. It is a side view for demonstrating operation | movement until the bonding roller of a film bonding apparatus bonds an optical film to a liquid crystal display panel. It is a top view which shows the 3rd optical film and the display area of a liquid crystal display panel. It is a top view which shows the state by which the 3rd optical film was bonded by the display area of the liquid crystal display panel. It is a schematic diagram which shows the structure of a load setting mechanism. It is a top view which shows the measurement position of the 3rd optical film bonded by the liquid crystal display panel. It is a graph which shows the evaluation result of Table 1 in the case shown in FIG. It is a photograph which shows the 3rd optical film bonded by the liquid crystal display panel in the case shown in FIG. It is a schematic diagram which shows the setting conditions of the load setting mechanism as a reference example. It is a graph which shows the evaluation result of Table 2 in the case shown in FIG. It is a photograph which shows the 3rd optical film bonded by the liquid crystal display panel in the case shown in FIG.

Embodiments of the present invention will be described below with reference to the drawings.
This embodiment demonstrates the film bonding system which comprises the one part as a production system of an optical display device.

The film laminating system is applied to a panel-like optical display component (optical display panel) such as a liquid crystal display panel or an organic EL display panel, and a film-like optical member (optical) such as a polarizing film, a retardation film, or a brightness enhancement film. Film). The film bonding system constitutes a part of a production system for producing an optical display device including such optical display components and optical members.

In this embodiment, a transmissive liquid crystal display device is illustrated as an optical display device. The transmissive liquid crystal display device generally includes a liquid crystal display panel and a backlight. In this liquid crystal display device, illumination light emitted from the backlight is incident from the back side of the liquid crystal display panel, and light modulated by the liquid crystal display panel is emitted from the front side of the liquid crystal display panel, thereby displaying an image. It is possible.

(Optical display device)
First, the configuration of the liquid crystal display panel P shown in FIGS. 1 and 2 will be described as an optical display device. FIG. 1 is a plan view showing the configuration of the liquid crystal display panel P. FIG. 2 is a cross-sectional view of the liquid crystal display panel P along the cutting line AA shown in FIG. In FIG. 2, hatching showing a cross section is omitted.

As shown in FIGS. 1 and 2, the liquid crystal display panel P includes a first substrate P1, a second substrate P2 disposed opposite to the first substrate P1, a first substrate P1, and a second substrate. And a liquid crystal layer P3 disposed between the substrate P2 and the substrate P2.

The first substrate P1 is made of a transparent substrate having a rectangular shape in plan view. The second substrate P2 is made of a transparent substrate having a rectangular shape that is relatively smaller than the first substrate P1. The liquid crystal layer P3 seals the periphery between the first substrate P1 and the second substrate P2 with a sealing material (not shown), and the inside of the region that is rectangular in plan view surrounded by the sealing material. Is arranged. In the liquid crystal display panel P, an area that fits inside the outer periphery of the liquid crystal layer P3 in plan view is a display area P4, and an outer area that surrounds the display area P4 is a frame portion G.

A first optical film F11 as a polarizing film is bonded to the back surface (backlight side) of the liquid crystal display panel P. On the surface (display surface side) of the liquid crystal display panel P, a second optical film F12 as a polarizing film, and a third optical film as a FPR film (patterned retardation film) are stacked on the second optical film F12. The optical film F13 is bonded. Hereinafter, the first, second, and third optical films F11, F12, and F13 may be collectively referred to as an optical film F1X.

(Optical film)
Next, an example of the optical sheet FX constituting the optical film F1X shown in FIG. 3 will be described. FIG. 3 is a cross-sectional view showing the configuration of the optical sheet FX. In FIG. 3, hatching showing a cross section is omitted.

The optical film F1X is obtained by cutting a sheet piece having a predetermined length from the long belt-like optical sheet FX shown in FIG. Specifically, the optical sheet FX includes a base material sheet F4, an adhesive layer F5 provided on one surface (upper surface in FIG. 3) of the base material sheet F4, and the base material sheet F4 via the adhesive layer F5. And a surface protection sheet F7 provided on the other surface (lower surface in FIG. 3) of the base sheet F4.

In the case of a polarizing film, for example, the base sheet F4 has a structure in which a polarizer F4a is sandwiched between a pair of protective films F4b and F4c. The adhesive layer F5 adheres the base material sheet F4 to the liquid crystal display panel P. The separate sheet F6 protects the adhesive layer F5, and is peeled from the adhesive layer F5 when a sheet piece (optical film F1X) is cut out from the optical sheet FX. Hereinafter, the part (part which becomes optical film F1X) remove | excluding the separate sheet | seat F6 from the optical film F1X is called the bonding sheet | seat F8. The surface protection sheet F7 protects the surface of the base material sheet F4, and is peeled off from the surface of the base material sheet F4 after the base material sheet F4 is attached to the liquid crystal display panel P.

In addition, about the base material sheet F4, it is good also as a structure which abbreviate | omitted any one among a pair of protective films F4b and F4c. For example, the protective film F4b on the adhesive layer F5 side may be omitted, and the adhesive layer F5 may be directly provided on the polarizer F4a. The protective film F4c on the surface protective sheet F7 side may be subjected to a surface treatment such as a hard coat treatment that protects the outermost surface of the liquid crystal display panel P or an antiglare treatment that provides an antiglare effect. . Moreover, about the base material sheet F4, not only the thing of the laminated structure mentioned above but the thing of a single layer structure may be sufficient. Further, the surface protection sheet F7 can be omitted.

(Film bonding system)
Next, an example of the film bonding system 1 shown in FIGS. 4 and 5 will be described. FIG. 4 is a plan view showing the configuration of the film bonding system 1. FIG. 5 is a side view showing the configuration of the film bonding system 1.

The film bonding system 1 includes a carry-in conveyor 2, a carry-out conveyor 3, and an intermediate conveyor 4 as shown in FIGS. 4 and 5. The carry-in conveyor 2 and the carry-out conveyor 3 are arranged in parallel to each other. The intermediate conveyor 4 is disposed between the carry-in conveyor 2 and the carry-out conveyor 3. The intermediate conveyor 4 extends in a direction orthogonal to the carry-in conveyor 2 and the carry-out conveyor 3 from the board carry-in position 2 a of the carry-in conveyor 2 toward the substrate carry-out position 3 a of the carry-out conveyor 3.

In the film bonding system 1, the board | substrate carrying-in position 2a of the conveyor 2 for carrying in is made into the starting point of a film bonding process, and the board | substrate carrying-out position 3a of the conveyor 3 for carrying out is made into the end point of a film bonding process.

In the following description, the upstream side in the transport direction of the liquid crystal display panel P is referred to as the panel transport upstream side, and the downstream side in the transport direction of the liquid crystal display panel P is referred to as the panel transport downstream side.

