JP5868733B2 - 光学表示パネルの連続製造方法および光学表示パネルの連続製造システム - Google Patents
光学表示パネルの連続製造方法および光学表示パネルの連続製造システム Download PDFInfo
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- 239000004973 liquid crystal related substance Substances 0.000 description 63
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Classifications
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- 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
- G02F1/133528—Polarisers
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- B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
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- B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
- B29C65/7858—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus characterised by the feeding movement of the parts to be joined
- B29C65/7861—In-line machines, i.e. feeding, joining and discharging are in one production line
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
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- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
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- B29C66/723—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/80—General aspects of machine operations or constructions and parts thereof
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- B29C66/8322—Joining or pressing tools reciprocating along one axis
- B29C66/83221—Joining or pressing tools reciprocating along one axis cooperating reciprocating tools, each tool reciprocating along one axis
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/80—General aspects of machine operations or constructions and parts thereof
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- B29C66/834—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools moving with the parts to be joined
- B29C66/8341—Roller, cylinder or drum types; Band or belt types; Ball types
- B29C66/83411—Roller, cylinder or drum types
- B29C66/83413—Roller, cylinder or drum types cooperating rollers, cylinders or drums
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/80—General aspects of machine operations or constructions and parts thereof
- B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
- B29C66/834—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools moving with the parts to be joined
- B29C66/8341—Roller, cylinder or drum types; Band or belt types; Ball types
- B29C66/83411—Roller, cylinder or drum types
- B29C66/83415—Roller, cylinder or drum types the contact angle between said rollers, cylinders or drums and said parts to be joined being a non-zero angle
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/90—Measuring or controlling the joining process
