TWI551913B - A manufacturing method of a liquid crystal display element, and a manufacturing system of a liquid crystal display device - Google Patents
A manufacturing method of a liquid crystal display element, and a manufacturing system of a liquid crystal display device Download PDFInfo
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- G—PHYSICS
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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
- G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
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Description
本發明係關於液晶顯示元件之製造方法及液晶顯示元件之製造系統。The present invention relates to a method of manufacturing a liquid crystal display element and a manufacturing system of the liquid crystal display element.
專利文獻1記載有將複數片光學膜每片光學膜依序積層於液晶面板而製造液晶顯示元件之方法。具體而言,係從捲繞積層有光學膜之襯膜而成之連續輥,送出襯膜,留下襯膜,將光學膜於膜寬方向切斷成特定尺寸(半切斷),從而形成片材,並將已剝離襯膜之片材貼附於液晶面板,在積層於該液晶面板之光學膜上,依序積層形成下一光學膜之片材的方法。Patent Document 1 describes a method of manufacturing a liquid crystal display element by sequentially laminating an optical film of a plurality of optical films on a liquid crystal panel. Specifically, the film is fed from a continuous roll in which a film of an optical film is laminated, and a liner film is left, and the film is cut into a specific size (semi-cut) in the film width direction to form a sheet. A material, and a sheet of the release liner is attached to a liquid crystal panel, and a film of the next optical film is sequentially laminated on the optical film laminated on the liquid crystal panel.
專利文獻1:日本特開2009-271516號公報Patent Document 1: Japanese Laid-Open Patent Publication No. 2009-271516
上述專利文獻1之情形,為了依序積層複數片光學膜之片材,要求高精度之貼合。然而,在專利文獻1中,必須將從連續輥送出之連續網狀物形態之光學膜及襯膜,連續搬送至與液晶面板之貼附位置,且因光學膜之半切斷處理機構、襯膜之剝離處理機構、液晶面板之輸送處理機構、片材貼附處理機構、襯膜輸送處理機構等之各種機械誤差或控制誤差之影響,導致難以在面位置精密地進行片材彼此之積層。為縮小片材彼此之貼附偏差量,亦可將製造速度放慢進行處理,但製造速度越下降,越會導致生產率降低。In the case of the above Patent Document 1, in order to sequentially laminate a plurality of sheets of an optical film, high-precision bonding is required. However, in Patent Document 1, it is necessary to continuously transfer the optical film and the liner film in the form of a continuous web fed from a continuous roll to the position where it is attached to the liquid crystal panel, and the half-cut processing mechanism and the liner film of the optical film. The influence of various mechanical errors or control errors such as the peeling processing means, the liquid crystal panel transport processing means, the sheet attaching processing means, and the liner transport processing means makes it difficult to precisely laminate the sheets at the surface position. In order to reduce the amount of deviation between the sheets, the manufacturing speed can be slowed down, but the lower the manufacturing speed, the lower the productivity.
假定在片材彼此之積層中產生偏差之情形,會導致形成於光學膜之粘著劑露出,而於該露出之粘著劑附著異物,有使顯示品質降低之虞。又,亦焦慮露出溢出之粘著劑在搬送時會與外部接觸變成膠球,且該膠球成為貼合時之異物。又,若偏差較大,則亦焦慮未覆蓋液晶面板之顯示區域而被積層。It is assumed that a deviation occurs in the laminate between the sheets, and the adhesive formed on the optical film is exposed, and the exposed adhesive adheres to the foreign matter, which degrades the display quality. In addition, the adhesive which is anxiously exposed to overflow will become a rubber ball when it is transported to the outside, and the rubber ball becomes a foreign matter at the time of bonding. Moreover, if the deviation is large, the anxiety layer is not covered by the display area of the liquid crystal panel.
且,各片材必須以至少覆蓋液晶面板之顯示區域(液晶單元)之方式積層,再者,從液晶面板之端溢出而積層亦不佳。在片材從液晶面板之端溢出而積層之情形,必須將溢出部份切斷除去。Further, each sheet must be laminated so as to cover at least the display region (liquid crystal cell) of the liquid crystal panel, and further, it is not preferable to overflow from the end of the liquid crystal panel. In the case where the sheet overflows from the end of the liquid crystal panel and is laminated, the overflow portion must be cut off.