In the carry-in conveyor 2 and the carry-out conveyor 3, the liquid crystal display panel P is conveyed in a state of being placed on the carry-in rack 5 and the carry-out rack 6, respectively. In the carry-in conveyor 2 and the carry-out conveyor 3, for example, the liquid crystal display panel P is transported in a direction in which the short side of the display area P4 is aligned with the transport direction. In the intermediate conveyor 4, for example, the liquid crystal display panel P is transported in a direction in which the long side of the display area P <b> 4 is along the transport direction.

The film bonding system 1 includes a first transport device 7 and a second transport device 8.
The first transport device 7 transports the liquid crystal display panel P from the substrate carry-in position 2 a to the initial position 4 a of the intermediate conveyor 4. The second transport device 8 transports the liquid crystal display panel P from the end point position 4 b of the intermediate conveyor 4 to the substrate unloading position 3 a of the unloading conveyor 3.

On the line formed by the intermediate conveyor 4, the cleaning device 9, the first film laminating device 10, the second film laminating device 11, and the film from the upstream side of the panel conveyance toward the downstream side of the panel conveyance The peeling apparatus 12, the 3rd film bonding apparatus 13, and the test | inspection apparatus 14 are arrange | positioned in this order.

The film bonding system 1 includes a third transport device 15, a fourth transport device 16, and a fifth transport device 17. The 3rd conveying apparatus 15 conveys liquid crystal display panel P mutually between the 1st film bonding apparatus 10 and the intermediate conveyor 4 from the 1st panel delivery position 4c of the intermediate conveyor 4 as the starting point. The 4th conveying apparatus 16 starts liquid crystal display panel P among the 2nd film bonding apparatus 11, the film peeling apparatus 12, and the intermediate conveyor 4 from the 2nd panel delivery position 4d of the intermediate conveyor 4. Carry each other. The 5th conveying apparatus 17 mutually conveys liquid crystal display panel P between the 3rd film bonding apparatus 13 and the intermediate conveyor 4 from the 3rd panel delivery position 4e of the intermediate conveyor 4 as the starting point.

The film bonding system 1 includes a control device 20. The control device 20 controls each part of the film bonding system 1.

(Film pasting process)
Next, the film bonding process using the said film bonding system 1 is demonstrated.
In the film bonding process using the film bonding system 1, while the liquid crystal display panel P is transported on the line formed by the intermediate conveyor 4, a long strip shape with respect to the front and back surfaces of the liquid crystal display panel P. From the first optical film F11 cut out from the first optical sheet F1, the second optical film F12 cut out from the long second optical sheet F2, and the third optical sheet F3 from the long band The cut out third optical film F13 is bonded.

Specifically, in this film bonding system 1, the carry-in conveyor 2 carries the liquid crystal display panel P placed on the carry-in rack 5 to the substrate carry-in position 2a. At the substrate carry-in position 2a, the first transport device 7 transports the liquid crystal display panel P to the starting position 4a of the intermediate conveyor 4 while holding the liquid crystal display panel P. At the first departure position 4 a, the first transport device 7 places the liquid crystal display panel P on the intermediate conveyor 4. The intermediate conveyor 4 conveys the liquid crystal display panel P from the initial position 4a to the cleaning device 9.

The cleaning device 9 performs, for example, brushing or water washing on the front and back surfaces of the liquid crystal display panel P. Thereafter, the front and back surfaces of the liquid crystal display panel P are drained. Note that the cleaning device 9 is not limited to performing such water-based cleaning, and for example, the front and back surfaces of the liquid crystal display panel P may be subjected to dry cleaning such as static electricity removal or dust collection.

The intermediate conveyor 4 conveys the cleaned liquid crystal display panel P from the cleaning device 9 to the first panel delivery position 4c. In the 1st panel delivery position 4c, this 3rd conveying apparatus 15 conveys this liquid crystal display panel P to the 1st film bonding apparatus 10, holding the liquid crystal display panel P which reversed front and back.

When the third transport device 15 transports the liquid crystal display panel P, an operation of turning the liquid crystal display panel P by 90 ° is performed. Thereby, when the direction of the liquid crystal display panel P was conveyed to the 1st film bonding apparatus 10, as shown with the broken line in FIG. 4, the short side of the display area P4 was made to follow the conveyance direction. It becomes the direction.

The 1st film bonding apparatus 10 bonds the 1st optical film F11 cut out from the 1st optical sheet F1 to the surface at the side of the backlight of liquid crystal display panel P. As shown in FIG. After the 1st optical film F11 is bonded, liquid crystal display panel P is again conveyed from the 1st film bonding apparatus 10 to the 1st panel delivery position 4c of the intermediate conveyor 4 by the 3rd conveying apparatus 15. FIG. Is done.

At the first panel delivery position 4c, the third transport device 15 places the liquid crystal display panel P on the intermediate conveyor 4 with the front and back sides of the liquid crystal display panel P reversed. Further, when the third transport device 15 transports the liquid crystal display panel P, an operation of turning the liquid crystal display panel P by 90 ° is performed. Thereby, as shown by the solid line in FIG. 4, when the liquid crystal display panel P is transported to the first panel delivery position 4c, the long side of the display region P4 is oriented along the transport direction. It becomes.

The intermediate conveyor 4 conveys the liquid crystal display panel P on which the first optical film F11 is bonded from the first panel delivery position 4c to the second panel delivery position 4d. At the second panel delivery position 4d, the fourth transport device 16 transports the liquid crystal display panel P to the second film bonding device 11 while holding the liquid crystal display panel P.

When the fourth transport device 16 transports the liquid crystal display panel P, the liquid crystal display panel P is not rotated. Therefore, the direction of the liquid crystal display panel P is the direction in which the long side of the same display area P4 as that on the intermediate conveyor 4 is along the transport direction even after being transported to the second film bonding apparatus 11.

The 2nd film bonding apparatus 11 bonds the 2nd optical film F12 cut out from the 2nd optical sheet F2 to the surface at the side of the display surface of liquid crystal display panel P. As shown in FIG. The liquid crystal display panel P is conveyed from the second film bonding apparatus 11 to the film peeling apparatus 12 by the fourth conveying device 16 after the second optical film F12 is bonded.

The film peeling device 12 peels the surface protective sheet F7 from the second optical film F12 bonded to the liquid crystal display panel P. The liquid crystal display panel P is conveyed again from the film peeling device 12 to the second panel delivery position 4d of the intermediate conveyor 4 by the fourth conveying device 16 after the surface protection sheet F7 is peeled off.

At the second panel delivery position 4d, the fourth transport device 16 places the liquid crystal display panel P on the intermediate conveyor 4 without inverting the front and back of the liquid crystal display panel P. Further, when the fourth transport device 16 transports the liquid crystal display panel P, the liquid crystal display panel P is not rotated. Therefore, the direction of the liquid crystal display panel P is the direction in which the long side of the display area P4 is along the transport direction even after the liquid crystal display panel P is transported to the second panel delivery position 4d.

