CN107924649B - Method and system for manufacturing optical display panel - Google Patents
Method and system for manufacturing optical display panel Download PDFInfo
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- CN107924649B CN107924649B CN201780002537.3A CN201780002537A CN107924649B CN 107924649 B CN107924649 B CN 107924649B CN 201780002537 A CN201780002537 A CN 201780002537A CN 107924649 B CN107924649 B CN 107924649B
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/30—Polarising elements
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- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
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- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
- G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
- G02F1/1333—Constructional arrangements; Manufacturing methods
- G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
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- G—PHYSICS
- G09—EDUCATION; CRYPTOGRAPHY; DISPLAY; ADVERTISING; SEALS
- G09F—DISPLAYING; ADVERTISING; SIGNS; LABELS OR NAME-PLATES; SEALS
- G09F9/00—Indicating arrangements for variable information in which the information is built-up on a support by selection or combination of individual elements
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- G—PHYSICS
- G09—EDUCATION; CRYPTOGRAPHY; DISPLAY; ADVERTISING; SEALS
- G09F—DISPLAYING; ADVERTISING; SIGNS; LABELS OR NAME-PLATES; SEALS
- G09F9/00—Indicating arrangements for variable information in which the information is built-up on a support by selection or combination of individual elements
- G09F9/30—Indicating arrangements for variable information in which the information is built-up on a support by selection or combination of individual elements in which the desired character or characters are formed by combining individual elements
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- General Physics & Mathematics (AREA)
- Nonlinear Science (AREA)
- Optics & Photonics (AREA)
- Chemical & Material Sciences (AREA)
- Crystallography & Structural Chemistry (AREA)
- Mathematical Physics (AREA)
- Engineering & Computer Science (AREA)
- Theoretical Computer Science (AREA)
- Liquid Crystal (AREA)
- Polarising Elements (AREA)
- Devices For Indicating Variable Information By Combining Individual Elements (AREA)
Abstract
A method for manufacturing an optical display panel, wherein a sheet-like optical film (2) having the same structure as that of an optical film having been removed is attached again to one surface (P1) of an optical element having the optical film removed from the optical display panel and the optical element having the optical film provided on the one surface (P1), the method comprising: a re-attaching step of detaching a release film from a sheet-like optical film (2) in which the release film, an adhesive layer, an optical functional film, a 1 st surface protective film and a 2 nd surface protective film (25) are laminated in this order, and attaching the sheet-like optical film to the one surface of the optical element via the adhesive layer to thereby remanufacture the optical display panel; and a 2 nd surface protection film removing step of removing the 2 nd surface protection film (25) after the re-attaching step.
Description
Technical Field
The present invention relates to a method for manufacturing an optical display panel and a system for manufacturing an optical display panel.
Background
An optical film, in which a release film, an adhesive layer, an optical functional film (typically, a polarizing film) and a surface protective film are laminated in this order, is configured in a roll form. The method comprises the following steps: a method (hereinafter, also referred to as a "roll to panel" method ") in which an optical film released from the rolled optical film is cut (half-cut) in the width direction while leaving a release film as the optical film, the adhesive layer, the optical functional film, and the surface protective film, the release film is peeled from the cut optical film, and the optical film is bonded to an optical element via the exposed adhesive layer (see, for example, patent documents 1 and 2).
On the other hand, as a bonding method of an optical film different from the roll-to-roll panel method, there is a method of: a method of bonding an optical film in a sheet state prepared in advance to an optical element via an adhesive layer exposed by peeling off a release film (hereinafter, also referred to as a "sheet to panel (sheet) method") (for example, see patent document 3).
Documents of the prior art
Patent document
Patent document 1: japanese patent laid-open publication No. 2011-123208
Patent document 2: japanese laid-open patent publication No. 2015-049115
Patent document 3: japanese patent laid-open publication No. 2006-039238
Disclosure of Invention
Problems to be solved by the invention
However, in the field of manufacturing optical display panels such as liquid crystal display panels, there are newly produced examples in which optical display panels having the same structure are manufactured not only in a roll-to-roll panel manner but also in a sheet-to-sheet panel manner. For example, patent document 2 discloses: optical display panels are continuously manufactured by a roll-to-roll panel method, and the optical display panels determined to be defective are subjected to a rework process. It can be considered that: when defective products are not so large, a sheet-to-panel method is used when a new optical functional film is bonded to the optical element in the above-described rework process. In addition, it is also considered that: for example, when optical display panels having the same structure must be mass-produced in a short time, the roll-to-roll panel system cannot provide the entire supply amount, and the sheet-to-panel system is used in combination.
In recent years, with the progress of thinning of optical display panels, optical functional films (for example, polarizing films having a thickness of 60 μm or less) thinner than conventional ones, such as polarizing films, have been developed. Such a thin optical functional film is weak in stiffness (elastic modulus) and is liable to twist, curl, and the like.
In the roll-to-roll panel system, a thin optical functional film is fed to a bonding position in a state of being laminated on a carrier film (release film), and the optical functional film is peeled from the carrier film (release film) at the bonding position to bond the optical functional film to an optical element. However, in the sheet-to-panel system, handling such as conveyance of the optical functional film in a sheet form, peeling of the release film, and bonding of the optical functional film to the liquid crystal cell is difficult, and there is a concern that defective bonding may occur and yield may decrease.
The object of the present invention is to provide: a method and a system for manufacturing an optical display panel, by which an optical display panel having the same structure as an optical display panel manufactured by a roll-to-roll method can be manufactured suitably even if a thin optical functional film is laminated to an optical element in a sheet-to-panel manner.
Means for solving the problems
The present invention is a method for manufacturing an optical display panel, which comprises a step of sticking a sheet-like optical film having the same structure as that of an optical film removed from an optical display panel to one surface of the optical element from which the optical film has been removed, wherein the optical display panel comprises an optical film obtained by laminating a pressure-sensitive adhesive layer, an optical functional film, and a No. 1 surface protective film in this order, and an optical element having the optical film provided on the one surface,
the manufacturing method comprises the following steps:
a re-attaching step of detaching a release film from a sheet-like optical film in which the release film, an adhesive layer, an optical functional film, a 1 st surface protective film and a 2 nd surface protective film are laminated in this order, and attaching the sheet-like optical film to the one surface of the optical element via the adhesive layer to remanufacture the optical display panel; and
and a 2 nd surface protective film removing step of removing the 2 nd surface protective film after the re-attaching step.
The above invention may further include a removing step of removing the optical film from the optical display panel based on a result of inspection of the optical element to which the optical film is attached.
The above invention may further comprise an inspection step of inspecting the optical element to which the optical film is attached.
The above invention may further comprise: a cutting step of cutting a tape-shaped optical film, which is unwound from a roll-shaped optical film wound up from a tape-shaped optical film in which a release film, an adhesive layer, an optical functional film, and a 1 st surface protection film are laminated in this order, while leaving the release film in a direction orthogonal to the longitudinal direction of the optical film; and
and a bonding step of bonding the optical film from which the release film is peeled to the one surface of the optical element via the pressure-sensitive adhesive layer.