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
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- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
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- 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
- G02F1/1303—Apparatus specially adapted to the manufacture of LCDs
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
- B29C63/02—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
- B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
- B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/80—General aspects of machine operations or constructions and parts thereof
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- B32B2457/00—Electrical equipment
- B32B2457/20—Displays, e.g. liquid crystal displays, plasma displays
- B32B2457/202—LCD, i.e. liquid crystal displays
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Nonlinear Science (AREA)
- Manufacturing & Machinery (AREA)
- General Physics & Mathematics (AREA)
- Chemical & Material Sciences (AREA)
- Crystallography & Structural Chemistry (AREA)
- Optics & Photonics (AREA)
- Liquid Crystal (AREA)
- Mathematical Physics (AREA)
- Quality & Reliability (AREA)
- Polarising Elements (AREA)
- Theoretical Computer Science (AREA)
- Container, Conveyance, Adherence, Positioning, Of Wafer (AREA)
- Devices For Indicating Variable Information By Combining Individual Elements (AREA)
- Lining Or Joining Of Plastics Or The Like (AREA)
Description
粘着剤を含む光学フィルムが当該粘着剤を介して積層されているキャリアフィルムを搬送するキャリアフィルム搬送工程と、
前記キャリアフィルム搬送工程により搬送された前記キャリアフィルムを内側にして折り返して当該キャリアフィルムから前記光学フィルムを剥離する剥離工程と、
前記剥離工程により剥離された前記光学フィルムの前端部を光学セルの前端部に貼り合せる前端部貼合工程と、
前記キャリアフィルム搬送工程による前記キャリアフィルムの搬送開始よりも先に、前記前端部が貼り合された前記光学フィルムの前記前端部以降の部分の前記光学セルへの貼合開始が実行されるように、光学セルを搬送しながら、前記剥離工程で前記キャリアフィルムから剥離された前記光学フィルムを前記粘着剤を介して該光学セルに貼り合せて光学表示パネルを形成する貼合工程と、を含む。
粘着剤を含む光学フィルムが当該粘着剤を介して積層されているキャリアフィルムを搬送するキャリアフィルム搬送部と、
前記キャリアフィルム搬送部により搬送されたキャリアフィルムを内側にして折り返して当該キャリアフィルムから前記光学フィルムを剥離する剥離部と、
前記剥離部で剥離された前記光学フィルムの前端部を光学セルの前端部に貼り合せ、かつ、 光学セルを搬送しながら、前記キャリアフィルムから剥離された前記光学フィルムを前記粘着剤を介して該光学セルに貼り合せて光学表示パネルを形成する貼合部と、
前記キャリアフィルム搬送部による前記キャリアフィルムの搬送開始よりも先に、前記貼合部による前記前端部が貼り合された前記光学フィルムの前記前端部以降の部分の前記光学セルへの貼合開始が実行されるように、該貼合部を駆動制御し、かつ該キャリアフィルム搬送部を駆動制御する駆動制御部と、を有する。
前記光学フィルムを前記光学セルに貼り合せ始める貼合開始時点から貼り合せ完了する貼合完了時点までの間にある途中の時点から所定の期間、前記キャリアフィルム搬送部による前記光学フィルムが剥離されたキャリアフィルムの搬送速度を前記貼合部による前記光学フィルムの前記光学セルへの貼合速度に一致させるように、または前記貼合速度よりも大きくなるように、該貼合部および該キャリアフィルム搬送部を駆動制御することが好ましい。
前記貼合開始時点から前記貼合完了時点まで、前記貼合速度がゼロより大きくなるように、該貼合部を駆動制御し、および、前記貼合完了前に前記キャリアフィルムの搬送速度をゼロにするように、該キャリアフィルム搬送部を駆動制御することが好ましい。
次の貼合開始時点直前において、貼合速度=0、キャリアフィルム搬送速度=0になるように、貼合部を駆動制御し、キャリアフィルム搬送部を駆動制御することが好ましい。
前記駆動制御部が、前記貼合ローラおよび/または前記受けローラを駆動制御する。