The intermediate conveyor 4 conveys the liquid crystal display panel P on which the first optical film F11 and the second optical film F12 are bonded from the second panel delivery position 4d to the third panel delivery position 4e. At the third panel delivery position 4e, the fifth transport device 17 transports the liquid crystal display panel P to the third film bonding device 13 while holding the liquid crystal display panel P.

When the fifth transport device 17 transports the liquid crystal display panel P, the liquid crystal display panel P is not rotated. Therefore, the direction of the liquid crystal display panel P is the direction in which the long side of the same display region P4 as that on the intermediate conveyor 4 is aligned with the transport direction after being transported to the third film laminating device 13.

The 3rd film bonding apparatus 13 affixes the 3rd optical film F13 cut out from the 3rd optical sheet F3 on the surface by the side of the display surface of liquid crystal display panel P on the 2nd optical film F12. Match. The liquid crystal display panel P is transported from the third film pasting device 13 to the third panel delivery position 4e of the intermediate conveyor 4 again by the fifth transport device 17 after the third optical film F13 is pasted. Is done.

At the third panel delivery position 4e, the fifth transport device 17 places the liquid crystal display panel P on the intermediate conveyor 4 without inverting the front and back of the liquid crystal display panel P. Further, when the fifth transport device 17 transports the liquid crystal display panel P, an operation for turning the liquid crystal display panel P is not involved. Therefore, the direction of the liquid crystal display panel P is the direction in which the long side of the display area P4 is along the transport direction even after the liquid crystal display panel P is transported to the third panel delivery position 4e.

The intermediate conveyor 4 conveys the liquid crystal display panel P on which the first optical film F11, the second optical film F12, and the third optical film F13 are bonded from the third panel delivery position 4e to the inspection position 4f. . At the inspection position 4f, the inspection device 14 inspects the liquid crystal display panel P. That is, it is inspected whether or not the bonding positions of the first, second and third optical films F11, F12, and F13 with respect to the liquid crystal display panel P are appropriate.

Intermediate conveyor 4 conveys liquid crystal display panel P after inspection from inspection position 4f to end position 4b. On the other hand, about the liquid crystal display panel P determined that the bonding position is not appropriate by the inspection, the liquid crystal display panel P is discharged out of the system by a dispensing means (not shown).

At the end position 4b, the second transport device 8 transports the liquid crystal display panel P to the substrate carry-out position 3a while holding the liquid crystal display panel P. At the substrate carry-out position 3a, the second transfer device 8 holds the liquid crystal display panel P and places the liquid crystal display panel P on the carry-out rack 6. The carry-out conveyor 3 conveys the liquid crystal display panel P placed on the carry-out rack 6 to the panel conveyance downstream side.

By passing through the above processes, the film bonding process by the film bonding system 1 is completed. The liquid crystal display panel P that has completed the film bonding step is sent to the next step.

(Film pasting device)
Next, an example of the film bonding apparatus 30 shown in FIG. 6 is demonstrated. FIG. 6 is a side view showing the configuration of the film bonding apparatus 30.

The film bonding apparatus 30 comprises the said 1st, 2nd and 3rd film bonding apparatus 10,11,13. Therefore, in this film bonding apparatus 30, the case where the sheet piece (optical film F1X) cut out from the optical sheet FX is bonded to the liquid crystal display panel P will be described.

Hereinafter, the upstream side in the conveyance direction of the optical sheet FX is referred to as a sheet conveyance upstream side, and the downstream side in the conveyance direction of the optical sheet FX is referred to as a sheet conveyance downstream side. The optical sheet FX has a width equivalent to the long side length or the short side length of the display region P4 of the liquid crystal display panel P in the horizontal direction (sheet width direction) orthogonal to the conveying direction.

The film bonding apparatus 30 includes a sheet conveyance unit 31, a sheet cutting unit 32, and a film bonding unit 33. The sheet conveying unit 31 conveys the optical sheet FX along its longitudinal direction while unwinding the optical sheet FX from the original roll R1 around which the optical sheet FX is wound. The sheet cutting part 32 cuts out the sheet piece (optical film F1X) of the bonding sheet F8 from the optical sheet FX. The film bonding unit 33 holds the optical film F1X and bonds the optical film F1X to the liquid crystal display panel P.

The sheet conveying unit 31 includes an unwinding unit 34 positioned on the upstream side of the sheet conveying, a winding unit 35 positioned on the downstream side of the sheet conveying, and a plurality of units positioned between the unwinding unit 34 and the winding unit 35. Guide rollers 36a, 36b, 36c and a pressing roller 37 are arranged.

The unwinding part 34 unwinds the optical sheet FX along the longitudinal direction while holding the original fabric roll R1. The winding unit 35 winds the separation sheet F6 remaining after the optical film F1X is cut out from the optical sheet FX while holding the separation roll R2.
That is, the unwinding part 34 and the winding part 35 convey the bonding sheet F8 from the sheet conveying upstream side to the sheet conveying downstream side using the separate sheet F6 as a carrier while being synchronized with each other.

The plurality of guide rollers 36a, 36b, 36c wind the separate sheet F6 along a predetermined conveyance path between the unwinding unit 34 and the winding unit 35. The pressing roller 37 sandwiches the separate sheet F6 with the guide roller 36b.

In the sheet cutting unit 32, a cutting stage 38 and a cutting machine 39 are arranged. The cutting stage 38 is located between the guide roller 36a and the guide roller 36b, and supports the lower surface of the optical sheet FX. The cutting machine 39 performs a half cut on the optical sheet FX on the cutting stage 38 by the cutting blade 39a. Note that the cutting machine 39 may be configured to use, for example, laser light instead of using the cutting blade 39a.

When half-cutting the optical sheet FX, the optical sheet FX is fed out onto the cutting stage 38 by a length corresponding to the long side length of the display area P4. The cutting machine 39 cuts the bonding sheet F8 over the entire width in the sheet width direction while adjusting the cutting depth of the cutting blade 39a with respect to the optical sheet FX while leaving the separate sheet F6.

Thereby, the cut line C is formed in the optical sheet FX over the entire width in the sheet width direction of the bonding sheet F8. And from this optical sheet FX, one sheet piece corresponding to the optical film F1X is cut out.

In the film bonding unit 33, a bonding stage 40, a bonding roller 41, a moving operation mechanism 42, and a knife edge 43 are arranged.

The bonding stage 40 is disposed on the downstream side of the sheet conveyance from the cutting stage 38. On the upper surface of the bonding stage 40, a placement surface 40a on which the liquid crystal display panel P is placed is provided. The mounting surface 40a is provided with a mechanism for holding the liquid crystal display panel P by means such as suction.

In the bonding stage 40, since the alignment adjustment of the liquid crystal display panel P to be described later is performed, the placement surface 40a can be moved and operated in two directions orthogonal to each other in a plane parallel to the placement surface 40a. Moreover, in the bonding stage 40, the mounting surface 40a can be rotated around an axis orthogonal to the mounting surface 40a.