The above invention may further comprise a sticking step of sticking the optical film, from which the release film is peeled off, onto the one surface of the optical element via the pressure-sensitive adhesive layer by feeding the optical film, from a roll-like optical film wound with the release film, the pressure-sensitive adhesive layer, the optical functional film, and the 1 st surface protective film laminated in this order and with the cuts formed at predetermined intervals in addition to the release film.
According to this structure, there is no need to cut (half-cut) the optical film in the roll-to-roll panel method.
The above invention may further include a step of preparing an optical film module including: a rolled optical film having a structure in which a release film, an adhesive layer, an optical functional film, and a 1 st surface protective film are sequentially stacked; and
the optical film is a sheet-like optical film having a structure in which a release film, an adhesive layer, an optical functional film, a 1 st surface protective film and a 2 nd surface protective film are sequentially laminated. The "preparation step" may be a manufacturing step or a step of transporting the product from another place and setting the product at a predetermined position.
The above invention may further include a step of preparing an optical film module including: a roll-shaped optical film in which a release film, an adhesive layer, an optical functional film, a No. 1 surface protective film, and an optical film in which cuts are formed at predetermined intervals in addition to the release film are sequentially laminated; and
the optical film is a sheet-like optical film having a structure in which a release film, an adhesive layer, an optical functional film, a 1 st surface protective film and a 2 nd surface protective film are sequentially laminated. The "preparation step" may be a manufacturing step or a step of transporting the product from another place and setting the product at a predetermined position.
According to this structure, there is no need to cut (half-cut) the optical film in the roll-to-roll panel method.
Another invention is a system for manufacturing an optical display panel, wherein a sheet-like optical film having the same structure as that of an optical film removed from an optical display panel is bonded again to one surface of the optical element from which the optical film has been removed, the optical display panel comprising an optical film in which a pressure-sensitive adhesive layer, an optical functional film, and a 1 st surface protective film are laminated in this order, and an optical element having the optical film provided on the one surface thereof,
the optical display panel manufacturing system includes: a re-attaching section for detaching a release film from a sheet-like optical film in which the release film, an adhesive layer, an optical functional film, a 1 st surface protective film and a 2 nd surface protective film are laminated in this order, and attaching the sheet-like optical film to the one surface of the optical element via the adhesive layer to remanufacture the optical display panel; and
and a 2 nd surface protection film removing unit that removes the 2 nd surface protection film after the processing of the re-attaching unit.
The invention may further include an optical film removing unit that removes the optical film from the optical display panel based on a result of inspection of the optical element to which the optical film is attached.
The above invention may further comprise an inspection unit for inspecting the optical element to which the optical film is attached.
The above invention may further comprise: a cutting unit that cuts a strip-shaped optical film, which is unwound from a rolled optical film, around which the strip-shaped optical film, in which a release film, an adhesive layer, an optical functional film, and a 1 st surface protection film are sequentially laminated, in a direction orthogonal to the longitudinal direction of the optical film, while leaving the release film; and
and a bonding portion for bonding the optical film from which the release film is peeled to the one surface of the optical element via the pressure-sensitive adhesive layer.
The above invention may further comprise a bonding section for bonding the optical film, from which the release film is peeled off, to the one surface of the optical element via the adhesive layer, by feeding the optical film, which is wound in a roll form and in which the release film, the adhesive layer, the optical functional film, and the 1 st surface protective film are laminated in this order and the optical film, which is cut out at a predetermined interval, is wound.
With this structure, there is no need to cut (half-cut) the optical film in the roll-to-roll panel method.
The above invention may further include a manufacturing unit that manufactures an optical film unit including: a rolled optical film having a structure in which a release film, an adhesive layer, an optical functional film, and a 1 st surface protective film are sequentially stacked; and
the optical film is a sheet-like optical film having a structure in which a release film, an adhesive layer, an optical functional film, a 1 st surface protective film and a 2 nd surface protective film are sequentially laminated.
The above invention may further include a manufacturing unit that manufactures an optical film unit including: a roll-shaped optical film in which a release film, an adhesive layer, an optical functional film, a No. 1 surface protective film, and an optical film in which cuts are formed at predetermined intervals in addition to the release film are sequentially laminated; and
the optical film is a sheet-like optical film having a structure in which a release film, an adhesive layer, an optical functional film, a 1 st surface protective film and a 2 nd surface protective film are sequentially laminated.
With this structure, there is no need to cut (half-cut) the optical film in the roll-to-roll panel method.
The "roll-to-roll panel system" is a system in which a release film is peeled from an optical film unwound from a roll of the optical film, and the optical film is attached to an optical element via an exposed pressure-sensitive adhesive layer. Here, before the release film is peeled off, notches may be formed at a predetermined interval in the optical film so that the release film remains in the width direction of the optical film. The optical film may be slit in the width direction before being unwound from a roll, or may be slit in the width direction before being unwound from a roll and peeled off from a release film.
The "sheet-to-panel system" is a system in which a release film is peeled from an optical film in a sheet state prepared in advance, and the optical film is bonded to an optical element via an exposed adhesive layer.
In the above invention, when a polarizing film is used as the optical functional film (the 1 st optical functional film, the 2 nd optical functional film) or when a polarizing film is included as one member of the structure of the optical functional film, the absorption axis direction of the polarizing film is not particularly limited as long as the absorption axis direction of the polarizing film does not hinder achievement of the object of the present invention with respect to the optical film (the 1 st optical film, the 2 nd optical film) and the optical film roll (the 1 st optical film roll, the 2 nd optical film roll) in a roll or sheet form. That is, in the case of a combination in which the optical display panel having the same structure can be manufactured even by using the roll-to-roll panel method and the sheet-to-panel method in combination, the absorption axis direction of the polarizing film may be parallel to the longitudinal direction, may be orthogonal to the longitudinal direction, or may be inclined (for example, a direction at an angle of 45 ° to the longitudinal direction) in the rolled optical film (1 st optical film, 2 nd optical film) and the optical film roll (1 st optical film roll, 2 nd optical film roll). The absorption axis direction of the rectangular sheet-like polarizing film may be parallel to the longitudinal direction, may be orthogonal to the longitudinal direction, or may be oblique (for example, a direction at an angle of 45 ° to the longitudinal direction). The absorption axis direction of the square sheet-like polarizing film may be parallel to any one side or may be oblique (for example, a direction at an angle of 45 ° to the side).
In the above invention, the optical element may be a VA-type or IPS-type liquid crystal cell or an organic EL cell.
The shape of the optical element is not particularly limited as long as it has one set of opposing sides and the other set of opposing sides, and it may be square or rectangular. It should be noted that, in general, one set of opposing sides of the optical element is orthogonal to the other set of opposing sides.
ADVANTAGEOUS EFFECTS OF INVENTION
According to the present invention, since the sheet-like optical film provided with the 2 nd surface protective film has improved handling properties, occurrence of twist, curl, and the like can be suppressed, and the sheet-to-panel system can be used to appropriately bond the optical film to the optical element. Further, by removing (e.g., peeling) the 2 nd surface protective film from the sheet-like optical film laminated to the optical display panel, an optical display panel having the same laminated structure as that of an optical display panel manufactured in a roll-to-panel manner can be manufactured as a result. That is, according to the optical film module (optical film set) of the present invention, when an optical film is bonded to an optical element, even when a roll-to-panel method and a sheet-to-panel method are used in combination, an optical display panel having the same structure can be suitably manufactured.