本發明係鑑於上述之實際情況而完成者,提供一種無需降低製造速度而考慮貼附偏差量,且不會產生所積層之片材間之粘著劑之溢出(露出)之液晶顯示元件之製造方法及液晶顯示元件之製造系統。The present invention has been made in view of the above-described actual circumstances, and provides a liquid crystal display element which is manufactured without considering a reduction in the manufacturing speed and which does not cause an overflow (exposure) of the adhesive between the sheets of the laminated layer. Method and manufacturing system of liquid crystal display element.
為解決上述問題,重複潛心研究之結果,直至完成以下之本發明。In order to solve the above problems, the results of the research are repeated until the following invention is completed.
本發明之液晶顯示元件之製造方法,其包含2個以上光學膜之片材積層步驟,該步驟包含:從將積層有含有粘著劑之特定膜寬之光學膜之襯膜捲繞而成之連續輥,搬送該襯膜之襯膜搬送子步驟;留下該襯膜,在與光學膜之長度方向正交之膜寬方向以特定之切斷間隔將該光學膜切斷而形成光學膜之片材之切斷子步驟;搬送液晶面板之搬送子步驟;及一面搬送前述液晶面板,一面將已從前述襯膜剝離之前述片材介隔前述粘著劑而積層於該液晶面板側之貼附子步驟;且藉由該2個以上之片材積層步驟,將2片以上之片材按每片片材依序積層於液晶面板側而形成液晶顯示元件,且積層於前述液晶面板之一面之2片以上之片材中,以使接下來要積層之片材之4條邊各者小於其前已積層之片材之4條邊中在積層狀態下所對應之邊的方式,設定前述2片以上捲繞於連續輥之光學膜之膜寬,及設定前述切斷子步驟之前述切斷間隔。A method for producing a liquid crystal display device of the present invention, comprising a sheet stacking step of two or more optical films, comprising: winding a liner film of an optical film having a specific film width containing a binder; a continuous roller that transports the liner film transfer sub-step; leaving the liner film to cut the optical film at a specific cutting interval in a film width direction orthogonal to the longitudinal direction of the optical film to form an optical film a cutting step of the sheet; a step of transporting the liquid crystal panel; and a layer on the liquid crystal panel side by sandwiching the sheet which has been peeled off from the backing film while the liquid crystal panel is being conveyed In the two or more sheet stacking steps, two or more sheets are sequentially laminated on the liquid crystal panel side for each sheet to form a liquid crystal display element, and laminated on one side of the liquid crystal panel In the two or more sheets, the two sides of the sheet to be laminated next are set to be smaller than the two sides of the four sides of the sheet which has been laminated in the stacking state, and the two or more sheets are set. Winding on a continuous roll The film width of the optical film and the aforementioned cutting interval of the cutting step are set.
該構成係考慮貼附偏差,使接下來(後)積層之側之片材之4條邊各者小於先前所積層之片材之4條邊內,在積層狀態下對應之邊,藉此,亦不會產生依序積層之片材間之粘著劑之溢出(露出)者。This configuration considers the adhesion deviation so that the four sides of the sheet on the side of the next (post) buildup layer are smaller than the four sides of the sheet of the previously laminated layer, and the corresponding side in the laminated state, thereby not It will cause the overflow (exposure) of the adhesive between the sheets which are sequentially laminated.