The bonding roller 41 is disposed above the cutting stage 38 and the bonding stage 40. The movement operation mechanism 42 moves the bonding roller 41 between the cutting stage 38 and the bonding stage 40. The moving operation mechanism 42 moves the bonding roller 41 in the vertical direction with respect to the cutting stage 38 and the bonding stage 40, and moves the bonding roller 41 in the front-rear direction with respect to the cutting stage 38 and the bonding stage 40. Move to.

The both ends of the bonding roller 41 are rotatably supported. A rotation drive mechanism 44 that rotationally drives the bonding roller 41 is provided on one end side of the bonding roller 41. A holding surface 41 a that holds the optical film F <b> 1 </ b> X is provided on the outer peripheral surface of the bonding roller 41. The holding surface 41a has adhesive force, and the optical film F1X can be repeatedly attached to or peeled from the holding surface 41a.

The knife edge 43 is arrange | positioned in the sheet | seat conveyance downstream rather than the position where the bonding roller 41 starts bonding. The knife edge 43 is provided on the bonding stage 40 so as to be movable in the front-rear direction. When separating the optical film F1X from the optical sheet FX after half-cutting, the knife edge 43 presses the separate sheet F6 from above over the entire width in the sheet width direction.

The film bonding apparatus 30 is provided with a first detection camera 45 that detects an end F8a of the bonding sheet F8 among the optical sheets FX conveyed on the cutting stage 38. The first detection camera 45 is disposed facing a detection hole 38 a provided in the cutting stage 38.

The film bonding apparatus 30 is provided with a second detection camera 46 that detects the position of the bonding sheet F8 held on the holding surface 41a of the bonding roller 41. The 2nd detection camera 46 is arrange | positioned facing the holding surface 41a of the bonding roller 41 located above the bonding stage 40. FIG.

The film bonding apparatus 30 is provided with a third detection camera 47 that detects the position of the liquid crystal display panel P mounted on the mounting surface 40a of the bonding stage 40. The 3rd detection camera 47 is located above the bonding stage 40, and is arrange | positioned facing the mounting surface 40a.

Specific operations of the film bonding apparatus 30 having the above-described configuration will be described with reference to FIGS. 7A to 7D, the optical sheet FX is half-cut and the optical film F1X is pasted (transferred) to the holding surface 41a of the laminating roller 41 from the half-cut optical sheet FX. It is a side view of the film bonding apparatus 30 which shows this operation | movement. FIG. 8 is a schematic plan view for explaining alignment adjustment between the liquid crystal display panel P and the optical film F1X. FIGS. 9A and 9B are side views of the film bonding apparatus 30 showing the operation until the optical film F1X is transferred (bonded) to the liquid crystal display panel P. FIG.

In the film bonding apparatus 30, first, as shown to Fig.7 (a), the 1st detection camera 45 detects the edge part F8a of the bonding sheet | seat F8 among the optical sheets FX conveyed on the cutting | disconnection stage 38. FIG. It detects through the hole 38a. The detection information of the first detection camera 45 is sent to the control device 20. Based on the detection information of the first detection camera 45, the control device 20 determines that the bonding sheet F8 on the separate sheet F6 has been fed out by a predetermined length, and transports the optical sheet FX by the sheet transport unit 31. Is temporarily stopped.

In the sheet cutting unit 32, after the conveyance of the optical sheet FX is stopped, the cutting machine 39 performs a half cut on the optical sheet FX on the cutting stage 38. Thereby, one sheet piece (henceforth optical film F1X) corresponding to the optical film F1X is cut out from the bonding sheet F8 leaving the separate sheet F6.

Here, in the sheet cutting unit 32, the cutting machine 39 is movable in the conveyance direction of the optical sheet FX. As the cutting machine 39 moves, the distance between the detection position of the first detection camera 45 and the cutting position of the cutting machine 39 is changed. Thereby, the length of the optical film F1X cut out from the optical sheet FX can be adjusted.

Further, in the sheet cutting unit 32, for example, when the cut line formed in the bonding sheet F8 after half-cutting is deviated from a predetermined reference position, the cutting position of the cutting machine 39 is corrected so as to correct this positional deviation. Can be adjusted. Moreover, it can respond also to the cutting of the sheet piece from which length differs.

Next, as shown in FIG. 7B, after the half cut, the moving operation mechanism 42 lowers the laminating roller 41 that has been waiting above the cutting stage 38. Thereby, it will be in the state which the optical film F1X cut out from the optical sheet FX and the holding surface 41a of the bonding roller 41 can contact.

In this state, the movement operation mechanism 42 moves the laminating roller 41 from the sheet conveyance downstream side (right side in FIG. 7B) toward the sheet conveyance upstream side (left side in FIG. 7B). Thereby, the optical film F1X is bonded (transferred) to the holding surface 41a of the bonding roller 41 while the bonding roller 41 rotates on the optical film F1X.

Further, when the optical film F1X is transferred to the holding surface 41a of the bonding roller 41, the winding unit 35 is rotated in the direction opposite to the direction in which the separate sheet F6 is wound (clockwise in FIG. 7B). . Accordingly, the separate sheet F6 is sent out to the upstream side of the sheet conveyance. At this time, the separate sheet F6 is bent upward while causing the slack F6a.

At such timing, the knife edge 43 in the retracted position is moved from the sheet conveying downstream side toward the sheet conveying upstream side. Accordingly, the separate sheet F6 comes into contact with the knife edge 43.

Next, as shown in FIG. 7 (c), in this state, the take-up portion 35 is rotated in the direction in which the separate sheet F6 is taken up (counterclockwise in FIG. 7 (c)). Thereby, the separate sheet F6 is wound around the winding portion 35 while being pressed by the knife edge 43. At this time, the force of the direction which peels both will generate | occur | produce in the interface between the optical film F1X stuck to the holding surface 41a, and the separate sheet | seat F6.

Thereby, the optical film F1X is separated from the separate sheet F6 and is held (transferred) on the holding surface 41a. On the other hand, as the separate sheet F6 is wound around the winding portion 35, the slackness F6a gradually decreases. Then, when the slack F6a disappears, the rotation of the winding unit 35 is stopped.

Next, as shown in FIG. 7D, after the optical film F <b> 1 </ b> X is transferred to the holding surface 41 a of the bonding roller 41, the moving operation mechanism 42 raises the bonding roller 41 and the bonding roller 41. Is moved to above the bonding stage 40. The knife edge 43 moves from the upstream side of the sheet conveyance toward the downstream side of the sheet conveyance and stops at the standby position.

Next, as shown in FIG. 8, bonding between the liquid crystal display panel P placed on the placement surface 40 a of the bonding stage 40 and the optical film F <b> 1 </ b> X held on the holding surface 41 a of the bonding roller 41. Adjust the position (alignment).