Drawings
FIG. 1 shows a schematic view of an optical pellicle assembly
FIG. 2A is a schematic diagram illustrating a method of manufacturing a 1 st optical film in a roll form
FIG. 2B is a schematic diagram illustrating a method of manufacturing a sheet-like 1 st optical film
FIG. 3 is a schematic view of a system for continuously manufacturing an optical display panel according to embodiment 1
FIG. 4 is a diagram illustrating a remanufacturing process
Detailed Description
< optical film Assembly >
First, an optical film module used in the present invention will be described. FIG. 1 is a schematic diagram illustrating an optical pellicle assembly. The upper part of fig. 1 shows an enlarged view of the side, plane and a part of the cross section of the 1 st optical film 1 in a roll form. The lower part of fig. 1 shows an enlarged view of the side, plane and a part of the cross section of the 1 st optical film 2 in the form of a sheet. The 1 st optical film 1 in a roll form is laminated with a 1 st release film 11, a 1 st pressure-sensitive adhesive layer 12, a 1 st optical functional film 13, and a 1 st surface protective film 14 in this order.
The 1 st optical film 1 in a roll form is used to manufacture an optical display panel in a roll-to-roll panel manner. In this case, the 1 st optical film 10 having a band shape with the width a, which is fed from the 1 st optical film 1 in a roll shape, is cut at a predetermined interval b by the cutting member C so that the 1 st release film 11 remains. Symbol s is a notch formed in the 1 st optical film 10 by the above-described cutting.
Further, the 1 st optical film 2 in a sheet form is laminated with a 1 st release film 21, a 1 st pressure-sensitive adhesive layer 22, a 1 st optical functional film 23, a 1 st surface protective film 24, and a 2 nd surface protective film 25 in this order. The size of the sheet-like 1 st optical film 2 is a length a and a width b. The sheet-like 1 st optical film 2 is used to manufacture an optical display panel in a sheet-to-panel manner.
In the present embodiment, the 1 st release film 11 and the 1 st release film 21 have the same structure. The 1 st adhesive layer 12 and the 1 st adhesive layer 22 have the same structure. The 1 st optical functional film 13 has the same structure as the 1 st optical functional film 23. The 1 st surface protection film 14, the 1 st surface protection film 24 and the 2 nd surface protection film 25 have the same structure. The "same structure" is not only completely uniform in material, thickness, and the like, but also substantially the same (for example, the same in manufacturing quality).
In this embodiment, the 1 st surface protection film 14 (or 24) has a 1 st base film and a 1 st adhesive layer, and is laminated on the 1 st optical functional film 13 (or 23) via the 1 st adhesive layer. As another embodiment, the 1 st surface protection film 14 (or 24) may be a self-adhesive film.
In the present embodiment, the 2 nd surface protection film 25 has a 2 nd base film and a 2 nd adhesive layer, and is laminated on the 1 st surface protection film 24 via the 2 nd adhesive layer. In another embodiment, the 2 nd surface protective film 25 may be a self-adhesive film.
(relationship between interlayer peeling force)
The peeling force between the 1 st surface protection film 24 and the 1 st optical functional film 23 is larger than the peeling force between the 2 nd surface protection film 25 and the 1 st surface protection film 24. With this structure, the 2 nd surface protection film 25 can be peeled off more smoothly. As the measurement of the peeling force, for example, a tensile tester can be used. The peel strength was measured under a 180 ℃ peel of 0.3 m/min. The peel force is controlled by the composition, thickness, etc. of the adhesive.
The relationship between the magnitude of the peeling force between the layers of the sheet-like 1 st optical film 2 is as follows.
The 1 st release film 21 and the 1 st pressure-sensitive adhesive layer 22 have an interlayer peeling force of A,
The 1 st pressure-sensitive adhesive layer 22 and the 1 st optical functional film 23 have an interlayer peeling force of B,
The 1 st optical functional film 23 and the 1 st surface protective film 24 have an interlayer peeling force of C,
When the interlayer peeling force between the 1 st surface protective film 24 and the 2 nd surface protective film 25 is D,
is a < B, A < C, A < D.
Preferably A < D < C ≦ B or A < D < B ≦ C.
More preferably a < D < C < B.
According to the relationship between the interlayer peeling forces, the peeling of the 2 nd surface protection film can be suppressed when the 1 st release film is peeled.
< optical functional film >
The 1 st optical functional film 13, 23 is not particularly limited as long as it has an optical function, and examples thereof include: a polarizing film, a retardation film, a brightness enhancement film, a diffusion film, and the like, and a typical polarizing film is used.
(polarizing film)
In the present embodiment, a polarizing film having a thickness (total thickness) of preferably 60 μm or less, more preferably 55 μm or less, and still more preferably 50 μm or less is used from the viewpoint of reduction in thickness. Examples of the polarizing film include: (1) a structure in which protective films (sometimes referred to as "polarizer protective films") are laminated on both sides of a polarizer (sometimes referred to as "two-protective polarizing films"); (2) a structure in which a protective film is laminated only on one side of a polarizing plate (may be referred to as a "single-protection polarizing film").
(polarizing plate)
The polarizing plate may be made of a polyvinyl alcohol resin. Examples of the polarizing plate include: a polarizing plate obtained by uniaxially stretching a hydrophilic polymer film such as a polyvinyl alcohol film, a partially formalized polyvinyl alcohol film, or an ethylene/vinyl acetate copolymer partially saponified film, a polyene-based oriented film such as a dehydrated polyvinyl alcohol film or a desalted polyvinyl chloride film, or the like, to which a dichroic substance such as iodine or a dichroic dye is adsorbed. Among these, a polarizing plate containing a polyvinyl alcohol film and a dichroic material such as iodine is suitable.
The polarizing plate obtained by uniaxially stretching a polyvinyl alcohol film dyed with iodine can be produced, for example, by immersing the polyvinyl alcohol film in an aqueous iodine solution, dyeing the film, and stretching the film to 3 to 7 times the original length. If necessary, boric acid, zinc sulfate, zinc chloride, etc. may be contained, and the composition may be immersed in an aqueous solution of potassium iodide, etc. If necessary, the polyvinyl alcohol film may be washed with water by immersing it in water before dyeing. The washing of the polyvinyl alcohol film with water can clean contaminants and an anti-blocking agent on the surface of the polyvinyl alcohol film, and the swelling of the polyvinyl alcohol film can prevent uneven dyeing and the like. The stretching may be performed after the dyeing with iodine, or may be performed while dyeing, or may be performed after the stretching with iodine. Stretching may also be carried out in an aqueous solution of boric acid, potassium iodide, or the like, or in a water bath.
From the viewpoint of reduction in thickness, the thickness of the polarizing plate is preferably 10 μm or less, more preferably 8 μm or less, even more preferably 7 μm or less, and even more preferably 6 μm or less. On the other hand, the thickness of the polarizing plate is preferably 2 μm or more, and more preferably 3 μm or more. Such a thin polarizing plate has excellent durability against thermal shock because of its excellent visibility with little thickness unevenness and little dimensional change. On the other hand, in a polarizing film including a polarizing plate having a thickness of 10 μm or less, since the film has a significantly low stiffness (elastic modulus), there is a high possibility that torsion, curling, or the like occurs in the sheet-to-panel system. Therefore, the present invention is particularly suitable for the polarizing film.