在上述發明中,前述片材中,將相當於捲繞於前述連續輥之光學膜之膜寬之邊設為第1邊,將與該第1邊正交且相當於前述切斷間隔之長度之邊設為第2邊時,可實行以下兩個積層處理:第1積層處理(第1片材積層步驟),其係以對先前所積層之前一片片材之前述第1邊對應接下來積層之下一片片材之前述第1邊,而對該前一片之片材之前述第2邊對應該下一片片材之前述第2邊的方式,於該前一片片材上積層該下一片片材;與第2積層處理(第2片材積層步驟),其係以對先前所積層之前一片片材之前述第1邊對應接下來所積層之下一片片材之前述第2邊,而對該前一片片材之前述第2邊對應該下一片片材之前述第1邊的方式,於該前一片片材上積層該下一片片材;亦可實行任意一者之積層處理。第1積層處理與第2積層處理之順序無特別限定。又,可在實行1次或1次以上第1積層處理後,實行1次或1次以上第2積層處理,亦可相反。又,可在進行複數次第1積層處理期間實行第2積層處理,亦可相反。In the above invention, in the sheet, the side corresponding to the film width of the optical film wound around the continuous roll is the first side, and the first side is orthogonal to the length of the cutting interval. When the side is set to the second side, the following two lamination processes can be performed: the first lamination process (the first sheet lamination step), which is performed by substituting the first side of the preceding sheet of the previous layer. Lowering the first side of the sheet, and stacking the next sheet on the front sheet of the sheet of the preceding sheet corresponding to the second side of the next sheet And the second layering process (the second sheet layering step), wherein the first side of the sheet before the previous layer is laminated corresponds to the second side of the sheet below the next layer, and The second side of the preceding sheet corresponds to the first side of the next sheet, and the next sheet is laminated on the front sheet; or any one of them may be laminated. The order of the first buildup process and the second laminate process is not particularly limited. Further, after the first layering process is performed once or more, the second layering process may be performed once or more, or vice versa. Further, the second layering process may be performed during the plurality of first layering processes, or vice versa.
作為上述發明之一實施形態,前述片材中,將相當於捲繞於前述連續輥之光學膜之膜寬設為第1邊,將與該第1邊正交且相當於前述切斷間隔之長度之邊設為第2邊時,以對先前所積層之前一片片材之前述第1邊對應接下來要積層之下一片片材之前述第1邊,而對該前一片片材之前述第2邊對應該下一片片材之前述第2邊的方式,於該前一片片材上積層該下一片片材;且積層於前述液晶面板之一面之2片以上之片材中,以使最初積層之片材之膜寬最大,其後積層之片材之膜寬依序縮小的方式,設定前述2片以上捲繞於連續輥之光學膜之膜寬;及以使在前述切斷子步驟中形成之前述最初積層之片材之切斷間隔最大,其後積層之片材之切斷間隔依序縮小的方式,在前述切斷子步驟中將前述光學膜切斷而形成片材。According to one embodiment of the invention, in the sheet, the film width corresponding to the optical film wound around the continuous roll is set to be the first side, and the first side is orthogonal to the first side and corresponds to the cutting interval. When the side of the length is set to the second side, the first side of one sheet before the previous layer is placed corresponding to the first side of the sheet to be laminated next, and the first sheet of the previous sheet is The two sides of the sheet are stacked on the front sheet, and the second sheet is laminated on the front sheet of the liquid crystal panel to form the first sheet. The film width of the laminated sheet is the largest, and the film width of the laminated film is sequentially reduced, and the film width of the two or more optical films wound on the continuous roll is set; and in the cutting step The first laminated sheet formed in the middle has the largest cutting interval, and the cutting interval of the subsequently laminated sheet is sequentially reduced, and the optical film is cut in the cutting step to form a sheet.
該構成為將最初積層於液晶面板之片材之膜寬及特定之切斷間隔(與膜寬方向正交之方向之長度)設為最大者,使第2片以後之片材者等依序縮小,藉此第2片以後之片材不會從較其先積層之片材溢出而積層,亦不會產生所積層之片材間之粘著劑之溢出(露出)者。In this configuration, the film width of the first layer laminated on the liquid crystal panel and the specific cutting interval (the length in the direction orthogonal to the film width direction) are maximized, and the sheets after the second sheet are sequentially ordered. By shrinking, the sheet after the second sheet does not overflow from the sheet which is laminated first, and the overflow (exposure) of the adhesive between the sheets of the layer is not generated.