Specifically, the second detection camera 46 detects the start end position Ep1 and the end position Ep2 in the rotation direction of the optical film F1X held on the holding surface 41a while the rotation driving mechanism 44 rotates the bonding roller 41. To do. The start position Ep1 corresponds to one corner along one side in the longitudinal direction of the optical film F1X, and the end position Ep2 corresponds to the other corner along one side in the longitudinal direction of the optical film F1X.

The detection information of the second detection camera 46 is sent to the control device 20. The control device 20 calculates the distance Lc from the start end position Ep1 to the end position Ep2 based on the detection information from the second detection camera 46. This distance Lc corresponds to the length (long side length) of one side in the longitudinal direction of the optical film F1X.

Further, the control device 20 calculates the distance Le in the sheet width direction between the start end position Ep1 and the end position Ep2 based on the detection information from the second detection camera 46. This distance Le corresponds to a shift amount in the sheet width direction between one corner portion along one side in the longitudinal direction of the optical film F1X and the other corner portion along one side in the longitudinal direction of the optical film F1X.

The control device 20 calculates the correction angle α (tan α = Le / Lc) from the calculated distance Lc and distance Le. The correction angle α corresponds to the inclination of the optical film F1X held on the holding surface 41a with respect to the rotation direction of the laminating roller 41.

Further, the third detection camera 47 detects the alignment mark Pm provided on the liquid crystal display panel P. In the present embodiment, for example, three marks Pm1, Pm2, and Pm3 provided at three corners of the liquid crystal display panel P are detected.

The detection information of the third detection camera 47 is sent to the control device 20. The control device 20 specifies the position of the liquid crystal display panel P placed on the placement surface 40 a based on the detection information from the third detection camera 47.

In the film bonding apparatus 30, after specifying the position of the optical film F1X and the position of the liquid crystal display panel P, the liquid crystal display panel P and the optical film F1X are aligned (alignment adjustment).

Specifically, in this embodiment, the bonding stage 40 is rotated based on the correction angle α. Thereby, the direction of the liquid crystal display panel P is adjusted according to the inclination of the optical film F1X. Moreover, based on the detection information from the 2nd detection camera 46 and the 3rd detection camera 47, while moving the bonding stage 40, the bonding roller 41 is rotated. Thereby, the start end position Ep1 of the optical film F1X and the bonding start position Ep1 ′ of the liquid crystal display panel P coincide with each other at the start of bonding, and the end position Ep2 of the optical film F1X and the liquid crystal at the end of bonding. Position alignment (alignment adjustment) of liquid crystal display panel P and bonding sheet | seat F8 is performed so that bonding completion position Ep2 'of display panel P may correspond. The alignment adjustment between the liquid crystal display panel P and the optical film F1X is not necessarily limited to such a method, and another method may be used.

Next, as shown in FIGS. 9A and 9B, the optical film F1X held on the holding surface 41a of the bonding roller 41 is transferred (bonded) to the liquid crystal display panel P.

Specifically, in the film bonding apparatus 30, the movement operation mechanism 42 lowers the bonding roller 41 after alignment adjustment. Thereby, the liquid crystal display panel P placed on the placement surface 40a and the optical film F1X held on the holding surface 41a can be brought into contact with each other.

In this state, the movement operation mechanism 42 moves the laminating roller 41 from the sheet conveyance upstream side (right side in FIG. 9) toward the sheet conveyance downstream side (left side in FIG. 9). Accordingly, the optical film F1X held on the holding surface 41a is transferred (bonded) to the liquid crystal display panel P while the bonding roller 41 rotates on the liquid crystal display panel P. That is, the optical film F1X is peeled from the holding surface 41a and bonded to the liquid crystal display panel P by being pressed against the liquid crystal display panel P.

In the film bonding apparatus 30, after the optical film F <b> 1 </ b> X is bonded to the liquid crystal display panel P, the moving operation mechanism 42 raises the bonding roller 41 and moves the bonding roller 41 to above the cutting stage 38. .

In the film bonding apparatus 30, the operation | movement which bonds the optical film F1X cut out from the above optical sheets FX to the liquid crystal display panel P can be performed repeatedly.

(Pattern retardation film)
Next, the FPR film which comprises the 3rd optical film F13 as a patterned retardation film is demonstrated with reference to FIG.10 and FIG.11.
FIG. 10 is a plan view showing the third optical film F13 and the display region P4 of the liquid crystal display panel P. FIG. FIG. 11 is a plan view showing a state in which the third optical film F13 is bonded to the display region P4 of the liquid crystal display panel P. FIG.

In the display area P4 of the liquid crystal display panel P, as shown in FIG. 10, for example, a pixel R corresponding to red, a pixel G corresponding to green, and a pixel B corresponding to blue are periodically arranged in the left-right direction. A plurality of pixel rows L1 and L2 arranged side by side are arranged. The plurality of pixel columns L1 and L2 are configured by alternately arranging a pixel column L1 that forms an image corresponding to the left eye and a pixel column L2 that forms an image corresponding to the right eye in the vertical direction. .

The third optical film F13 has a plurality of polarization pattern rows PA1, PA2 corresponding to the plurality of pixel rows L1, L2 of the liquid crystal display panel P. The plurality of polarization pattern rows PA1 and PA2 are configured by alternately arranging a left-eye polarization pattern row PA1 and a right-eye polarization pattern row PA2 having different polarization directions. The left-eye polarization pattern array PA1 is provided corresponding to the pixel array L1 that forms an image corresponding to the left eye. The right-eye polarization pattern array PA2 is provided corresponding to the pixel array L2 that forms an image corresponding to the right eye.

In the 3rd film bonding apparatus 13, as shown in FIG. 11, 3rd so that each boundary line K of several polarization pattern row | line | column PA1, PA2 may be located between each of several pixel row | line | column L1, L2. The optical film F13 is bonded to the liquid crystal display panel P.

Here, if the boundary line K deviates from between the pixel rows L1 and L2, it causes crosstalk such as mixing the left eye image with the left eye image. Therefore, it is necessary to bond the third optical film F13 to the liquid crystal display panel P with high accuracy so that the boundary line K is located between the pixel columns L1 and L2.

In addition, the code | symbol pi1 in FIG. 11 represents the distance between pitches (distance between the boundary lines K) of pixel row | line L1, L2 and polarization pattern row | line | column PA1, PA2. Further, a symbol pi2 in FIG. 11 represents the distance between the pixel columns L1 and L2 (the width of the black matrix). A symbol Gap in FIG. 11 represents a distance (gap width) between the boundary line K and the pixel columns L1 and L2. For example, when the width pi2 of the black matrix is 86 μm, the gap width Gap is ideally 43 μm, but considering the fluctuation of the boundary line K and the like, the target value is about 40 to 50 μm.

(Load setting mechanism)
Next, an example of the load setting mechanism 50 shown in FIG. 12 will be described. FIG. 12 is a schematic diagram showing the configuration of the load setting mechanism 50.

