CN102119077A - 薄膜贴附装置、薄膜贴附方法及电子纸的制造方法 - Google Patents
薄膜贴附装置、薄膜贴附方法及电子纸的制造方法 Download PDFInfo
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- CN102119077A CN102119077A CN2008801306939A CN200880130693A CN102119077A CN 102119077 A CN102119077 A CN 102119077A CN 2008801306939 A CN2008801306939 A CN 2008801306939A CN 200880130693 A CN200880130693 A CN 200880130693A CN 102119077 A CN102119077 A CN 102119077A
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- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
- B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
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Abstract
本发明提供一种使多个薄膜基材弯曲而贴附的薄膜贴附装置、薄膜贴附方法及电子纸的制造方法。在该薄膜贴附装置上设有:模具,其具有期望形状的曲面状吸附面;吸附滚筒,其构成为能够在曲面状安装面上相对移动,并具有保持薄膜基材的多个真空室;以及,吸引装置,其能够针对真空室分别进行吸引处理。并且,吸附滚筒在与薄膜基材相对的相对位置上,开始对与该相对位置对应的真空室进行吸引处理,并依次停止对与所贴附的薄膜贴附装置对应的上述真空室的吸引处理。
Description
技术领域
本发明涉及薄膜贴附装置、薄膜贴附方法及电子纸的制造方法,特别是涉及使多个薄膜基材弯曲而贴附的薄膜贴附装置、薄膜贴附方法及电子纸的制造方法。
背景技术
例如,关于电车内广告及街头POP(Point of purchase advertising)广告,从纸资源的节约及耗电低的观点出发,期待用电子纸技术来对其进行替代。可以预想到该电子纸作为上述用途而安装在电车内上部或建筑物的柱子等具有曲面的场所。为了得到该用途所需的高耐久性及稳定的视觉确认性,期望以在制造工序内预先形成了期望的曲面形状的状态下出厂。
并且,虽然作为电子纸的制造工序之一,存在粘接多个薄膜基材的工序,但在利用该工序形成曲面形状时,目前应用了层叠多个树脂制薄片的技术(参照专利文献1)。具体地讲,如图1A所示,准备具有图中所期望的曲面形状的阴模2、和具有与此相对的形状的阳模3这两种模具2、3,并吸附保持分别粘接在该两种模具上的薄膜基材5A、5B。接着,如图1B所示,可以使用通过在组合上述两种模具2、3的状态下进行加压(用箭头F表示加压力),来贴附薄膜基材5A、5B的方法。
专利文献1:日本特开2005-161528号公报
但是,在使用了上述方法的情况下,会产生下述的(a)~(d)的问题点。
(a)需要两种专用的模具2、3,并且为了使这些模具2、3啮合,对于相对的模具的面(在图1A中用标号2a、3a表示的面)要求较高的加工精度。
(b)在粘贴了三张以上的薄膜基材时,由于薄膜基材的厚度增大、曲率半径变化,因此进一步需要改变了曲率半径的模具。
(c)由于将整个面一并粘接,因此没有使存在于粘结剂等中的气泡出逃的地方,因而为了除去该气泡,在粘接工序后另外需要气泡除去工序。
(d)在粘接时使用了粘结剂的情况下,由于模具2、3的弯曲形状而会使粘结剂产生偏向一方的情况,产品的厚度会不均匀。
发明内容
本发明的总体目的在于,提供一种解决上述现有技术的问题的、经改良的有用的薄膜贴附装置、薄膜贴附方法及电子纸的制造方法。
本发明的更详细的目的在于,提供一种薄膜贴附装置、薄膜贴附方法及电子纸的制造方法,其制造设备简单,并在内部不残存气泡等,能够在具有曲面的状态下,可靠地贴附多个薄膜基材。
为了达成上述目的,从一个观点出发提供一种薄膜贴附装置,其将第1薄膜基材和第2薄膜基材粘接成曲面形状,其中,所述薄膜贴附装置设有:模具,其安装有所述第1薄膜基材,并设有具备所期望的曲面形状的曲面状安装面;吸附保持装置,其构成为能够在所述曲面状安装面上相对移动,并具有多个真空室,该多个真空室设有对所述第2薄膜基材进行吸附保持的吸附面;以及吸引装置,其能够对所述多个真空室单独进行吸引处理,所述吸引装置随着所述吸附保持装置的移动,在与所述第2薄膜基材相对的相对位置,开始针对与该相对位置对应的所述真空室的吸引处理,随着所述第2薄膜基材贴附到所述第1薄膜基材,依次停止针对与所贴附的所述第2薄膜对应的所述真空室的吸引处理。