以下、図1〜3を参照しながら、本実施形態に係る光学表示パネルの連続製造システムを具体的に説明するが、本発明は本実施形態の態様に限定されるものではない。光学セルとして液晶セルを、光学フィルムとして偏光フィルムを例に説明する。以下では、偏光フィルムが両面に貼り合わされた液晶セルを液晶表示パネルと称する。図1は光学表示パネルの連続製造システムの概略図であり、図2は駆動制御部の動作を説明するための図である。図3は貼合速度と巻取速度との速度関係を示す図である。
第2液晶セル搬送部104は、第1貼合部103により第1偏光フィルム131が貼り合せられた液晶セルPを搬送して第2貼合部に供給する。第2液晶セル搬送部104には、第1偏光フィルム131が貼り合せられた液晶セルPを90°水平回転させる回転機構(不図示)と、第1偏光フィルム131が貼り合せられた液晶セルPを上下反転させる反転機構が備えられている。
本実施形態に係る光学表示パネルの連続製造方法は、 粘着剤を含む光学フィルムが当該粘着剤を介して積層されているキャリアフィルムを搬送するキャリアフィルム搬送工程と、
前記キャリアフィルム搬送工程により搬送された前記キャリアフィルムを内側にして折り返して当該キャリアフィルムから前記光学フィルムを剥離する剥離工程と、
前記剥離工程により剥離された前記光学フィルムの前端部を光学セルの前端部に貼り合せる前端部貼合工程と、
前記キャリアフィルム搬送工程による前記キャリアフィルムの搬送開始よりも先に、前記前端部が貼り合された前記光学フィルムの前記前端部以降の部分の前記光学セルへの貼合開始が実行されるように、光学セルを搬送しながら、前記剥離工程で前記キャリアフィルムから剥離された前記光学フィルムを前記粘着剤を介して該光学セルに貼り合せて光学表示パネルを形成する貼合工程と、を含む。
上記実施形態では、ロールから繰り出された積層光学フィルムを所定間隔で切断(ハーフカット)するものであったが、本発明はとくにこの構成に制限されない。例えば、ロールから繰り出された積層光学フィルムを欠点検査し、当該検査結果に基づいて欠点を避けるように切断(いわゆるスキップカット)してもよい。また、積層光学フィルムに予め付された欠点情報を読み取り、当該欠点情報に基づいて欠点を避けるように切断してもよい。欠点情報は、欠点位置がわかるようにマーキングしたものでもよい。
図1の連続製造システムで、偏光フィルム(日東電工株式会社製VEG1724DU)を対向配置される無アルカリガラス基板(コーニング製)間に液晶層が封止された構成の長方形状の液晶セルの片側の基板にその長辺側から短辺方向に沿って貼り合せた。実施例および比較例では、貼合速度V2および巻取速度(偏光フィルムが剥離されたキャリアフィルムの搬送速度)V1をそれぞれ以下のように設定して貼り合せた。
12 第1キャリアフィルム
131 第1偏光フィルム(光学フィルムの一例)
30 第1ダンサーロール
40 第1剥離部
50a 第1貼合ローラ
50b 第1駆動ローラ
60 第1巻取部
60a 巻取ローラ
101 第1キャリアフィルム搬送部
102 第1液晶セル搬送部
103 第1貼合部
110 第1駆動制御部
P 液晶セル(光学セルの一例)
Y 液晶表示パネル(光学表示パネルの一例)
Claims (5)
- 粘着剤を含む光学フィルムが当該粘着剤を介して積層されているキャリアフィルムを搬送するキャリアフィルム搬送工程と、
前記キャリアフィルム搬送工程により搬送された前記キャリアフィルムを内側にして折り返して当該キャリアフィルムから前記光学フィルムを剥離する剥離工程と、
前記剥離工程により剥離された前記光学フィルムの前端部を光学セルの前端部に貼り合せる前端部貼合工程と、
前記キャリアフィルム搬送工程による前記キャリアフィルムの搬送開始よりも先に、前記前端部が貼り合された前記光学フィルムの前記前端部以降の部分の前記光学セルへの貼合開始が実行されるように、光学セルを搬送しながら、前記剥離工程で前記キャリアフィルムから剥離された前記光学フィルムを前記粘着剤を介して該光学セルに貼り合せて光学表示パネルを形成する貼合工程と、を含む光学表示パネルの連続製造方法。 - 前記貼合工程は、前記光学フィルムを前記光学セルに貼り合せ始める貼合開始時点から貼り合せ完了する貼合完了時点までの間にある途中の時点から所定の期間、該光学フィルムが剥離されたキャリアフィルムの搬送速度を前記光学フィルムの該光学セルへの貼合速度に一致させる、または前記貼合速度よりも大きくさせる、請求項1に記載の光学表示パネルの連続製造方法。
- 粘着剤を含む光学フィルムが当該粘着剤を介して積層されているキャリアフィルムを搬送するキャリアフィルム搬送部と、
前記キャリアフィルム搬送部により搬送されたキャリアフィルムを内側にして折り返して当該キャリアフィルムから前記光学フィルムを剥離する剥離部と、
前記剥離部で剥離された前記光学フィルムの前端部を光学セルの前端部に貼り合せ、かつ、光学セルを搬送しながら、前記キャリアフィルムから剥離された前記光学フィルムを前記粘着剤を介して該光学セルに貼り合せて光学表示パネルを形成する貼合部と、
前記キャリアフィルム搬送部による前記キャリアフィルムの搬送開始よりも先に、前記貼合部による前記前端部が貼り合された前記光学フィルムの前記前端部以降の部分の前記光学セルへの貼合開始が実行されるように、該貼合部を駆動制御し、かつ該キャリアフィルム搬送部を駆動制御する駆動制御部と、を有する光学表示パネルの連続製造システム。 - 前記キャリアフィルム搬送部が、前記剥離部よりも上流側に、キャリアフィルムの搬送時の張力を調整する張力調整部を有する、請求項3に記載の光学表示パネルの連続製造システム。
- 前記駆動制御部が、
前記光学フィルムを前記光学セルに貼り合せ始める貼合開始時点から貼り合せ完了する貼合完了時点までの間にある途中の時点から所定の期間、前記キャリアフィルム搬送部による前記光学フィルムが剥離されたキャリアフィルムの搬送速度を前記貼合部による前記光学フィルムの前記光学セルへの貼合速度に一致させるように、または前記貼合速度よりも大きくなるように、該貼合部および該キャリアフィルム搬送部を駆動制御する、請求項3または4に記載の光学表示パネルの連続製造システム。
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