Typical examples of the thin polarizing plate include:
japanese patent No. 4751486,
Japanese patent No. 4751481,
Japanese patent No. 4815544,
Japanese patent No. 5048120,
WO 2014/077599,
WO 2014/077636,
And the like, or a thin polarizing plate obtained by the production method described in these documents.
The polarizing plate preferably satisfies the following equation in terms of optical characteristics represented by a single transmittance T and a polarization degree P
P>-(100.929T-42.4-1) × 100 (wherein, T<42.3), or,
P is more than or equal to 99.9 (wherein, T is more than or equal to 42.3)
The condition (2) is defined as follows. The polarizing plate configured to satisfy the above conditions has, above all, performance required as a display for a liquid crystal television using a large-sized display element. Specifically, contrast ratio 1000: 1 or more and a maximum luminance of 500cd/m2The above. For another use, for example, the organic EL element may be bonded to the visible side of the organic EL unit.
As the thin polarizing plate, a polarizing plate obtained by a method including a step of stretching in an aqueous boric acid solution as described in japanese patent No. 4751486, japanese patent No. 4751481, and japanese patent No. 4815544 is preferable in terms of being stretchable to a high magnification ratio and being capable of improving polarizing performance even in a method including a step of stretching in a laminated state and a step of dyeing, and a polarizing plate obtained by a method including a step of stretching in an aqueous boric acid solution as described in japanese patent No. 4751481 and patent No. 4815544 is particularly preferable in terms of being stretched in air in an auxiliary manner before stretching in an aqueous boric acid solution. These thin polarizing plates can be obtained by a production method including a step of stretching a polyvinyl alcohol resin (hereinafter, also referred to as PVA resin) layer and a stretching resin base material in a state of a laminate, and a step of dyeing. In this production method, even if the PVA-based resin layer is thin, the PVA-based resin layer can be supported by the resin base material for stretching, and thus stretching can be performed without causing troubles such as breakage due to stretching.
(protective film (polarizer protective film))
As a material constituting the protective film, a material excellent in transparency, mechanical strength, thermal stability, moisture resistance, isotropy, and the like is preferable. Examples thereof include: polyester polymers such AS polyethylene terephthalate and polyethylene naphthalate, cellulose polymers such AS cellulose diacetate and cellulose triacetate, acrylic polymers such AS polymethyl methacrylate, styrene polymers such AS polystyrene and acrylonitrile-styrene copolymer (AS resin), and polycarbonate polymers. Examples of the polymer forming the protective film include: polyethylene, polypropylene, polyolefin having a ring system or a norbornene structure, polyolefin-based polymer such as ethylene-propylene copolymer, vinyl chloride-based polymer, polyamide-based polymer such as nylon and aromatic polyamide, imide-based polymer, sulfone-based polymer, polyether ether ketone-based polymer, polyphenylene sulfide-based polymer, vinyl alcohol-based polymer, vinylidene chloride-based polymer, vinyl butyral-based polymer, aryl ester-based polymer, polyoxymethylene-based polymer, epoxy-based polymer, or a mixture of the above-mentioned polymers.
The protective film may contain 1 or more kinds of any appropriate additives. Examples of additives include: ultraviolet absorbers, antioxidants, lubricants, plasticizers, mold release agents, anti-coloring agents, flame retardants, nucleating agents, antistatic agents, pigments, colorants, and the like. The content of the thermoplastic resin in the transparent protective film is preferably 50 to 100% by weight, more preferably 50 to 99% by weight, still more preferably 60 to 98% by weight, and particularly preferably 70 to 97% by weight. When the content of the thermoplastic resin in the transparent protective film is 50% by weight or less, there is a fear that high transparency and the like originally possessed by the thermoplastic resin cannot be sufficiently exhibited.
As the protective film, a retardation film, a brightness enhancement film, a diffusion film, or the like can be used.
The protective film may be provided with a functional layer such as a hard coat layer, an antireflection layer, a release layer, a diffusion layer, or an antiglare layer on the surface to which the polarizing plate is not bonded. The functional layers such as the hard coat layer, the antireflection layer, the release layer, the diffusion layer, and the antiglare layer may be provided separately from the transparent protective film itself or may be provided separately from the transparent protective film.
(insertion layer)
The protective film is laminated on the polarizing plate via an interposed layer such as an adhesive layer, and a primer layer (primer layer). In this case, it is preferable that the two layers are laminated without an air gap by the interposed layer.
The adhesive layer is formed of an adhesive. The type of the adhesive is not particularly limited, and various adhesives can be used. The adhesive layer is not particularly limited as long as it is optically transparent, and as the adhesive, various types of adhesives such as aqueous, solvent, hot melt, and active energy ray-curable adhesives can be used, and an aqueous adhesive or an active energy ray-curable adhesive is preferable.
Examples of the aqueous adhesive include: isocyanate-based adhesives, polyvinyl alcohol-based adhesives, gelatin-based adhesives, vinyl-based latex-based adhesives, water-based polyesters, and the like. The water-based adhesive is generally used as an adhesive containing an aqueous solution, and usually contains 0.5 to 60% by weight of a solid content.
The active energy ray-curable adhesive is an adhesive that is cured by an active energy ray such as an electron ray or ultraviolet ray (radical-curable type or cation-curable type), and can be used in the form of, for example, an electron ray-curable type or an ultraviolet ray-curable type. As the active energy ray-curable adhesive, for example, a photo radical-curable adhesive can be used. When a photo radical curing active energy ray-curable adhesive is used as the ultraviolet curing adhesive, the adhesive contains a radical polymerizable compound and a photopolymerization initiator.
When the polarizing plate and the protective film are laminated, an easy-adhesion layer may be provided between the transparent protective film and the adhesive layer. The easy-adhesion layer can be formed of various resins having, for example, a polyester skeleton, a polyether skeleton, a polycarbonate skeleton, a polyurethane skeleton, a silicone skeleton, a polyamide skeleton, a polyimide skeleton, a polyvinyl alcohol skeleton, or the like. These polymer resins may be used alone in 1 kind, or in combination with 2 or more kinds. In addition, other additives can be added to the formation of the easy-bonding layer. Specifically, a thickener, an ultraviolet absorber, a stabilizer such as an antioxidant or a heat stabilizer, and the like may be further used.
The adhesive layer is formed of an adhesive. As the binder, various binders can be used, and examples thereof include: rubber-based adhesives, acrylic adhesives, silicone-based adhesives, urethane-based adhesives, vinyl alkyl ether-based adhesives, polyvinyl pyrrolidone-based adhesives, polyacrylamide-based adhesives, cellulose-based adhesives, and the like. The adhesive base polymer may be selected according to the kind of the adhesive. Among the above-mentioned pressure-sensitive adhesives, acrylic pressure-sensitive adhesives are preferably used from the viewpoint of excellent optical transparency, excellent adhesive properties such as favorable wettability, aggregation and adhesiveness, and excellent weather resistance and heat resistance.