从达成上述目的的另一观点出发,提供一种薄膜贴附方法,将多个薄膜基材粘接成曲面形状,其中,所述薄膜贴附方法包括:安装工序,在模具上安装第1薄膜基材,该模具设有具备所期望的曲面形状的曲面状安装面;以及贴附工序,使用吸附保持装置,将第2薄膜基材贴附到所述第1薄膜基材上,该吸附保持装置构成为能够在所述曲面状安装面上相对移动,并具有多个真空室,该多个真空室分别设有对所述第2薄膜基材进行吸附保持的吸附面;在所述贴附工序中,在与所述第2薄膜基材相对的相对位置,开始针对与该相对位置对应的所述真空室的吸引处理,随着所述吸附保持装置的移动而贴附所述第1及第2薄膜基材,伴随于此依次停止针对与所贴附的所述第2薄膜对应的所述真空室的吸引处理。
另外,从达成上述目的另一观点出发,提供一种电子纸制造方法,将第1及第2薄膜基材贴附成曲面形状,该第1及第2薄膜基材是夹着电子纸的液晶而配置的基板,其中,所述电子纸制造方法包括:安装工序,在模具上安装所述第1薄膜基材,该模具设有具备所期望的曲面形状的曲面状安装面;以及贴附工序,使用吸附保持装置,将所述第2薄膜基材贴附到所述第1薄膜基材上,该吸附保持装置构成为能够在所述曲面状安装面上相对移动,并具有多个真空室,该多个真空室分别设有对所述第2薄膜基材进行吸附保持的吸附面;在所述贴附工序中,在与所述第2薄膜基材相对的相对位置,开始针对与该相对位置对应的所述真空室的吸引处理,随着所述吸附保持装置的移动而贴附所述第1及第2薄膜基材,伴随于此依次停止针对与所贴附的所述第2薄膜对应的所述真空室的吸引处理。
根据本发明,即使在粘接3张以上的薄膜基材时,也不需要多个模具,并能够削减模具制造成本。并且,在进行贴附处理时,由于是一边赶出气泡一边粘接第1及第2薄膜基材,因此所贴附的薄膜基材内不存在气泡,从而可以不需要气泡除去工序。
附图说明
图1A是作为以往的一例的薄膜贴附装置的示意结构图(贴附前)。
图1B是作为以往的一例的薄膜贴附装置的示意结构图(贴附时)。
图2是示出作为本发明的一例的薄膜贴附装置的基本结构,并示出曲面状吸附面为向上凸出的形状的例子的图。
图3是放大表示图2所示的薄膜贴附装置的吸附保持装置的立体图。
图4是示出作为本发明的一例的薄膜贴附装置的基本结构,并示出曲面状吸附面为凹形状的例子的图。
图5是作为本发明的一个实施例的薄膜贴附装置的结构图。
图6A是用于说明吸附滚筒的结构的图。
图6B是吸附滚筒的截面图。
图7是示出作为本发明的一个实施例的薄膜贴附装置的吸附滚筒的控制***的框图。
图8是示出针对吸附滚筒的真空室的吸引处理的ON/OFF定时的时序图。
图9是示出作为本发明的一个实施例的薄膜贴附装置的动作的流程图。
图10是示出使模具的曲面状吸附面形成为波型的实施例的结构图。
标号说明:
10A、10B、30:薄膜贴附装置 11A、11B、11C:模具
12:吸附保持装置(吸附滚筒) 13-1~13-8:真空室
14-1~14-8:吸附面 15A、15B、15C:曲面状吸附面
17:吸引装置 20A、20B:薄膜基材
31:供给卷 32:间隔物散布装置
33:间隔物 34:粘结剂固化装置
35:分配器 36:粘结剂
37:进给台 39:薄膜切割器
40:滚筒旋转轴 41:滚筒加压装置
42:连通管 44:定位标记
45:角度检测装置 46:压力检测装置
49:控制装置
具体实施方式
以下,参照附图说明本发明的实施方式。
图2示出作为本发明的一例的薄膜贴附装置10A的基本结构,图3放大示出设在薄膜贴附装置10A的吸附保持装置12。薄膜贴附装置10A是将薄膜基材20A和薄膜基材20B粘在一起的装置。该薄膜贴附装置10A由模具11A、吸附保持装置12及吸引装置17等构成。
模具11A是与吸附保持装置12相对的面成为曲面形状(具体而言是凸的半圆筒形状)的曲面状吸附面15A。在图2所示的例子中,示出了曲面状吸附面15为向上凸的形状的例子。该曲面状吸附面15A上形成有多个微小的孔,并且在模具11A上连接有吸引装置17。当驱动该吸引装置17时,从曲面状吸附面15A的微小的孔进行吸引处理,从而薄膜基材20A吸附在曲面状吸附面15A。由此,薄膜基材20A安装在模具11A上。
如图5中放大表示,吸附保持装置12整体上具有圆筒形状,并构成为以旋转轴40为中心向图中箭头A所示的方向旋转。该吸附保持装置12起到如下所述的作用,即如后所述,通过一边针对薄膜基材20B适当地进行保持及解除保持,一边在模具11A上相对移动,从而将薄膜基材20B贴附(粘贴)到薄膜基材20A。
并且,模具11A相对上述吸附保持装置12的相对移动,可以是将吸附保持装置12固定而使模具11A移动的结构,也可以是相反地将模具11A固定而使吸附保持装置12移动的结构。另外,在进行该贴附处理时,预先在薄膜基材20A或薄膜基材20B中的至少一方上涂布粘结剂。