較佳的是預先測定因各片材積層裝置之機械等誤差而產生之貼附偏差量,以小於貼附偏差量的方式,設定片材之膜寬及切斷間隔。It is preferable to measure the amount of the deviation of the adhesion due to the mechanical error of each of the sheet laminating apparatuses, and to set the film width and the cutting interval of the sheet so as to be smaller than the amount of the deviation.
作為上述發明之一實施形態,進而包含水平旋轉步驟,其係使藉由前述貼附子步驟而積層有片材之液晶面板,在藉由下一個貼附子步驟積層下一片片材之前,相對於該液晶面板之搬送方向水平旋轉90°;且前述片材中,將相當於捲繞於前述連續輥之光學膜之膜寬之邊設為第1邊,將與該第1邊正交且相當於前述切斷間隔之長度之邊設為前述第2邊時,以對在前述水平旋轉步驟之前所積層之前一片片材之前述第1邊對應前述下一片片材之第2邊,而對該前一片片材之前述第2邊對應該下一片片材之前述第1邊的方式,於該前一片片材上積層該下一片片材;以使前述下一片片材之前述第1邊小於前述前一片片材之前述第2邊的方式,設定用於形成該下一片片材之捲繞於前述連續輥之光學膜之膜寬;及以使前述下一片片材之前述第2邊小於前述前一片片材之前述第1邊的方式,設定前述切斷間隔,且基於該切斷間隔,在前述切斷子步驟中將前述光學膜切斷而形成前述下一片片材。According to an embodiment of the invention, the method further includes a horizontal rotation step of laminating the liquid crystal panel with the sheet by the attaching sub-step, and before laminating the next sheet by the next attaching sub-step, The conveying direction of the liquid crystal panel is horizontally rotated by 90°; and in the sheet, the side corresponding to the film width of the optical film wound around the continuous roll is referred to as a first side, and is orthogonal to the first side and corresponds to When the side of the length of the cutting interval is the second side, the first side of one sheet before the layer is stacked before the horizontal rotation step corresponds to the second side of the next sheet, and the front side The second side of the one sheet corresponds to the first side of the next sheet, and the next sheet is laminated on the front sheet; so that the first side of the next sheet is smaller than the foregoing The second side of the preceding sheet is set to a film width of the optical film wound around the continuous roll for forming the next sheet; and the second side of the next sheet is smaller than the aforementioned The first side of the previous sheet Type, set the cutting interval and based on the cutting interval in the sub-step of cutting the optical film will be formed by cutting the next sheet piece.
如圖6、7所示,該構成係在前一片片材之貼附處理後,使液晶面板相對搬送方向D水平旋轉90°,將下一片片材進行貼附處理。由於下一片片材之膜寬(第1邊)小於前一片片材之切斷間隔(第2邊),且下一片片材之切斷間隔(第2邊)小於前一片片材之膜寬(第1邊),故下一片片材不會溢出,亦不會產生所積層之片材間之粘著劑之溢出(露出)。在本發明中,「90°水平旋轉」之「90°」包含差異之範圍。As shown in FIGS. 6 and 7, this configuration is such that after the attachment process of the preceding sheet, the liquid crystal panel is horizontally rotated by 90° with respect to the conveyance direction D, and the next sheet is attached. Since the film width (the first side) of the next sheet is smaller than the cutting interval (the second side) of the previous sheet, and the cutting interval (the second side) of the next sheet is smaller than the film width of the previous sheet (1st side), so the next sheet does not overflow, and there is no overflow (exposure) of the adhesive between the sheets. In the present invention, "90°" of "90° horizontal rotation" includes the range of the difference.