The film bonding apparatus 30 is provided with a load setting mechanism 50 that sets a load applied to the optical film F1X on the liquid crystal display panel P when the optical film F1X is bonded, as shown in FIG.

The load setting mechanism 50 includes a first support mechanism 51 that supports one end side (first end side, first shaft end portion) of the bonding roller 41 so as to be movable in the vertical direction, and the other end side of the bonding roller 41. And a second support mechanism 52 that supports the second end side and the second shaft end portion so as to be movable in the vertical direction.

The first support mechanism 51 is arranged between the first bearing portion 53a that rotatably supports the support shaft 41b on one end side of the bonding roller 41 and the movement operation mechanism 42. The first support mechanism 51 supports the one end side of the bonding roller 41 in a suspended state.

The first support mechanism 51 includes a first load adjustment unit 54a and a second load adjustment unit 54b. The 1st load adjustment part 54a adjusts the 1st load W1 added to the one end side of the bonding roller 41 toward the downward direction from the upper direction. The 2nd load adjustment part 54b adjusts the 2nd load W2 added to the one end side of the bonding roller 41 toward upper direction from the downward direction.

The second support mechanism 52 is disposed between the movement operation mechanism 42 and the second bearing portion 53b that rotatably supports the support shaft 41c on the other end side of the bonding roller 41. The second support mechanism 52 supports the other end side of the bonding roller 41 in a suspended state.

The second support mechanism 52 includes a third load adjustment unit 55a and a fourth load adjustment unit 55b. The third load adjustment unit 55a adjusts the third load W3 applied to the other end side of the bonding roller 41 from the upper side to the lower side. The 4th load adjustment part 55b adjusts the 4th load W4 added to the other end side of the bonding roller 41 toward upper direction from the downward direction.

In the present embodiment, air cylinder mechanisms 60A and 60B are used as the first support mechanism 51 and the second support mechanism 52. The air cylinder mechanisms 60 </ b> A and 60 </ b> B move the piston 62 in the cylinder 61 in the vertical direction by the pressure of air introduced into the cylinder 61. For the air cylinder mechanisms 60A and 60B, it is preferable to use a low friction cylinder capable of finely adjusting the air pressure.

The first support mechanism 51 is composed of a first air cylinder mechanism 60A. The first air cylinder mechanism 60 </ b> A supports the one end side of the bonding roller 41 through a rod 63 connected to the piston 62 so as to be movable in the vertical direction. The second support mechanism 52 is constituted by a second air cylinder mechanism 60B. The second air cylinder mechanism 60 </ b> B supports the other end side of the bonding roller 41 through a rod 63 connected to the piston 62 so as to be movable in the vertical direction.

The first air cylinder mechanism 60A includes a first line 64a and a first regulator 65a that constitute the first load adjustment unit 54a. The first line 64 a is connected to the upper side of the cylinder 61. The first regulator 65a is provided in the first line 64a. In the first air cylinder mechanism 60A, the piston 62 in the cylinder 61 is pressed downward from above by air supplied from the first line 64a. Further, the air pressure applied to the piston 62 in the cylinder 61 through the first line 64a is adjusted by the first regulator 65a. Thereby, in the 1st load adjustment part 54a, the 1st load W1 added toward the one end side of the bonding roller 41 toward the downward from the upper direction can be adjusted.

1st air cylinder mechanism 60A has the 2nd line 64b and the 2nd regulator 65b which constitute the 2nd load adjustment part 54b. The second line 64 b is connected to the lower side of the cylinder 61. The second regulator 65b is provided in the second line 64b. In the first air cylinder mechanism 60A, the piston 62 in the cylinder 61 is pressed upward from below by air supplied from the second line 64b. Further, the air pressure applied to the piston 62 in the cylinder 61 through the second line 64b is adjusted by the second regulator 65b. Thereby, in the 2nd load adjustment part 54b, the 2nd load W2 added toward the one end side of the bonding roller 41 toward the upper direction from the downward direction can be adjusted.

The second air cylinder mechanism 60B includes a third line 66a and a third regulator 67a that constitute the third load adjusting unit 55a. The third line 66 a is connected to the upper side of the cylinder 61. The third regulator 67a is provided in the third line 66a. In the second air cylinder mechanism 60B, the piston 62 in the cylinder 61 is pressed downward from above by the air supplied from the third line 66a. Further, the air pressure applied to the piston 62 in the cylinder 61 through the third line 66a is adjusted by the third regulator 67a. Thereby, in the 3rd load adjustment part 55a, the 3rd load W3 added to the other end side of the bonding roller 41 toward the downward direction from the upper direction can be adjusted.

The second air cylinder mechanism 60B includes a fourth line 66b and a fourth regulator 67b that constitute the fourth load adjustment unit 55b. The fourth line 66 b is connected to the upper side of the cylinder 61. The fourth regulator 67b is provided in the fourth line 66b. In the second air cylinder mechanism 60B, the air supplied from the fourth line 66b presses the piston 62 in the cylinder 61 from below to above. Further, the air pressure applied to the piston 62 in the cylinder 61 through the fourth line 66b is adjusted by the fourth regulator 67b. Thereby, in the 4th load adjustment part 55b, the 4th load W4 added to the other end side of the bonding roller 41 toward upper direction from the downward direction can be adjusted.

In the present embodiment, an upper line 68a in which the first line 64a and the third line 66a are connected, and a lower line 68b in which the second line 64b and the fourth line 66b are connected, respectively. It is configured to be connected to the same air supply source (not shown). As a result, the number of lines can be reduced and the installation space can be reduced. For example, a compressor or the like can be used as the air supply source. For the first to fourth regulators 65a, 65b, 67a, 67b, it is preferable to use a precision regulator capable of finely adjusting the air pressure.

The first to fourth lines 64a, 64b, 66a, 66b are not limited to the configuration connected to such a single air supply source, and for example, the upper line 68a and the lower line 68b are independent of each other. A configuration in which the two air supply sources are connected, or a configuration in which the lines 64a, 64b, 66a, and 66b are connected to four independent air supply sources, respectively.

In the load setting mechanism 50, one end side of the laminating roller 41 supported by the first support mechanism 51 (first air cylinder mechanism 60A) and the second support mechanism 52 (second air cylinder mechanism 60B). By adjusting the position in the vertical direction with the other end side of the supported bonding roller 41, the load applied to one end side of the bonding roller 41 and the bonding roller 41 when the optical film F1X is bonded. It is possible to adjust the load applied to the other end of each.

Incidentally, on one end side of the laminating roller 41, a drive motor, a clutch mechanism, and the like constituting the rotation drive mechanism 44 are provided. For this reason, a difference (WA−WB> 0) occurs between the load WA applied to one end of the bonding roller 41 and the load WB applied to the other end of the bonding roller 41.