在上述吸附保持装置12的内部设有多个(在本实施例中为8个)第1真空室13-1~第8真空室13-8。该各第1真空室13-1~第8真空室13-8的各外周面,成为形成有多个微小的孔的第1吸附面14-1~第8吸附面14-8。
并且,在吸附保持装置12上也连接有吸引装置17,并构成为能够对各第1真空室13-1~第8真空室13-8进行吸引处理的结构。此时,吸引装置17成为能够对各第1真空室13-1~第8真空室13-8分别进行吸引处理的结构。
因此,当驱动吸引装置17时,通过第1真空室13-1~第8真空室13-8从第1吸附面14-1~第8吸附面14-8的微小的孔进行吸引处理,从而将薄膜基材20B吸附到第1吸附面14-1~第8吸附面14-8。由此,薄膜基材20B安装在吸附保持装置12上。
此时,如上所述,由于吸引装置17成为能够对第1真空室13-1~第8真空室13-8分别进行吸引处理的结构,因此可以在吸附保持装置12的规定角度范围内保持薄膜基材20B,而不是在吸附保持装置12的全周上保持薄膜基材20B。
例如,在吸引装置17进行了仅对第1真空室13-1的吸引处理时,薄膜基材20B仅吸引保持在第1吸附面14-1。并且,在仅对第2真空室13-2和第3真空室13-3进行了吸引处理时,薄膜基材20B仅吸引保持在第2吸附面14-2和第3吸附面14-3。
接着,对如上构成的薄膜贴附装置10A的动作进行说明。
在图2所示的例子中,在固定吸附保持装置12的同时模具11A向图中的箭头V所示的方向移动,由此吸附保持装置12成为在模具11A的曲面状吸附面15A上向与箭头V方向的反方向(图中的左方向)相对移动的结构。
在将薄膜基材20A定位并放置在曲面状吸附面15A上后,通过吸引装置17向模具11A进行吸引处理,并通过该吸引力保持在曲面状吸附面15A上。
在开始薄膜基材20A和薄膜基材20B之间的贴附处理时(以下,称为贴附开始时),吸附保持装置12位于曲面状吸附面15A的图2中用箭头P1所示的位置(以下,称为贴附开始位置)。并且,在该贴附开始时,吸附保持装置12已经在其外周约180°的范围上保持薄膜基材20B。
如上所述,吸附保持装置12虽然具有第1真空室13-1~第8真空室13-8,但是伴随吸附保持装置12的移动,在薄膜基材20B与吸附保持装置12的表面相对的范围中的真空室通过吸引装置17进行吸引处理,由此进行该吸引处理的吸附面保持薄膜基板材料20B。
与此相对,随着薄膜基材20B通过吸附保持装置12的移动而贴附到薄膜基材20A,吸引装置17依次停止对与所贴附的第2薄膜20B对应的真空室的吸引处理。该对真空室的吸引处理的切换处理是在贴附时间开始之后,到吸附保持装置12从贴附开始位置P1移动到贴附结束位置P2(图2中用箭头表示)期间依次实施。
使用吸附保持装置12移动到曲面状吸附面15A的大致中央位置的状态的图2,说明上述处理的具体动作。
当从图2所示的状态,吸附保持装置12向箭头A方向旋转的同时,模具11A相对地向箭头V方向移动时,第1真空室13-1变成与薄膜基材20B相对。因此,通过吸引装置17开始针对第1真空室13-1的吸引处理。由此,在薄膜基材20B与第1吸附面14-1接触时,薄膜基材20B保持在第1吸附面14-1。
与此相对,当吸附保持装置12从图2所示的状态向箭头A方向旋转的同时模具11A相对地向箭头V方向移动时,保持在第6吸附面14-6上的薄膜基材20B贴附在薄膜基材20A上。如上所述,当薄膜基材20B贴附在薄膜基材20A之后,仍继续进行对第6真空室13-6的吸引处理时,第6吸附面14-6的薄膜基材20B的保持力(吸引力),作为将薄膜基材20B从薄膜基材20A剥离的力来发挥功能。
在此构成为,在薄膜基材20B贴附到薄膜基材20A之后,停止吸引装置17进行的、针对与贴附结束位置对应的第6真空室13-6的吸引处理的结构。随着吸附保持装置12的曲面状吸附面15A上的移动以及以滚筒旋转轴40为中心的旋转来实施上述处理,从而在薄膜基材20B与吸附保持装置12相对的规定范围(在图2所示的例子中,图中θ所示的约180°范围)中,能够可靠地保持薄膜基材20B。并且,由于将薄膜基材20B贴附到薄膜基材20A之后,立即解除对薄膜基材20B的保持,因此能够可靠地防止由吸附保持装置12引起的薄膜基材20B从薄膜基材20A剥离。
如上所述,由于图2所示的薄膜贴附装置10A构成为通过使圆筒形状的吸附保持装置12在设于模具11A的期望形状的曲面状吸附面15A的上部移动,从而一边贴附薄膜基材20A、20B一边成型,因此可以与以往不同地使模具仅为一个(仅模具11A)。如上所述,由于可以减少制造成本高的模具的数量,因此可以实现降低薄膜贴附装置10A的成本。并且,如上所述,由于并不需要使用两个模具,因此不再需要如以往那样为了组合两个模具而进行的高精度的模具加工,由此也可以实现成本的降低。