又,積層於液晶面板之全部之片材之面積較佳為液晶面板之顯示區域(有家單元區域)以上,且為液晶面板之表面面積以下。再者,積層於液晶面板之最外表面之片材之膜寬及切斷間隔,較佳為基於液晶面板之顯示區域(液晶單元區域)與貼附偏差量予以設定。貼附偏差量示例有液晶面板之搬送方向即X方向偏差量、與X方向正交之方向之Y方向偏差量(膜寬方向)、對液晶面板之搬送方向軸(X軸)貼附時之片材輸送方向軸之旋轉偏差即θ偏差量等。Moreover, it is preferable that the area of all the sheets laminated on the liquid crystal panel is equal to or larger than the display area (the unit cell area) of the liquid crystal panel, and is equal to or less than the surface area of the liquid crystal panel. Further, the film width and the cutting interval of the sheet laminated on the outermost surface of the liquid crystal panel are preferably set based on the display region (liquid crystal cell region) of the liquid crystal panel and the amount of adhesion deviation. The adhesion amount is exemplified by the X-direction deviation amount in the transport direction of the liquid crystal panel, the Y-direction deviation amount in the direction orthogonal to the X direction (film width direction), and the attachment to the transport direction axis (X-axis) of the liquid crystal panel. The rotation deviation of the sheet conveying direction axis, that is, the amount of θ deviation.
作為上述發明之一實施形態,用於積層第2片以後之片材之前述片材積層步驟之貼附子步驟,較佳為以使第1片片材之寬度方向中心軸線,與和該寬度方向正交之方向之中心軸線之交叉線,與第2片以後之片材之寬度方向中心軸線,與和該寬度方向正交之方向之中心軸線之交叉線一致的方式,積層該片材(參照圖4A~圖4C)。根據該構成,由於可以使片材彼此之交叉線一致或實質上一致的方式,積層片材彼此,故接下來所積層之片材不會從先前所積層之片材溢出。According to an embodiment of the present invention, the attaching sub-step of the sheet laminating step for laminating the second sheet or later is preferably such that the central axis of the first sheet in the width direction and the width direction The intersection line of the central axis of the orthogonal direction is laminated with the center line of the width direction direction of the sheet after the second sheet and the center line of the direction orthogonal to the width direction, and the sheet is laminated (see 4A to 4C). According to this configuration, since the sheets can be laminated so that the intersecting lines of the sheets can be aligned or substantially identical, the sheets to be laminated next do not overflow from the sheets stacked previously.
為以使片材彼此之交叉線一致的方式積層,較佳為基於附於液晶面板之對準標記,或液晶面板之端部或角部,進行所積層之片材之定位而貼附。從對準標記等至片材之端線之距離係與所積層之片材之順序按比例增大。即,所積層之全部之片材可以基於面板之對準標記等之面板基準之對準方式貼合。又,作為其他之對準方式,可採用片材基準對準方式。該片材基準對準方式係所積層之第1片片材基於對準標記等對準貼合,第2片以後所積層之片材,基於較其前一片貼合之片材之端部或角部,對準貼合之方法。由於該片材基準對準方式相較於面板基準,可更確實貼合於先貼合之片材內,故而較佳。In order to laminate the sheets so that the lines intersect with each other, it is preferable to perform positioning by attaching the sheets of the laminated sheets based on the alignment marks attached to the liquid crystal panel or the end portions or corner portions of the liquid crystal panel. The distance from the alignment mark or the like to the end line of the sheet is proportional to the order of the sheets of the laminated layer. That is, all of the sheets of the laminated layer can be bonded in accordance with the alignment of the panel reference such as the alignment mark of the panel. Further, as another alignment method, a sheet reference alignment method can be employed. In the sheet reference alignment method, the first sheet of the laminated layer is aligned and bonded by an alignment mark or the like, and the sheet laminated after the second sheet is based on the end of the sheet which is bonded to the previous sheet or Corner, align the method of fitting. Since the sheet reference alignment method is more surely adhered to the previously attached sheet than the panel reference, it is preferable.
作為上述發明之一實施形態,較佳為連續進行前述2以上之片材積層步驟。藉此,由於可連續製造於液晶面板依序積層光學膜之片材而成之液晶顯示元件,故可提高生產率。又,作為其他實施形態,可連續進行2個片材積層步驟,亦可於其後連續進行1以上之片材積層步驟。As an embodiment of the invention, it is preferable that the sheet stacking step of the above two or more is continuously performed. Thereby, since the liquid crystal display element in which the sheet of the optical film is sequentially laminated on the liquid crystal panel can be continuously manufactured, productivity can be improved. Further, as another embodiment, two sheet stacking steps may be continuously performed, or one or more sheet stacking steps may be continuously performed thereafter.