Therefore, in the film bonding apparatus 30, the first load W <b> 1, the second load W <b> 2 added to one end side of the bonding roller 41, and the other end side of the bonding roller 41 using the load setting mechanism 50. The third load W3 and the fourth load W4 to be added are adjusted, and the load applied to the optical film F1X on the liquid crystal display panel P is made uniform in the width direction of the bonding roller 41. .

Specifically, the load applied to the optical film F1X when the load applied to the optical film F1X on the liquid crystal display panel P is made uniform in the width direction of the laminating roller 41 is in the range of 0.05 to 0.60 MPa. It is preferable. Moreover, about the load added to the both sides of the width direction of the optical film F1X, it is ideal that the difference is 0 Mpa, However, If the difference is 0.01 Mpa or less, it is fully accept | permitted.

Here, the setting conditions of the load setting mechanism 50 when the third optical film (FPR film) F13 is bonded to the liquid crystal display panel P will be described.
In the present embodiment, in the load setting mechanism 50 shown in FIG. 12, the first load W1 and the third load W3 are set to equal values (W1 = W3), and the load applied to one end side of the laminating roller 41 The second load W2 is larger than the fourth load W4 (W2> W4) in order to cancel out the difference between WA and the load WB applied to the other end of the laminating roller 41 (WA-WB> 0). The case where it set to is illustrated.

And the distance (gap width Gap) between the boundary line K and the pixel rows L1, L2 when the third optical film F13 is bonded to the liquid crystal display panel P under the setting conditions of the load setting mechanism 50. Was measured.

Specifically, in this measurement, as shown in FIG. 13, among the third optical films F13 bonded to the liquid crystal display panel P, the bonding start end position of the third optical film F13 (the left side in FIG. 13). ) And the bonding end position (right side in FIG. 13), one end (upper side in FIG. 13), central part (middle side in FIG. 13), and the other end of each part The gap width Gap [mm] was measured at three locations (6 locations in total) with (the lower side in FIG. 13). Further, the same measurement was performed with the number of samples n being five. The measurement results are shown in Table 1.

As shown in FIG. 11, the gap width Gap is measured with the side in contact with the pixel columns L1 and L2 being the origin [0 mm] and the direction of the arrow in FIG. went. Therefore, when the numerical value of the gap width Gap is “−”, the boundary line K is located between the pixel columns L1 and L2. On the other hand, when the numerical value of the gap width Gap is “0”, the boundary line K is in contact with either one of the pixel columns L1 and L2. On the other hand, when the numerical value of the gap width Gap is “+”, the boundary line K is located on one of the pixel columns L1 and L2. The target value of the gap width Gap is -0.04 to -0.05 mm.

Moreover, in order to evaluate the rectilinearity of the boundary line K with respect to the pixel rows L1 and L2, the bonding start end position and bonding are performed at three locations of one end portion, the center portion, and the other end portion of the third optical film F13. The difference in gap width Gap from the end position was determined. The results are shown in Table 1 and a graph of the results is shown in FIG.

Furthermore, among the third optical film F13 bonded to the liquid crystal display panel P, each of the two locations on the bonding start end side (left side) and the bonding end side (right side) of the third optical film F13 The photograph which image | photographed the one end side (upper stage side), the center side (middle stage side), and the other end side (lower stage side) of this is shown in FIG.

In the setting condition of the load setting mechanism 50 according to the present embodiment, the load applied to the third optical film F13 on the liquid crystal display panel P can be made uniform in the width direction of the bonding roller 41. Moreover, as shown in Table 1 and FIG. 14, the gap width Gap is within the range of the target value from the bonding start end side to the bonding end side, and the linearity of the boundary line K with respect to the pixel rows L1 and L2 is also good. I understand that.

Therefore, in the setting conditions of the load setting mechanism 50 according to the present embodiment, as shown in FIG. 15, at one end, the center, and the other end of the third optical film F13, the bonding end side to the bonding end side, respectively. Until this, each boundary line K of the plurality of polarization pattern rows PA1 and PA2 can be positioned between each of the plurality of pixel rows L1 and L2.

On the other hand, as a reference example, in the load setting mechanism 50, one end side of the laminating roller 41 is used to cancel the difference in load applied to the one end side and the other end side of the laminating roller 41 (WA-WB> 0). FIG. 16 shows a case where the load W3 ′ applied to the other end of the laminating roller 41 is set higher than the load W1 ′ applied to (W3 ′> W1 ′).

And the distance (gap width Gap) between the boundary line K and the pixel rows L1, L2 when the third optical film F13 is bonded to the liquid crystal display panel P under the setting conditions of the load setting mechanism 50. Was measured. The measurement results are shown in Table 2. The measurement method is the same as that shown in Table 1 above.

Moreover, in order to evaluate the rectilinearity of the boundary line K with respect to the pixel rows L1 and L2, the bonding start end position and bonding are performed at three locations of one end portion, the center portion, and the other end portion of the third optical film F13. The difference in gap width Gap from the end position was determined. The results are shown in Table 2, and a graph of the results is shown in FIG.

Furthermore, among the third optical film F13 bonded to the liquid crystal display panel P, each of the two locations on the bonding start end side (left side) and the bonding end side (right side) of the third optical film F13 The photograph which image | photographed the one end side (upper stage side), the center side (middle stage side), and the other end side (lower stage side) of this is shown in FIG.

In the setting condition of the load setting mechanism 50 according to the reference example, the load applied to the third optical film F13 on the liquid crystal display panel P can be made uniform in the width direction of the bonding roller 41. However, it was found that the gap width Gap deviates from the target value as it goes from the bonding start end side to the bonding end side as shown in Table 2 and FIG. In particular, it can be seen that the linearity of the boundary line K is worse on the one end side and the other end side than the central portion of the third optical film F13. This is presumably because excessive pressure was applied to the optical film F1X on the liquid crystal display panel P, and the straightness of the boundary line K with respect to the pixel columns L1 and L2 deteriorated.

Therefore, under the setting conditions of the load setting mechanism 50 according to the reference example, as shown in FIG. 18, the positional deviation of the polarization pattern rows PA1 and PA2 with respect to the pixel rows L1 and L2 becomes large. In this case, it is difficult to position each boundary line K of the plurality of polarization pattern rows PA1 and PA2 between the plurality of pixel rows L1 and L2 from the bonding start end side to the bonding end side.

As described above, in the load setting mechanism 50, it is preferable to set the first load W1 and the third load W3 to equal values (W1 = W3). Thereby, the load applied to the optical film F1X on the liquid crystal display panel P can be optimized in the width direction of the bonding roller 41, and an excessive pressure can be prevented from being applied to the optical film F1X.

Moreover, in the load setting mechanism 50, the second load W2 and the fourth load are set so as to cancel the difference between the load WA applied to one end side of the bonding roller 41 and the load WB applied to the other end side of the bonding roller 41. The load W4 may be set to an unequal value. Thereby, the load applied to the optical film F1X on the liquid crystal display panel P is made uniform in the width direction of the bonding roller 41, and each boundary line K of the plurality of polarization pattern rows PA1, PA2 is changed to each of the plurality of pixel rows L1, L2. It is possible to be located between them.