并且,在上述的例子中说明了贴附薄膜基材20A和薄膜基材20B这两张薄膜基材的情况,但是在粘贴三张以上的薄膜基材的情况下,也可以进行贴附处理而不用将模具11A替代为其他的模具。即,当使薄膜基材的层叠数增加而伴随与此薄膜基材的厚度增大时,曲率半径变化。这样,当由于层叠而使薄膜基材的曲率半径变化时,在以往的组合两个模具5A、5B(参照图1A、1B)来成型的方法中,伴随曲率半径的变化需要制造多个模具。
与此相对,在上述的薄膜贴附装置10A中,即使通过在曲面状吸附面15A上层叠薄膜基材而使薄膜基材的曲率半径变化,也由于在其上部重复层叠下一个薄膜基材,并利用在其上部移动的吸附保持装置12来进行贴附及成型处理,因此不需要变更模具。
另外,由于上述的薄膜贴附装置10A构成为,吸附保持装置12在曲面状吸附面15上,从贴附开始位置P1移动到贴附结束位置P2,因此即使在为了粘结薄膜基材20A和薄膜基材20B而使用的粘结剂(未图示)中存在气泡,该气泡也会伴随吸附保持装置12的移动而被推向贴附结束位置P2,并从其端部排出到外部。由此,在结束了薄膜基材20A、20B的贴附之后,不需要另外进行气泡除去处理,可以实现贴附处理的简单化。进而,根据相同的理由,也可以防止粘结剂产生偏向一方的情况。
另外,在例如使用在内部配置电子纸用液晶的基板作为薄膜基材20A、20B的情况下,由于这些基板与一般的树脂薄膜相比刚性高,因此很难弯曲。因此,当将具有图2所示的凸形状的曲面状吸附面15A的模具11A应用于电子纸时,存在不得不破坏初始的曲面形状而不能进行适应性显示的顾虑。
在这样的情况下,使用具有图4所示的凹形状的曲面状吸附面15B的模具11B是有效的。并且,即使在液晶的注入处理中,如果在结束全部的薄膜基材的层叠的阶段中实施液晶的注入工序,则也可以消除层叠导致的对液晶的物理影响。
接着,根据上述的基本原理,说明作为本发明的一个实施例的薄膜贴附装置。
图5至图9是用于说明作为本发明的一个实施例的薄膜贴附装置30的图。图5是薄膜贴附装置30的结构图,图6是用于说明设在薄膜贴附装置30的吸附滚筒12(吸附保持装置12)的图。图7是示出薄膜贴附装置30的吸附滚筒12的控制***的图,图8是示出针对吸附滚筒12的真空室的吸引处理的ON/OFF定时的时序图。图9是示出薄膜贴附装置30的动作的流程图。另外,在图5至图9中,对于与图2及图3所示的结构对应的结构,附上相同标号而省略其说明。
首先,使用图5说明薄膜贴附装置30的整体结构。本实施例的薄膜贴附装置30是将在电子纸中使用的树脂制薄膜基材(以下,称为薄膜基材20A、20B)粘在一起的装置。
该薄膜贴附装置30由模具11A、构成吸附保持装置的吸附滚筒12、吸引装置17、供给卷31、间隔物散布装置32、粘结剂固化装置34、分配器35、进给台37以及薄膜切割器39等构成。
模具11A成为与吸附滚筒12相对的面成为曲面形状(具体地讲,凸的半圆筒形状)的曲面状吸附面15A。在本实施例中,示出了曲面状吸附面15向上凸的形状的例子。在该曲面状吸附面15A上形成有多个微小的孔,通过驱动吸引装置17,从曲面状吸附面15A的微小的孔进行吸引处理。薄膜基材20A通过该吸引处理而保持在曲面状吸附面15A。
进给台37配置在模具11A的下部。该进给台37起到使模具11A在图5中的左右方向上移动的功能。虽然后述的吸附滚筒12是固定的,但可以构成为,通过使模具11A根据进给台37的移动来移动,从而使吸附滚筒12能够相对于模具11A向图5中的左右方向上移动。
吸附滚筒12具有圆筒形状,并构成为以滚筒旋转轴40为中心向图中的箭头A所示的方向旋转。通过使该吸附滚筒12在模具11A上相对地移动,从而起到将薄膜基材20B贴附(粘贴)到薄膜基材20A的功能。
在上述的吸附滚筒12的内部设有多个(在本实施例中为8个)第1真空室13-1~第8真空室13-8。该各第1真空室13-1~第8真空室13-8的各外周面成为形成有多个微小的孔的第1吸附面14-1~第8吸附面14-8。
如图6A所示,在该各第1真空室13-1~第8真空室13-8上,分别连接有连通管42的一端。并且,连通管42的另一端分别与吸引装置17连接。如图6B所示,该连通管42配置在滚筒旋转轴40的内部。由此,即使是旋转的吸附滚筒12,也可以针对各第1真空室13-1~第8真空室13-8进行吸引处理。
并且,在连通吸引装置17和各第1真空室13-1~第8真空室13-8的连通管42的中途位置上,分别设有第1切换阀47-1~第8切换阀47-8(参照图7)。由此,通过切换该第1切换阀47-1~第8切换阀47-8,能够对第1真空室13-1~第8真空室13-8分别进行吸引处理。
当驱动吸引装置17,打开阀47-1~47-8而通过第1真空室13-1~第8真空室13-8从第1吸附面14-1~第8吸附面14-8的微小的孔进行吸引处理时,薄膜基材20B吸附到曲面状吸附面15A上。由此,薄膜基材20B保持在模具11A上。