The undercoat layer (primer layer) is formed to improve adhesion between the polarizing plate and the protective film. The material constituting the primer layer is not particularly limited as long as it exerts a certain degree of strong adhesion force to both the base film and the polyvinyl alcohol resin layer. For example, a thermoplastic resin having excellent transparency, thermal stability, stretchability, and the like can be used. Examples of the thermoplastic resin include: an acrylic resin, a polyolefin resin, a polyester resin, a polyvinyl alcohol resin, or a mixture thereof.
(surface protective film)
The 1 st and 2 nd surface protection films are provided on one surface (surface on which the pressure-sensitive adhesive layer is not laminated) of the polarizing film in the optical film, and protect the optical functional film such as the polarizing film.
The base film of the 1 st or 2 nd surface protection film may be made of a film material having isotropy or near isotropy, from the viewpoint of inspection property, manageability, and the like. Examples of the film material include: transparent polymers such as polyester resins, cellulose resins, acetate resins, polyether sulfone resins, polycarbonate resins, polyamide resins, polyimide resins, polyolefin resins, and acrylic resins, such as polyethylene terephthalate films. Among these, polyester resins are preferred. The substrate film may be used in the form of a laminate of 1 or 2 or more kinds of film materials, or a stretched product of the film may be used. The thickness of the base film is preferably 10 to 150 μm or less, and more preferably 20 to 100 μm.
The base film may be used as a self-adhesive film for the 1 st and 2 nd surface protective films, and a film having the base film and an adhesive layer may be used. From the viewpoint of protecting an optical functional film such as a polarizing film, a film having an adhesive layer is preferably used as the 1 st and 2 nd surface protective films.
As the pressure-sensitive adhesive layer used for laminating the 1 st and 2 nd surface protective films, for example, a pressure-sensitive adhesive using a polymer such as a (meth) acrylic polymer, a silicone polymer, a polyester, a polyurethane, a polyamide, a polyether, a fluorine-based polymer, or a rubber-based polymer as a base polymer can be suitably selected and used. From the viewpoint of transparency, weather resistance, heat resistance and the like, an acrylic adhesive containing an acrylic polymer as a base polymer is preferred. The thickness of the adhesive layer (dry film thickness) is determined according to the desired adhesive force. Usually about 1 to 100. mu.m, preferably about 5 to 50 μm.
The 1 st and 2 nd surface protection films may be provided with a release-treated layer on the side opposite to the side on which the pressure-sensitive adhesive layer is provided, using a low-adhesive material such as silicone treatment, long-chain alkyl treatment, or fluorine treatment.
< adhesive layer >
The adhesive layers 12 and 22 can be formed using a suitable adhesive, and the type thereof is not particularly limited. Examples of the binder include: rubber-based adhesives, acrylic adhesives, silicone-based adhesives, urethane-based adhesives, vinyl alkyl ether-based adhesives, polyvinyl alcohol-based adhesives, polyvinyl pyrrolidone-based adhesives, polyacrylamide-based adhesives, cellulose-based adhesives, and the like.
Among these pressure-sensitive adhesives, those excellent in optical transparency, adhesion characteristics such as appropriate wettability, aggregability and adhesiveness, weather resistance, heat resistance and the like can be preferably used. As the adhesive exhibiting such characteristics, an acrylic adhesive can be preferably used.
The adhesive layers 12 and 22 can be formed, for example, by the following method: a method in which the pressure-sensitive adhesive is applied to a release film (separator) or the like subjected to a peeling treatment, dried to remove a polymerization solvent or the like to form a pressure-sensitive adhesive layer, and then transferred to a polarizing plate (or a transparent protective film); or a method of forming an adhesive layer on a polarizing plate by applying the adhesive to a polarizing plate (or a transparent protective film) and drying to remove a polymerization solvent or the like. In the case of applying the adhesive, it is also possible to add one or more solvents other than the polymerization solvent newly.
As the release film subjected to the release treatment, a silicone release liner can be preferably used. In the step of forming the pressure-sensitive adhesive layer by applying the pressure-sensitive adhesive of the present invention on such a liner and drying the applied pressure-sensitive adhesive, a suitable method may be employed as a method for drying the pressure-sensitive adhesive according to the purpose. A method of drying the coating film by heating is preferably used. The heating and drying temperature is preferably 40 to 200 ℃, more preferably 50 to 180 ℃, and particularly preferably 70 to 170 ℃. By setting the heating temperature in the above range, an adhesive having excellent adhesive properties can be obtained.
The drying time may be suitably and appropriately selected. The drying time is preferably 5 seconds to 20 minutes, more preferably 5 seconds to 10 minutes, and particularly preferably 10 seconds to 5 minutes.
As a method for forming the 1 st adhesive layers 12, 22, various methods can be used. Specifically, examples thereof include: roll coating, kiss roll coating, gravure coating, reverse coating, roll brush coating, spray coating, dip roll coating, bar coating, knife coating, air knife coating, curtain coating, lip coating, extrusion coating using a die coater or the like.
The thickness of the 1 st pressure-sensitive adhesive layers 12 and 22 is not particularly limited, and is, for example, about 1 μm to 100 μm. Preferably 2 to 50 μm, more preferably 2 to 40 μm, and still more preferably 5 to 35 μm.
< mold release film >
The 1 st release film 11, 21 protects the adhesive layer until it is put into use. Examples of the material constituting the release film include: plastic films such as polyethylene, polypropylene, polyethylene terephthalate, and polyester films, porous materials such as paper, cloth, and nonwoven fabrics, and sheets such as nets, foamed sheets, metal foils, and laminates thereof are preferably used from the viewpoint of excellent surface smoothness.
The plastic film is not particularly limited as long as it can protect the pressure-sensitive adhesive layer, and examples thereof include: polyethylene film, polypropylene film, polybutylene film, polybutadiene film, polymethylpentene film, polyvinyl chloride film, vinyl chloride copolymer film, polyethylene terephthalate film, polybutylene terephthalate film, polyurethane film, ethylene-vinyl acetate copolymer film, and the like.
The thickness of the 1 st release film 11, 21 is usually about 5 μm to 200. mu.m, preferably about 5 μm to 100. mu.m. The separator may be subjected to release and anti-fouling treatment with a silicone-based, fluorine-based, long-chain alkyl-based or fatty acid amide-based release agent, silica powder or the like, or antistatic treatment with a coating type, a kneading type, a vapor deposition type or the like, as necessary. In particular, by appropriately subjecting the surface of the release film to a release treatment such as a silicone treatment, a long-chain alkyl treatment, or a fluorine treatment, the releasability from the pressure-sensitive adhesive layer can be further improved.
< production of optical film Assembly >
Next, a method for manufacturing the 1 st optical film unit and the 2 nd optical film unit will be described. Fig. 2A is a schematic diagram illustrating a method of manufacturing the 1 st optical film 1 in a roll form. Fig. 2B is a schematic diagram illustrating a method of manufacturing the 1 st optical film 2 in a sheet form.