As mentioned above, in the film bonding apparatus 30 shown in this embodiment, it is possible to raise the bonding precision of the optical film F1X with respect to liquid crystal display panel P. FIG.

In addition, this invention is not necessarily limited to the thing of the said embodiment, A various change can be added in the range which does not deviate from the meaning of this invention.
Specifically, in the said embodiment, although illustrated about the case where optical film F1X was bonded to liquid crystal display panel P, not only liquid crystal display panel P but an optical film is stuck on image display panels, such as an organic EL display panel, for example. Also in the case of combining, the present invention can be widely applied.

In the above embodiment, the case where the air cylinder mechanisms 60 </ b> A and 60 </ b> B are used as the first support mechanism 51 and the second support mechanism 52 is exemplified. However, the first support mechanism 51 and the second support mechanism 52 are not limited to using the air cylinder mechanisms 60A and 60B, and other support mechanisms such as a hydraulic cylinder mechanism may be used.

Moreover, in the said embodiment, the 1st support mechanism 51 contains the 1st load adjustment part 54a and the 2nd load adjustment part 54b, and the 2nd support mechanism 52 has the 3rd load adjustment part 55a and the 4th. However, the configuration is not necessarily limited to such a configuration.

For example, a first support mechanism including a first load adjustment unit supports one end side of the bonding roller from the upper side, and a second support mechanism including a second load adjustment unit extends one end side of the bonding roller. A third support mechanism that supports from the lower side and includes a third load adjustment unit supports the other end side of the bonding roller from the upper side, and a fourth support mechanism that includes the fourth load adjustment unit bonds. It is also possible to adopt a configuration in which the other end of the roller is supported from the lower side.

DESCRIPTION OF SYMBOLS 1 ... Film bonding system 2 ... Carry-in conveyor 3 ... Carry-out conveyor 4 ... Intermediate conveyor 5 ... Carry-in rack 6 ... Carry-out rack 7 ... 1st conveying apparatus 8 ... 2nd conveying apparatus 9 ... Cleaning apparatus 10 ... 1st film bonding apparatus 11 ... 2nd film bonding apparatus 12 ... Film peeling apparatus 13 ... 3rd film bonding apparatus 14 ... Inspection apparatus 15 ... 3rd conveying apparatus 16 ... 4th conveying apparatus 17 ... 5th conveying apparatus 20 ... Control apparatus 30 ... Film laminating apparatus 31 ... Sheet conveying part 32 ... Sheet cutting part 33 ... Film laminating part 34 ... Unwinding part 35 ... Winding part 36a, 36b, 36c ... Guide roller 37 ... Pressing roller 38 ... Cutting stage 39 ... Cutting machine 40 ... Pasting stage 41 ... Pasting roller 42 ... Moving operation mechanism 43 ... If Edge 44 ... Rotation drive mechanism 45 ... First detection camera 46 ... Second detection camera 47 ... Third detection camera 50 ... Load setting mechanism 51 ... First support mechanism 52 ... Second support mechanism 53a ... First Bearing portion 53b ... second bearing portion 54a ... first load adjustment portion 54b ... second load adjustment portion 55a ... third load adjustment portion 55b ... fourth load adjustment portion 60A ... first air cylinder mechanism 60B ... Second air cylinder mechanism 61 ... Cylinder 62 ... Piston 63 ... Rod 64a ... First line 64b ... Second line 65a ... First regulator 65b ... Second regulator 66a ... Third line 66b ... Third 4 line 67a ... third regulator 67b ... fourth regulator P ... liquid crystal display panel F1X ... optical fill F11 ... 1st optical film F12 ... 2nd optical film F13 ... 3rd optical film F4 ... Base material sheet F4a ... Polarizer F4b, F4c ... Protective film F5 ... Adhesive layer F6 ... Separate sheet F7 ... Surface protective sheet F8 ... bonding sheet FX ... optical sheet F1 ... first optical sheet F2 ... second optical sheet F3 ... third optical sheet

Claims (8)

1. A film laminating apparatus for laminating a film on a panel,
   A stage having a mounting surface on which the panel is mounted;
   A laminating roller having a holding surface for holding the film;
   The film held on the holding surface is transferred to the panel while rotating the bonding roller on the panel by moving the bonding roller relative to the panel on the placement surface. A movement operation mechanism;
   A load setting mechanism that is arranged on one end side and the other end side of the bonding roller, and sets a load applied to the film on the panel at the time of bonding of the film;
   The load setting mechanism is
   A first load adjusting unit that adjusts a first load that is applied from the upper side to the lower side on one end side of the laminating roller;
   A second load adjusting unit that adjusts a second load that is applied to one end side of the laminating roller from below to above;
   A third load adjusting unit for adjusting a third load applied from the upper side to the lower side on the other end side of the laminating roller;
   And a fourth load adjusting unit that adjusts a fourth load that is applied to the other end side of the laminating roller from below to above.
2. In the load setting mechanism, a load applied to one end side of the bonding roller and a load applied to the other end side of the bonding roller when the first load and the third load are set to be equal values. The film bonding apparatus according to claim 1, wherein the second load and the fourth load are set to unequal values so as to cancel the difference between the first load and the fourth load.
3. The load setting mechanism is
   A first support mechanism that includes the first load adjustment unit and the second load adjustment unit, and supports one end side of the bonding roller so as to be movable in the vertical direction;
   A second support mechanism that includes the third load adjustment unit and the fourth load adjustment unit, and supports the other end side of the bonding roller so as to be movable in the vertical direction;
   The film bonding apparatus according to claim 1 or 2, characterized by comprising:
4. The film bonding apparatus according to claim 3, wherein the first support mechanism and the second support mechanism are air cylinder mechanisms.
5. A rotation driving mechanism for rotating the laminating roller;
   The film bonding apparatus according to any one of claims 1 to 4, wherein the rotation driving mechanism is provided on one side of one end side and the other end side of the bonding roller.
6. Equipped with a film laminating device for laminating an optical film on an optical display panel,
   The production system for an optical display device, wherein the film laminating apparatus is the film laminating apparatus according to any one of claims 1 to 5.
7. Including a film bonding step of bonding an optical film to the optical display panel,
   6. A method for producing an optical display device, wherein the film laminating apparatus according to claim 1 is used in the film laminating step.
8. The optical display panel is an image display panel having a plurality of pixel columns,
   The optical film is a patterned retardation film having a plurality of polarization pattern rows corresponding to the plurality of pixel rows,
   In the film bonding step, the patterned retardation film is bonded to the image display panel so that each boundary line of the plurality of polarization pattern columns is positioned between each of the plurality of pixel columns. A method for producing an optical display device according to claim 7.

Images