此时,通过适当地调整阀47-1~47-8的开闭,吸引装置17可以对第1真空室13-1~第8真空室13-8单独进行吸引处理。由此,可以在规定的角度范围保持薄膜基材20B,而不是在吸附滚筒12的全周保持薄膜基材20B。
如上述构成的吸附保持装置12构成为能够通过滚筒加压装置41朝向模具11A进行加压的结构(用图中的箭头F表示加压力)。并且,在吸附保持装置12的内部设有角度检测装置45及压力检测装置46(参照图7)。角度检测装置45是检测吸附保持装置12的旋转角度的角度传感器。并且,压力检测装置46是检测吸附保持装置12通过滚筒加压装置41对模具11A进行加压的加压力的压力传感器。如后所述,由角度检测装置45检测出的角度信息、以及由压力检测装置46检测出的加压力信息,分别发送到控制装置49。
供给卷31卷绕薄膜基材20B。在本实施例中,构成为能够从该供给卷31连续供给薄膜基材20B。从该供给卷31供给的薄膜基材20B被引导辊38引导而卷绕在吸附保持装置12上,并通过吸附保持装置12相对模具11A的相对移动,而贴附到薄膜基板材料20A。
另外,虽然在本实施例中示出了薄膜基材20B从供给卷31连续供给的例子,但是也可以构成为预先将薄膜基材20B切断为与薄膜基材20A的长度(曲面状吸附面15A的长度)对应的长度,并按照每张供给到薄膜贴附装置30。
间隔散布装置32是对薄膜基材20B散布间隔物33的装置。本实施例中是如上所述将在电子纸中使用的薄膜基材20A、20B粘在一起的装置。在电子纸的情况下,在薄膜基材20A与薄膜基材20B之间注入有液晶。因此,需要形成用于在薄膜基材20A与薄膜基材20B之间注入液晶的间隙。因此,间隔物散布装置32散布用于形成该间隙的间隔物33。
分配器35起到涂布用于将薄膜基材20A与薄膜基材20B贴附的粘结剂36的功能。在本实施例中,相对于上述吸附保持装置12相对模具11A的相对移动方向,分配器35配置在吸附保持装置12的前方位置。
由此,可以对贴附前的薄膜基材20A涂布粘结剂36,并且通过在其之上利用吸附保持装置12将薄膜基材20B加压到薄膜基材20A,从而贴附薄膜基材20A与薄膜基材20B。另外,虽然在本实施例中构成为,在即将贴附薄膜基材20A与薄膜基材20B之前,将粘结剂36涂布到薄膜基材20A上的结构,但是也可以考虑在贴附前预先在薄膜基材20A的贴附面的整个面上涂布粘结剂36的方法。如上所述,虽然可以考虑各种粘结剂36的涂布方法,但是只要考虑所使用的粘结剂的特性等而适当选择即可。
粘结剂固化装置34起到通过粘结剂36贴附薄膜基材20A和薄膜基材20B之后,使该粘结剂36发挥效果的功能。在本实施例中,相对于上述吸附保持装置12相对模具11A的相对移动方向,粘结剂固化装置34配置在吸附保持装置12的后方位置。
利用该粘结剂固化装置34的硬化处理根据所使用的粘结剂36的种类来选定。例如,如果粘结剂36具有紫外线固化性,则作为粘结剂固化装置34使用紫外线照射装置。而如果粘结剂36具有热固化性,则作为粘结剂固化装置34使用加热装置。
另外,在本实施例中,使用在吸附滚筒12的附近配置粘结材料固化装置34,并从粘接部分进行固化的方法。但是,也可以考虑在将薄膜基材20A及薄膜基材20B的整个面粘接之后,使整个粘结位置一并固化的方法。可以考虑所使用的粘结剂的特性等而适当选择这些固化方法。
薄膜切割器39起到如下所述的功能,即在薄膜基材20B由于吸附保持装置12的移动而从贴附开始位置P1拉出到贴附结束位置P2的同时而贴附时,切断薄膜基材20B。另外,该切断位置也可以是刚好从供给卷31拉出薄膜基材20B之后的位置。但是,由于能够维持在吸附滚筒12上吸附下一个粘接部分的状态,因此从转移到下一个贴附作业的顺利化的面上考虑,优选在吸附保持装置12移动到图中的虚线所示的位置的状态下(薄膜基材20B比贴附结束位置P2还要被进一步拉出的状态)进行切断。
接着,使用图7说明吸附滚筒12的控制***。
上述的吸引装置17、滚筒加压装置41、角度检测装置45、压力检测装置46及第1切换阀47-1~第8切换阀47-8与控制装置49连接。控制装置49起到整体控制薄膜贴附装置30的动作的功能。
由角度检测装置45检测出的角度信息及由压力检测装置46检测出的加压力信息,分别发送到控制装置49。控制装置49根据滚筒旋转轴40的角度信息,实施第1切换阀47-1~第8切换阀47-8的切换处理。
如上所述,吸附滚筒12利用滚筒加压装置41而向模具11(曲面状吸附面15A)加压。当该加压力随着吸附滚筒12的移动而变动时,不能均匀且稳定地贴附薄膜基材20A和薄膜基材20B。因此,控制装置49根据由压力检测装置46检测出的吸附滚筒12针对模具11A的加压力,控制滚筒加压装置41,使得吸附滚筒12以一定的稳定的加压力对模具11A进行加压。
接着,对控制装置49实施的第1切换阀47-1~第8切换阀47-8的转换控制,进行更详细的说明。