In fig. 2A, a 1 st optical film roll 5 in a roll form is prepared, in which a 1 st release film, a 1 st pressure-sensitive adhesive layer, a 1 st optical functional film, and a 1 st surface protective film are sequentially laminated. Next, the 1 st optical film is unwound from the 1 st optical film roll 5, and slit-processed into 3 ribbons of optical film with a predetermined width "a" by a slit cutter sc. The slit-processed 3-strip optical films were wound up to produce a 1 st optical film in a roll form.
In the present embodiment, the slit is processed into a 3-stripe optical film, but is not limited thereto. In the present embodiment, both end portions e1 and e2 are trimmed (end trimming), but either end portion may be cut off, or both end portions may not be trimmed.
In fig. 2B, the 2 nd surface protection film 25 fed from the 2 nd surface protection film roll S25 is bonded to the 1 st surface protection film 14 side of the 1 st optical film 1 (corresponding to the 1 st optical film roll) in a roll form by a bonding member (a pair of bonding rollers R1, R2), and an optical film roll S2 on which the 2 nd surface protection film 25 is laminated is manufactured. Next, the 1 st optical film 2 in a sheet form is produced by subjecting the optical film roll S2 on which the 2 nd surface protecting film 25 is laminated to full-cut processing at a predetermined interval b by using a cutting member FC. The sheet-like 1 st optical film 2 may be stored in a predetermined storage section, or may be laminated on a carrier film. The 1 st optical film package can be manufactured using the above method.
As other embodiments, may include: a step of winding the optical film roll S2, and a step of feeding the 1 st optical film in a tape form from the optical film roll S2 and cutting the optical film at a predetermined interval b by using a cutting member FC.
In addition, as another embodiment, the method may further include: after the slit processing, the adhesive layer 12, the 1 st optical functional film, and the 1 st surface protective film are cut (half-cut) at predetermined intervals so as to leave the 1 st release film 11 in a strip shape, thereby forming a plurality of slits.
(liquid Crystal cell, liquid Crystal display Panel)
The liquid crystal cell has a structure in which a liquid crystal layer is sealed between a pair of substrates (a 1 st substrate (visible side surface) Pa and a 2 nd substrate (back surface) Pb) disposed to face each other. The liquid crystal cell may use any type of liquid crystal cell, but in order to achieve high contrast, a liquid crystal cell of a Vertical Alignment (VA) type, an in-plane switching (IPS) type is preferably used. The liquid crystal display panel is a liquid crystal display panel in which a polarizing film is bonded to one surface or both surfaces of a liquid crystal cell, and a drive circuit is incorporated as necessary.
(organic EL Unit, organic EL display Panel)
The organic EL unit has a structure in which an electroluminescent layer is sandwiched between a pair of electrodes. As the organic EL unit, any type of organic EL unit such as a Top Emission (Top Emission) system, a Bottom Emission (Bottom Emission) system, and a Double Emission (Double Emission) system can be used. The organic EL display panel is formed by laminating a polarizing film on one surface or both surfaces of an organic EL unit, and a driving circuit is incorporated as necessary.
< remanufacturing Using the optical film Assembly of item 1 >
Fig. 3 is a schematic diagram of a continuous manufacturing system for optical display panels. In the present embodiment, the 1 st optical film 1 in a roll form is used for manufacturing an optical display panel in a roll-to-roll panel manner. For the sheet-like 1 st optical film 2, an optical display panel was manufactured in the following structure: the optical display panel manufactured using the 1 st optical film 1 in a roll form is judged as defective, and the 1 st pressure-sensitive adhesive layer, the 1 st optical functional film and the 1 st surface protection film are laminated in this order on one surface of the optical element of the optical display panel from which the 1 st pressure-sensitive adhesive layer, the 1 st optical functional film and the 1 st surface protection film are peeled. Specifically, the 1 st release film 21 is peeled from the 1 st optical film 2 in a sheet form by a sheet-to-sheet method on one surface of the optical element from which the 1 st pressure-sensitive adhesive layer 22, the 1 st optical functional film 23 and the 1 st surface protection film 24 are peeled, the 1 st pressure-sensitive adhesive layer 22, the 1 st optical functional film 23, the 1 st surface protection film 24 and the 2 nd surface protection film 25 are sequentially laminated, and then the 2 nd surface protection film 25 is peeled. In this embodiment, a liquid crystal cell is taken as an example of an optical element, and a liquid crystal display panel is taken as an example of an optical display panel.
The 1 st optical film 1 in a roll form is laminated with a 1 st release film 11, a 1 st pressure-sensitive adhesive layer 12, a 1 st optical functional film 13, and a 1 st surface protective film 14 in this order. As shown in fig. 1, the 1 st optical film 1 in a roll shape has a width a corresponding to the long side of the liquid crystal panel (a width substantially shorter than the long side of the liquid crystal cell P).
As shown in fig. 3, the system for manufacturing a liquid crystal display panel according to the present embodiment includes: a 1 st transport unit 81 for transporting the liquid crystal cell P to the 1 st bonding unit 64, and a 2 nd transport unit 82 for transporting the liquid crystal cell P having the optical film bonded to the 1 st surface P1 of the liquid crystal cell P using the 1 st optical film 1 in a roll form. Each of the conveying sections is configured to have a plurality of conveying rollers R for conveying the liquid crystal cell P by rotating about a rotation axis parallel to a direction orthogonal to the conveying direction. The conveyance roller may be provided with a suction plate or the like.
(liquid Crystal cell transfer Process)
The liquid crystal cell P is placed on the 1 st conveying section 81 from the storage section 91 that stores the liquid crystal cell P such that the 1 st plane P1 is a top plane, and is conveyed to the 1 st pasting section 64 by the rotation of the conveying roller R.
(1 st optical film feeding step, 1 st optical film cutting step)
While the 1 st optical film 10 in a band form released from the 1 st optical film 1 in a roll form is sucked and fixed to the 1 st release film 11 side, the adhesive layer 12 in a band form, the 1 st optical functional film 13 in a band form, and the 1 st surface protective film 14 in a band form are cut into a predetermined size (corresponding to the length of the short side of the liquid crystal cell P (substantially shorter than the short side)) by the cutting section 61 so as to remain without cutting the 1 st release film 11, and a cut-out section s is formed. Examples of the cutting by the cutting section 61 include cutting using a cutter (cutting by a cutting cutter) and cutting by a laser device. Although an example of the cut portion s after cutting is shown by an arrow in fig. 3, the cut is described in an enlarged manner for ease of explanation. The nip roller, not shown, may be disposed upstream or downstream of the cutting unit 61 and may be configured to convey the 1 st optical film 10 in a belt shape. The nip rollers may be disposed on the upstream side and the downstream side of the cutter 61.
(tension adjusting step)
The 1 st tension adjusting unit 62 is provided to continuously perform the cutting process and the post-bonding process of the 1 st optical film 10 in a strip form for a long time without interruption and to adjust the slack of the film. The 1 st tensioning force adjusting portion 62 is configured to have a bouncing device using a hammer, for example. The nip roller, not shown, may be disposed upstream or downstream of the 1 st tension adjusting unit 62 to convey the 1 st optical film 10. The nip rollers may be disposed upstream and downstream of the 1 st tension adjusting portion 62.