又,作為上述發明之一實施形態,前述光學膜之一為2色偏光膜,另一光學膜為反射偏光膜;且2色偏光膜之片材積層步驟係於前述液晶面板積層前述2色偏光膜之片材;反射偏光膜之片材積層步驟係以使前述2色偏光膜之片材之透射軸與前述反射偏光膜之片材之透射軸為相同方向的方式,將該反射偏光膜之片材貼附於該2色偏光膜之片材,而於前述液晶面板上積層該反射偏光膜之片材。在該構成中,前述反射偏光膜及貼附有該反射偏光膜之前述2色偏光膜,較佳為於與膜寬方向正交之長度方向上具有透射軸。Further, in one embodiment of the invention, one of the optical films is a two-color polarizing film, and the other optical film is a reflective polarizing film; and the step of laminating the two color polarizing films is performed by laminating the two-color polarized light on the liquid crystal panel a sheet of a film; a step of laminating a sheet of the reflective polarizing film, wherein the transmission axis of the sheet of the two color polarizing film and the transmission axis of the sheet of the reflective polarizing film are in the same direction, and the reflective polarizing film is The sheet is attached to the sheet of the two-color polarizing film, and the sheet of the reflective polarizing film is laminated on the liquid crystal panel. In the above configuration, the reflective polarizing film and the two-color polarizing film to which the reflective polarizing film is attached preferably have a transmission axis in a longitudinal direction orthogonal to the film width direction.
藉此,可使用長度方向(MD方向)具有透射軸,膜寬方向具有吸收軸之2色偏光膜。由於其長度方向(MD方向)具有2色偏光膜之透射軸,且其長度方向(MD方向)具有反射偏光膜之透射軸,且可使2色偏光膜、反射偏光膜、液晶面板之搬送方向為相同方向,故無需採用旋轉機構等之複雜之機構,即可使生產線為直線路線。Thereby, a two-color polarizing film having a transmission axis in the longitudinal direction (MD direction) and an absorption axis in the film width direction can be used. The longitudinal direction (MD direction) has a transmission axis of the two-color polarizing film, and the longitudinal direction (MD direction) has a transmission axis of the reflective polarizing film, and the two-color polarizing film, the reflective polarizing film, and the liquid crystal panel can be transported. In the same direction, the production line can be made into a straight line without using a complicated mechanism such as a rotating mechanism.
又,作為上述發明之一實施形態,進而包含檢查步驟,其係藉由2個前述2色偏光膜之片材積層步驟,於前述液晶面板之兩面積層2色偏光膜之片材後,將該液晶面板進行光學檢查;且反射偏光膜之片材積層步驟,其在藉由前述檢查步驟檢查後,在積層於前述液晶面板之一面之2色偏光膜之片材上,以使該2色偏光膜之片材之透射軸之方向,與反射偏光膜之片材之透射軸之方向相同的方式,貼附該反射偏光膜之片材。藉此,介隔2色偏光膜,將反射偏光膜積層於液晶面板。Further, in an embodiment of the invention, further comprising an inspection step of laminating the two color-changing films of the two liquid crystal panels by the sheet stacking step of the two two-color polarizing films The liquid crystal panel is optically inspected; and the sheet stacking step of the reflective polarizing film is performed on the sheet of the two color polarizing film laminated on one surface of the liquid crystal panel after being inspected by the inspection step to make the two colors polarized. The sheet of the film is attached to the sheet of the reflective polarizing film in such a manner that the direction of the transmission axis of the film is the same as the direction of the transmission axis of the sheet of the reflective polarizing film. Thereby, the two-color polarizing film is interposed and the reflective polarizing film is laminated on the liquid crystal panel.
該構成由於在積層反射偏光膜之前,檢查於兩面積層有2色偏光膜之液晶面板,於判斷為良品之液晶面板積層反射偏光膜,而於判斷為不良品之液晶面板無需積層反射偏光膜即可,故可提高反射偏光膜之良率。In this configuration, the liquid crystal panel having the two-color polarizing film in the two-layer layer is inspected before the laminated layer is reflected, and the liquid crystal panel is judged to be a good reflection of the polarizing film, and it is determined that the liquid crystal panel of the defective product does not need to have a reflective polarizing film. Yes, it can improve the yield of the reflective polarizing film.