本实施例的控制装置49进行如下的控制,即第1切换阀47-1~第8切换阀47-8的各开闭的定时依序按照吸附滚筒12的旋转角度依次偏离45°。并且,控制装置49在打开切换阀47-1~47-8之后,到吸附滚筒12旋转180°为止维持开阀状态。并且,之后进行闭阀处理,并在闭阀之后进行使该闭阀状态维持180°的控制。即、控制装置49构成为以180°的间隔对各切换阀47-1~47-8进行ON/OFF控制。
图8是示出控制装置49进行了如上所述的控制时对第1真空室13-1~第8真空室13-8的真空处理的ON/OFF的时序图。在本实施例中,在吸附保持装置12的第1真空室13-1刚要与薄膜基材20B接触之前的位置作为0°。
当控制装置49根据来自角度检测装置45的角度信息判断为吸附保持装置12的旋转角度为0°时,第1切换阀47-1开阀。由此,第1真空室13-1通过连通管42与吸引装置17连接,从而开始(ON)对第1真空室13-1的真空处理。
之后,当吸附保持装置12旋转45°时,控制装置49维持第1切换阀47-1的开阀状态的同时,第2切换阀47-2开阀。之后,在每次将吸附保持装置12旋转45°时,依次切换各切换阀47-3~47-8。由此,如图8所示,第2真空室13-2~第8真空室13-8也依次开始真空处理。另一方面,控制装置49在各切换阀47-1~47-8的开阀状态继续180°时,依次实施闭阀处理。图8示出吸附滚筒12在0°~360°的范围内旋转时的各切换阀47-1~47-8的切换定时。
在本实施例中,如上所述将吸附保持装置12的第1真空室13-1(第1吸附面14-1)与薄膜基材20B接触的位置作为0°。因此,通过第1吸附面14-1与薄膜基材20B接触,使第1真空室13-1进行吸引处理,从而薄膜基材20B吸附保持在第1真空室13-1(第1吸附面14-1)。
如上所述,在薄膜基材20B保持在第1吸附面14-1的状态下,成为薄膜基材20B已经在180°的范围内卷绕在吸附滚筒12上的状态。由此,成为薄膜基材20B也与第6吸附面14-6~第8吸附面14-8接触的状态。
如上所述,控制装置49进行如下所述的控制处理,即通过控制各切换阀47-1~47-8,对与和薄膜基材20B接触的吸附面(在图5所示的例子中,第1吸附面14-1、第6吸附面14-6~第8吸附面14-8)对应的真空室(在图5所示的例子中,第1真空室13-1、第6真空室13-6~第8真空室13-8)实施吸引处理。
如图8所示,由于吸附该薄膜基材20B的吸附面在吸附滚筒12每旋转45°时切换,因此吸附滚筒12始终将薄膜基材20B保持在该180°的整个范围内。由此,可以可靠地从供给卷31拉出薄膜基材20B,进行将其贴附到安装在曲面状吸附面15A上的薄膜基材20A的处理。
另一方面,吸附滚筒12对薄膜基材20A、20B进行加压的位置,是吸附滚筒12与模具11A的曲面状吸附面15A抵接的位置。在该位置处,薄膜基材20A与薄膜基材20B贴附。由此,当贴附薄膜基材20A和薄膜基材20B之后,还维持利用吸附滚筒12保持薄膜基材20B的状态时,如上所述,该保持力会相反地作为将薄膜基材20B从薄膜基材20A剥离的力来发挥作用。
因此,在图5所示的状态中,控制装置49使第5切换阀47-5停止,结束对第5真空室13-5(第5吸附面14-5)的吸引处理。由此,可以防止所贴附的薄膜基材20A、20B由于吸附滚筒12而剥离的情况。另外,控制装置49控制第2切换阀47-2~第4切换阀47-4,以使不对与没有和薄膜基材20B接触的其他吸附面(在图5所示的例子中为第2吸附面14-2~第4吸附面14-4)对应的真空室(在图5所示的例子中为第2真空室13-2~第4真空室13-4),实施吸引处理。
如图8所示,由于没有吸附该薄膜基材20B的吸附面也在吸附滚筒12每旋转45°时切换,因此也不实施没有与吸附滚筒12的薄膜基材20B接触的部分的吸引处理。由此,在防止上述薄膜基材20A、20B的剥离的同时,可以抑制吸引装置17的无用的驱动,并可以实现运行成本的减少。
接着,对如上所述构成的薄膜贴附装置30的动作进行说明。图9是示出贴附薄膜基材20A、20B时的薄膜贴附装置30的动作的流程图。
当开始贴附处理时,在步骤10(在图中,将步骤简称为S)中,进行将薄膜基材20A安装到模具11A的处理。此时,在本实施例中,使用将切断为预先规定形状的薄膜基材20A载置到模具11A的曲面状吸附面15A的方法。但是,也可以使用如下所述的方法,即使用与供给卷31相同的、卷绕了薄膜基材20A的供给卷,向曲面状吸附面15A上连续供给薄膜基材20A。
并且,在曲面状吸附面15A的贴附开始位置P1处,设有定位标记44。在将薄膜基材20A安装到曲面状吸附面15A时,使用该定位标记44进行两者15A、20A的定位。由此,可以将薄膜基材20A高精度地安装到曲面状吸附面15A上的规定安装位置处。