(peeling step)
The 1 st optical film 10 is wound around the 1 st peeling section 63 and reversed, and the 1 st optical film 10 is peeled from the 1 st release film 11. The 1 st release film 11 is wound into a roll by the 1 st winding part 65. The 1 st winding section 65 has a roller and a rotation driving section that winds the 1 st release film 11 into a roll by rotating the roller. The nip roller, not shown, may be disposed upstream or downstream of the peeling section 63 and may convey the 1 st optical film 10 or the 1 st release film 11. The nip rollers may be disposed on the upstream side and the downstream side of the peeling section 63.
(the 1 st pasting step)
The 1 st attaching part 64 attaches the 1 st optical film 10 from which the 1 st release film 11 is peeled to the 1 st surface P1 of the liquid crystal cell P via the 1 st pressure-sensitive adhesive layer 12 while conveying the liquid crystal cell P. The 1 st pasting part 64 is constituted by a pair of 1 st roller 64a and 2 nd roller 64 b. Either one of the rollers may be a driving roller and the other one may be a driven roller, or both of the rollers may be driving rollers. The 1 st optical film 10 and the liquid crystal cell P are fed downstream while being sandwiched between a pair of 1 st and 2 nd rollers 64a and 64b, whereby the 1 st optical film 10 is stuck to the 1 st surface P1 of the liquid crystal cell P. The liquid crystal cell P having the sheet-like 1 st optical film 10 adhered to the 1 st surface P1 of the liquid crystal cell P is conveyed downstream by the 2 nd conveying unit 82.
(inspection step 1)
The 1 st inspection unit 70 performs optical inspection of the liquid crystal cell P. The 1 st inspection unit 70 includes: a light source 71 disposed on one surface side of the liquid crystal cell P and transmitting light to the liquid crystal cell P; and a 1 st image pickup unit 72 disposed on the opposite side of the light source with the liquid crystal cell P therebetween, and picking up a transmitted optical image of the liquid crystal cell P. The 1 st image pickup unit 72 may be an area sensor or a line sensor. The 1 st inspection unit 70 may further include a 2 nd imaging unit (not shown) for imaging a reflected optical image for inspecting the bonding position of the 1 st optical film 10. The 1 st image analysis unit 51 analyzes the image captured by the 1 st inspection unit 70. The control section 50 controls operation timing and the like of each configuration of the continuous manufacturing system.
(determination step 1)
The 1 st determination unit 52 determines whether the liquid crystal cell P is a non-defective product or a defective product based on the result of analyzing the image by the 1 st image analysis unit 51. Examples of defective products include a distortion of the adhesive sheet and air bubbles. The liquid crystal cell P determined as a non-defective product is collected in the 1 st non-defective product collecting unit 92. The liquid crystal cell P determined as defective is collected in the 1 st defective collection unit 93.
(1 st step of peeling off defective film)
The process of remanufacturing a defective liquid crystal panel into a non-defective liquid crystal panel will be described with reference to fig. 4. As shown in fig. 4, the 1 st optical film 10 is removed from the liquid crystal cell P determined as defective by the 1 st determining section 52. The removal process may be performed manually or by a peeling device. Next, a case will be described in which the sheet-like 1 st optical film 2 is attached to the 1 st surface P1 of the liquid crystal cell P by using a die bonding apparatus and remanufactured (also referred to as "remanufacturing").
(1 st reattachment step)
Next, the sheet-like 1 st optical film 2 from which the 1 st release film 21 was peeled off is attached to the 1 st surface P1 of the liquid crystal cell P from which the 1 st optical film 10 was peeled off, which was determined to be defective, in a sheet-to-panel manner (e.g., a sheet attaching device). As the patch device, an existing device may be used. Refer to sheet-like 1 st optical film 2 of fig. 1.
(step 2 of peeling off surface protective film)
After the 1 st re-pasting step, the 2 nd surface protection film 25 is peeled from the 1 st optical film 2 in a sheet form. The peeling process may be performed by hand, so as to be performed by a peeling apparatus. Through the above steps, a liquid crystal panel having the same laminated structure as a liquid crystal panel manufactured in a roll-to-roll panel manner can be manufactured (remanufactured).
In the above embodiment, the optical film is attached to one surface (the 1 st surface P1) of the liquid crystal cell in a roll-to-roll panel manner, but the present invention is not limited thereto. The optical film may be attached to the other surface (the 2 nd surface P2) of the liquid crystal cell in a roll-to-roll panel manner.
In the above embodiment, the 1 st inspection step and the 1 st determination step are performed after the 1 st bonding step, but the inspection and determination may be performed after the optical film is bonded to the other surface (the 2 nd surface P2) of the liquid crystal cell. The optical film determined as defective at the time of determination may be peeled off from the liquid crystal cell and attached to the liquid crystal cell in a sheet-to-panel manner using a sheet-like optical film.
(modification example)
In the present embodiment, a case where an optical film unit such as a rolled optical film and a sheet-like optical film is used in a continuous manufacturing method of a liquid crystal display panel is described, but the present invention is not limited thereto, and the present invention may be used in a continuous manufacturing method of an organic EL display panel.
In the embodiment, the optical film is used as a rolled optical film, but the structure of the rolled optical film is not limited thereto. For example, a film (slit-formed optical film) obtained by winding a strip-shaped optical film having a plurality of cutting lines formed in the width direction, in addition to the release film, may be used.
In the embodiment, the band-shaped optical film is cut (half-cut) at predetermined intervals in the width direction, but from the viewpoint of improving the yield, the band-shaped optical film may be cut (skip-cut) in the width direction so as to avoid defective portions of the band-shaped optical film, or the optical film including the defective portions may be cut in a size smaller than the predetermined intervals (the size of the optical elements) (more preferably, in a size as small as possible).
In the embodiments, a liquid crystal cell and a liquid crystal display panel having a horizontal rectangular shape are exemplified, but the shapes of the liquid crystal cell and the liquid crystal display panel are not particularly limited as long as they have one set of sides facing each other and the other set of sides facing each other.
Description of the reference numerals
1 roll-shaped optical film
11 Release film
12 adhesive layer
13 optical functional film
14 st surface protective film
2 sheet-like optical film
21 Release film
22 adhesive layer
23 optical functional film
24 st surface protective film
25 nd 2 nd surface protective film
Claims (14)
1. A method for manufacturing an optical display panel comprising a step of sticking a sheet-like optical film having the same structure as that of an optical film removed from an optical display panel to one surface of the optical element from which the optical film has been removed, the optical display panel comprising an optical film obtained by laminating a pressure-sensitive adhesive layer, an optical functional film and a No. 1 surface protective film in this order, and an optical element having the optical film provided on the one surface,
the manufacturing method comprises the following steps:
a re-attaching step of detaching a release film from a sheet-like optical film in which the release film, an adhesive layer, an optical functional film, a 1 st surface protective film and a 2 nd surface protective film are laminated in this order, and attaching the sheet-like optical film to the one surface of the optical element via the adhesive layer to remanufacture the optical display panel; and
and a 2 nd surface protective film removing step of removing the 2 nd surface protective film after the re-attaching step.