又,另一發明之液晶顯示元件之製造系統,其具備2個以上光學膜之片材積層裝置,該裝置具備:從將積層有含有粘著劑之特定膜寬之光學膜之襯膜捲繞而成之連續輥,搬送該襯膜之襯膜搬送機構;留下該襯膜,在與光學膜之長度方向正交之膜寬方向以特定之切斷間隔將該光學膜切斷而形成光學膜之片材之切斷機構;搬送液晶面板之搬送機構;及一面搬送前述液晶面板,一面將已從前述襯膜剝離之前述片材介隔前述粘著劑而積層於該液晶面板側之貼附機構;且藉由該2個以上之片材積層裝置,將2片以上之片材按每片片材依序積層於液晶面板側而形成液晶顯示元件,且,積層於前述液晶面板之一面之2片以上之片材中,以使接下來要積層之片材之4條邊之各者小於其前已積層之片材之4條邊中在積層狀態下所對應之邊的方式,設定前述2片以上捲繞於連續輥之光學膜之膜寬,及前述切斷機構之前述切斷間隔。Moreover, the manufacturing system of the liquid crystal display element of another invention is equipped with the sheet-layering apparatus of two or more optical film, and this apparatus is equipped with the lining film of the optical film which laminated the specific film width containing the adhesive agent. The continuous roll is used to transport the liner film transport mechanism; the liner is left, and the optical film is cut at a specific cutting interval in the film width direction orthogonal to the longitudinal direction of the optical film to form an optical a cutting mechanism for a sheet of a film; a conveying mechanism for conveying the liquid crystal panel; and a layer which is laminated on the liquid crystal panel side with the sheet which has been peeled off from the backing film while the liquid crystal panel is being conveyed In addition, two or more sheets are laminated on the liquid crystal panel side in order to form a liquid crystal display element, and laminated on one side of the liquid crystal panel. In the two or more sheets, the above two are set such that each of the four sides of the sheet to be laminated next is smaller than the side corresponding to the four sides of the sheet which has been laminated before the laminated state. The sheet is wound on a continuous roll The film width of the optical film and the aforementioned cutting interval of the cutting mechanism.
該構成係考慮貼附偏差,使接下來(後)積層側之片材之4條邊之各者小於先前所積層之片材之4條邊內,在積層狀態下對應之邊,從而亦不會產生依序積層之片材間之粘著劑之溢出(露出)者。This configuration considers the attachment deviation so that each of the four sides of the sheet on the next (post) build-up side is smaller than the four sides of the sheet of the previously laminated layer, and the corresponding side in the laminated state does not occur. The overflow (exposed) of the adhesive between the sheets which are sequentially laminated.
作為上述發明之一實施形態,前述片材中,將相當於捲繞於前述連續輥之光學膜之膜寬之邊設為第1邊,將與該第1邊正交且相當於前述切斷間隔之長度之邊設為第2邊時,以對先前所積層之前一片片材之前述第1邊對應接下來要積層之下一片片材之前述第1邊,而對該前一片片材之前述第2邊對應該下一片片材之前述第2邊的方式,於該前一片片材上積層該下一片片材;且積層於前述液晶面板之一面之2片以上之片材中,以使最初積層之片材之膜寬最大,其後積層之片材之膜寬依序縮小的方式,設定前述2片以上捲繞於連續輥之光學膜之膜寬;及前述片材積層裝置之切斷機構係以使前述最初積層之片材之前述切斷間隔最大,其後面積層之片材之切斷間隔依序縮小的方式,切斷前述光學膜形成片材。According to one embodiment of the invention, in the sheet, the side corresponding to the film width of the optical film wound around the continuous roll is the first side, and the first side is orthogonal to the first side and corresponds to the cutting. When the side of the length of the interval is the second side, the first side of one sheet before the previous layer is placed corresponding to the first side of the sheet to be laminated next to the sheet, and the sheet of the previous sheet is The second side corresponds to the second side of the next sheet, and the next sheet is laminated on the front sheet; and the sheet is laminated on two or more sheets on one surface of the liquid crystal panel. The film width of the first laminated film is maximized, and the film width of the laminated film is sequentially reduced, and the film width of the two or more optical films wound on the continuous roll is set; and the sheet laminating device is The cutting mechanism cuts the optical film forming sheet so that the cutting interval of the first laminated sheet is maximized, and the cutting interval of the sheet of the area layer is sequentially reduced.