如上所述,当薄膜基材20A安装到曲面状吸附面15A上的规定安装位置处时,控制装置49驱动吸引装置17。由此,薄膜基材20A吸附到曲面状吸附面15A上,由此薄膜基材20A保持在模具11A上。
接着,在步骤20中,使用定位标记44,将从供给卷31拉出的20B的前端部安装到模具11A的曲面状吸附面15A。由此,在贴附开始位置P1,成为薄膜基材20A与薄膜基材20B一起被定位而重叠的状态。
接着,在步骤30中,使用分配器35将粘结剂36涂布到薄膜基材20A上。并且,吸附滚筒12移动到贴附开始位置P1位置的同时,控制装置49驱动滚筒加压装置41而用规定的加压力,朝向模具11A对吸附滚筒12进行加压。由此,介于吸附滚筒12与模具11A之间的薄膜基材20A和薄膜基材20B也被加压,由此贴附薄膜基材20A和薄膜基材20B。
在步骤40中,进给台37开始向箭头V方向移动。由此,吸附滚筒12相对地开始在曲面状吸附面15A上向V方向的反方向移动。此时,由于分配器35相对吸附保持装置12相对于模具11A的相对移动方向(V方向的反方向)配置在吸附保持装置12的前方位置,因此粘结剂36被依次涂布在薄膜基材20A上。并且,吸附滚筒12通过移动,在涂布有粘结剂36的薄膜基材20A上依次对薄膜基材20B进行加压而进行贴附处理。
此时,如上所述,吸附滚筒12构成为,以在180°范围内将薄膜基材20B吸附保持到吸附滚筒12的状态下移动,对薄膜基材20B进行加压而贴附到薄膜基材20A之后,立即解除吸附而解除吸附滚筒12对薄膜基材20B的保持。由此,可以可靠地防止由吸附滚筒12引起的、薄膜基材20B从薄膜基材20A的剥离。
并且,步骤40的处理是在吸附滚筒12从贴附开始位置P1移动到贴附结束位置P2为止的期间中实施。由此,即使在粘结薄膜基材20A与薄膜基材20B的粘结剂36内存在气泡,该气泡也会随着吸附滚筒12的移动而被挤压到贴附结束位置P2,从其端部放出到外部。
由此,在结束薄膜基材20A、20B的贴附之后,粘结剂36内不会残存气泡,从而由于无需实施气泡除去处理,因此可以实现贴附处理的简单化。并且,由于吸附滚筒12根据控制装置49对滚筒加压装置41的控制,而始终以一定的加压力向模具11A施加加压力,因此可以防止粘结剂36产生偏向一方的情况。
在步骤50中,粘结剂固化装置34进行粘结剂36的固化处理。在本实施例中,由于作为粘结剂36使用紫外线固化树脂,因此粘结剂固化装置34向粘结剂36照射紫外线。此时,由于粘结剂固化装置34相对于吸附保持装置12相对于模具11A的相对移动方向(V方向的反方向),配置在吸附保持装置12的后方位置,因此粘结剂固化装置34的固化处理针对由分配器35涂布的粘结剂36依次进行。
步骤30~50的处理是在吸附滚筒12移动到贴附结束位置P2之前实施的。然后,当薄膜基材20A、20B在从贴附开始位置P1到贴附结束位置P2的范围内贴附后,由薄膜切割器39切断薄膜基材20A、20B,由此结束薄膜基材20A和薄膜基材20B的贴附处理。
由于上述的实施例的薄膜贴附装置30构成为通过使吸附滚筒12移动来贴附薄膜基材20A、20B的同时成型,因此可以仅在一个模具11A上进行薄膜基材20A、20B的贴附处理。由此,可以减少制造成本高的模具的使用数量,并且可以实现成本降低。并且,不需要在使用多个模具时所需的用于模具匹配的高精度的模具加工,由此也可以实现成本降低。
另外,在上述实施例中虽然示出了模具11A的形状成为向上凸的半圆筒形的例子,但是如图10所示,能够使形成在模具11C的曲面状吸附面15C成为自由曲面形状。并且,即使使吸附装置和吸附滚筒的上下设置位置相反,也可以实现。
以上,虽然详细说明了本发明的优选实施例,但本发明不限于上述的特定的实施方式,可以在权利要求中记载的本发明的要旨的范围内,进行各种变形/变更。
Claims (16)
1.一种薄膜贴附装置,其将第1薄膜基材和第2薄膜基材粘接成曲面形状,其中,所述薄膜贴附装置设有:
模具,其安装有所述第1薄膜基材,并设有具备所期望的曲面形状的曲面状安装面;
吸附保持装置,其构成为能够在所述曲面状安装面上相对移动,并具有多个真空室,该多个真空室分别设有对所述第2薄膜基材进行吸附保持的吸附面;以及
吸引装置,其能够对所述多个真空室单独进行吸引处理,
所述吸引装置构成为,随着所述吸附保持装置的移动,在与所述第2薄膜基材相对的相对位置,开始针对与该相对位置对应的所述真空室的吸引处理,
随着所述第2薄膜基材贴附到所述第1薄膜基材上,依次停止针对与所贴附的所述第2薄膜对应的所述真空室的吸引处理。
2.根据权利要求1所述的薄膜贴附装置,其中,
所述吸附保持装置设有旋转角度检测装置,
并且,所述吸引装置根据由所述旋转角度检测装置检测的所述吸附保持装置的旋转角度,切换对所述真空室的吸引处理。
3.根据权利要求1所述的薄膜贴附装置,其中,
所述薄膜贴附装置还设有:
加压装置,其朝向所述模具对所述吸附保持装置进行加压;