2. The method for manufacturing an optical display panel according to claim 1, further comprising a removing step of removing the optical film from the optical display panel based on a result of inspection of the optical element to which the optical film is attached.
3. The method for manufacturing an optical display panel according to claim 1 or 2, further comprising an inspection step of inspecting the optical element to which the optical film is attached.
4. The method of manufacturing an optical display panel according to claim 1 or 2, further comprising:
a cutting step of cutting a tape-shaped optical film, which is unwound from a roll-shaped optical film wound up from a tape-shaped optical film in which a release film, an adhesive layer, an optical functional film, and a 1 st surface protection film are laminated in this order, while leaving the release film in a direction orthogonal to the longitudinal direction of the optical film; and
and a bonding step of bonding the optical film from which the release film is peeled to the one surface of the optical element via the pressure-sensitive adhesive layer.
5. The method of manufacturing an optical display panel according to claim 1 or 2, further comprising:
and a bonding step of bonding the optical film, from which the release film is peeled off, to the one surface of the optical element via the adhesive layer, by feeding the optical film from a roll-like optical film wound with the release film, the adhesive layer, the optical functional film, and the 1 st surface protection film laminated in this order and with the cuts formed at predetermined intervals in addition to the release film.
6. The method for manufacturing an optical display panel according to claim 1 or 2, further comprising a step of preparing an optical film assembly having:
a rolled optical film having a structure in which a release film, an adhesive layer, an optical functional film, and a 1 st surface protective film are sequentially stacked; and
the optical film is a sheet-like optical film having a structure in which a release film, an adhesive layer, an optical functional film, a 1 st surface protective film and a 2 nd surface protective film are sequentially laminated.
7. The method for manufacturing an optical display panel according to claim 1 or 2, further comprising a step of preparing an optical film assembly having:
a roll-shaped optical film in which a release film, an adhesive layer, an optical functional film, a No. 1 surface protective film, and an optical film in which cuts are formed at predetermined intervals in addition to the release film are sequentially laminated; and
the optical film is a sheet-like optical film having a structure in which a release film, an adhesive layer, an optical functional film, a 1 st surface protective film and a 2 nd surface protective film are sequentially laminated.
8. A system for manufacturing an optical display panel, wherein a sheet-like optical film having the same structure as that of an optical film removed from an optical display panel is bonded again to one surface of the optical element from which the optical film has been removed, the optical display panel comprising an optical film in which a pressure-sensitive adhesive layer, an optical functional film, and a No. 1 surface protective film are laminated in this order, and an optical element having the optical film provided on the one surface,
the optical display panel manufacturing system includes: a re-attaching section for detaching a release film from a sheet-like optical film in which the release film, an adhesive layer, an optical functional film, a 1 st surface protective film and a 2 nd surface protective film are laminated in this order, and attaching the sheet-like optical film to the one surface of the optical element via the adhesive layer to remanufacture the optical display panel; and
and a 2 nd surface protection film removing unit that removes the 2 nd surface protection film after the processing of the re-attaching unit.
9. The system for manufacturing an optical display panel according to claim 8, further comprising an optical film removing unit that removes the optical film from the optical display panel based on a result of inspection of the optical element to which the optical film is attached.
10. The system for manufacturing an optical display panel according to claim 8 or 9, further comprising an inspection unit that inspects the optical element to which the optical film is attached.
11. The system for manufacturing an optical display panel according to claim 8 or 9, further comprising:
a cutting unit that cuts a strip-shaped optical film, which is unwound from a rolled optical film, around which the strip-shaped optical film, in which a release film, an adhesive layer, an optical functional film, and a 1 st surface protection film are sequentially laminated, in a direction orthogonal to the longitudinal direction of the optical film, while leaving the release film; and
and a bonding portion for bonding the optical film from which the release film is peeled to the one surface of the optical element via the pressure-sensitive adhesive layer.
12. The system for manufacturing an optical display panel according to claim 8 or 9, further comprising a bonding section for bonding the optical film, from which the release film is peeled, to the one surface of the optical element via the adhesive layer, by feeding the optical film from a roll-like optical film in which the release film, the adhesive layer, the optical functional film, and the 1 st surface protective film are laminated in this order and the optical film, other than the release film, having the cuts formed at predetermined intervals is wound.
13. The manufacturing system of an optical display panel according to claim 8 or 9, further comprising a manufacturing section that manufactures an optical film assembly having:
a rolled optical film having a structure in which a release film, an adhesive layer, an optical functional film, and a 1 st surface protective film are sequentially stacked; and
the optical film is a sheet-like optical film having a structure in which a release film, an adhesive layer, an optical functional film, a 1 st surface protective film and a 2 nd surface protective film are sequentially laminated.
14. The manufacturing system of an optical display panel according to claim 8 or 9, further having a manufacturing section that manufactures an optical film assembly having:
a roll-shaped optical film in which a release film, an adhesive layer, an optical functional film, a No. 1 surface protective film, and an optical film in which cuts are formed at predetermined intervals in addition to the release film are sequentially laminated; and
the optical film is a sheet-like optical film having a structure in which a release film, an adhesive layer, an optical functional film, a 1 st surface protective film and a 2 nd surface protective film are sequentially laminated.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2016-144840 | 2016-07-22 | ||
| JP2016144840A JP6654113B2 (en) | 2016-07-22 | 2016-07-22 | Optical display panel manufacturing method and optical display panel manufacturing system |
| PCT/JP2017/023945 WO2018016287A1 (en) | 2016-07-22 | 2017-06-29 | Method for manufacturing optical display panels and system for manufacturing optical display panels |
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| Publication Number | Publication Date |
|---|---|
| CN107924649A CN107924649A (en) | 2018-04-17 |
| CN107924649B true CN107924649B (en) | 2020-11-03 |
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| Application Number | Title | Priority Date | Filing Date |
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| CN201780002537.3A Active CN107924649B (en) | 2016-07-22 | 2017-06-29 | Method and system for manufacturing optical display panel |
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| Country | Link |
|---|---|
| JP (1) | JP6654113B2 (en) |
| KR (1) | KR102326712B1 (en) |
| CN (1) | CN107924649B (en) |
| TW (1) | TWI723195B (en) |
| WO (1) | WO2018016287A1 (en) |
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| KR102164778B1 (en) * | 2018-03-23 | 2020-10-13 | 주식회사 엘지화학 | System for manufacturing display unit |
| TW202142410A (en) * | 2020-05-05 | 2021-11-16 | 威光自動化科技股份有限公司 | Automatic adhesive tape pasting device and automatic adhesive tape pasting and film stripping device thereof |
| JP2022038978A (en) * | 2020-08-27 | 2022-03-10 | 日東電工株式会社 | Optical laminate and method of manufacturing polarizing plate using the same |
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| JP2018013726A (en) | 2018-01-25 |
| KR20190032261A (en) | 2019-03-27 |
| KR102326712B1 (en) | 2021-11-17 |
| TW201805701A (en) | 2018-02-16 |
| TWI723195B (en) | 2021-04-01 |
| JP6654113B2 (en) | 2020-02-26 |
| CN107924649A (en) | 2018-04-17 |
| WO2018016287A1 (en) | 2018-01-25 |
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