压力检测装置,其检测所述吸附保持装置对所述模具的加压力;以及
压力控制装置,其根据所述压力检测装置检测的加压力,控制所述加压装置,以使得用一定的加压力朝向所述模具对所述吸附保持装置进行加压。
4.根据权利要求1所述的薄膜贴附装置,其中,
所述吸附保持装置被固定,并且在所述模具上设置有移动装置,由此所述吸附保持装置在所述曲面状安装面上移动。
5.根据权利要求1所述的薄膜贴附装置,其中,
在所述吸附保持装置的旋转中心轴内配置有连通所述真空室与所述吸引装置的连通管。
6.根据权利要求1所述的薄膜贴附装置,其中,
所述薄膜贴附装置构成为能够从供给卷连续供给至少所述第2薄膜基材,
并且,所述薄膜贴附装置设有以期望的长度切断从所述供给卷供给的所述第2薄膜基材的薄膜切割器。
7.根据权利要求1所述的薄膜贴附装置,其中,
所述第1薄膜基材及第2薄膜基材是夹着电子纸的液晶而配置的基板。
8.根据权利要求6所述的薄膜贴附装置,其中,
在所述供给卷与所述吸附保持装置之间设有对所述第2薄膜基材散布间隔物的间隔物散布装置。
9.一种薄膜贴附方法,将多个薄膜基材粘接成曲面形状,其中,所述薄膜贴附方法包括:
安装工序,在模具上安装第1薄膜基材,该模具设有具备所期望的曲面形状的曲面状安装面;以及
贴附工序,使用吸附保持装置,将所述第2薄膜基材贴附到所述第1薄膜基材上,该吸附保持装置构成为能够在所述曲面状安装面上相对移动,并具有多个真空室,该多个真空室分别设有对第2薄膜基材进行吸附保持的吸附面;
在所述贴附工序中,
在与所述第2薄膜基材相对的相对位置,开始针对与该相对位置对应的所述真空室的吸引处理,
随着所述吸附保持装置的移动而贴附所述第1薄膜基材及第2薄膜基材,伴随于此,依次停止针对与所贴附的所述第2薄膜对应的所述真空室的吸引处理。
10.根据权利要求9所述的薄膜贴附方法,其中,
所述吸附保持装置设有旋转角度检测装置,
并且,根据由所述旋转角度检测装置检测的所述吸附保持装置的旋转角度,切换对所述真空室的吸引处理。
11.根据权利要求9所述的薄膜贴附方法,其中,
所述薄膜贴附装置设有:
加压装置,其朝向所述模具对所述吸附保持装置进行加压;
压力检测装置,其检测所述吸附保持装置对所述模具的加压力;以及
压力控制装置,其根据所述压力检测装置检测的加压力,控制所述加压装置,使得以一定的加压力朝向所述模具对所述吸附保持装置进行加压。
12.根据权利要求9所述的薄膜贴附方法,其中,
固定所述吸附保持装置,并使所述模具相对于所述吸附保持装置移动,由此使所述吸附保持装置在所述曲面状安装面上相对移动。
13.根据权利要求9所述的薄膜贴附方法,其中,
构成为能够从供给卷连续供给至少所述第2薄膜基材,
将从所述供给卷供给的所述第2薄膜基材与所述第1薄膜基材贴附之后,利用薄膜切割器切断该第2薄膜基材。
14.根据权利要求9所述的薄膜贴附方法,其中,
所述第1薄膜基材及第2薄膜基材是夹着电子纸的液晶而配置的基板。
15.根据权利要求13所述的薄膜贴附方法,其中,
在所述第2薄膜基材从所述供给卷移动到所述吸附保持装置的期间中,对所述第2薄膜基材散布间隔物。
16.一种电子纸制造方法,其将第1薄膜基材及第2薄膜基材贴附成曲面形状,该第1薄膜基材及第2薄膜基材为夹着电子纸的液晶而配置的基板,其中,所述电子纸制造方法包括:
安装工序,在模具上安装所述第1薄膜基材,该模具设有具备所期望的曲面形状的曲面状安装面;以及
贴附工序,使用吸附保持装置,将所述第2薄膜基材贴附到所述第1薄膜基材上,该吸附保持装置构成为能够在所述曲面状安装面上相对移动,并具有多个真空室,该多个真空室分别设有对所述第2薄膜基材进行吸附保持的吸附面;
在所述贴附工序中,在与所述第2薄膜基材相对的相对位置,开始针对与该相对位置对应的所述真空室的吸引处理,
随着所述吸附保持装置的移动而贴附所述第1薄膜基材及第2薄膜基材,伴随于此,依次停止针对与所贴附的所述第2薄膜对应的所述真空室的吸引处理。
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Also Published As
Publication number | Publication date |
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WO2010018628A1 (ja) | 2010-02-18 |
US8163126B2 (en) | 2012-04-24 |
JPWO2010018628A1 (ja) | 2012-01-26 |
US20110120619A1 (en) | 2011-05-26 |
JP4973783B2 (ja) | 2012-07-11 |
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