該構成係將最初積層於液晶面板之片材之膜寬及切斷間隔(與寬度方向正交之方向之長度)設為最大,使第2片以後之片材者等依序縮小,藉此第2片以後之片材不會從較其先積層之片材溢出而積層,亦不會產生所積層之片材間之粘著劑之溢出(露出)者。In this configuration, the film width of the sheet laminated on the liquid crystal panel and the cutting interval (the length in the direction orthogonal to the width direction) are maximized, and the sheets of the second sheet and the like are sequentially reduced. The sheet after the second sheet does not overflow from the sheet which is laminated first, and does not cause the overflow (exposure) of the adhesive between the sheets of the laminate.
又,作為上述發明之一實施形態,亦可具有控制2個以上前述片材積層裝置之切斷機構及襯膜搬送機構之控制部控制部係控制全部之切斷機構及襯膜搬送機構,使最初積層之片材之切斷間隔最大,接下來後面所積層之片材之切斷間隔依序縮小。Furthermore, as one embodiment of the invention, the cutting mechanism for controlling the two or more sheet stacking devices and the control unit of the film transport mechanism may control all of the cutting mechanism and the film transport mechanism. The cut interval of the first laminated sheet is the largest, and the cutting interval of the later laminated sheets is sequentially reduced.
較佳的是預先測定因各片材積層裝置之機械等誤差而產生之貼附偏差量,以小於貼附偏差量的方式,設定片材之膜寬及切斷間隔。該等切斷間隔預先儲存於控制部之記憶體,控制部控制襯膜之進給量及切斷機構,以便以該切斷間隔進行切斷。進給量可藉由例如測定構成襯膜搬送機構之一部份之進給輥等之旋轉量的編碼器之檢測進行測定。It is preferable to measure the amount of the deviation of the adhesion due to the mechanical error of each of the sheet laminating apparatuses, and to set the film width and the cutting interval of the sheet so as to be smaller than the amount of the deviation. The cutting intervals are stored in advance in the memory of the control unit, and the control unit controls the feed amount of the lining film and the cutting mechanism to perform cutting at the cutting interval. The feed amount can be measured by, for example, detection of an encoder that measures the amount of rotation of a feed roller or the like that constitutes a part of the film transport mechanism.
又,作為上述發明之一實施形態,進而包含水平旋轉部,其係使藉由前述貼附機構積層有片材之液晶面板,在藉由下一個貼附機構積層下一片片材之前,相對於該液晶面板之搬送方向水平旋轉90°;且前述片材中,將相當於捲繞於前述連續輥之光學膜之膜寬之邊設為第1邊,將與該第1邊正交且相當於前述切斷間隔之長度之邊設為前述第2邊時,以對藉由前述水平旋轉部旋轉之前所積層之前一片片材之前述第1邊對應前述下一片片材之第2邊,而對該前一片片材之前述第2邊對應該下一片片材之前述第1邊的方式,於該前一片片材上積層該下一片片材;且以使前述下一片片材之前述第1邊,小於前述前一片片材之前述第2邊的方式,設定用於形成該下一片片材之捲繞於前述連續輥之光學膜之膜寬;及以使前述下一片片材之前述第2邊小於前述前一片片材之前述第1邊的方式,設定前述切斷間隔,且前述切斷機構基於該切斷間隔切斷前述光學膜,形成前述下一片片材。Further, in an embodiment of the invention, the horizontal rotating portion further includes a liquid crystal panel in which a sheet is laminated by the attaching mechanism, and the lower sheet is laminated on the next sheet by the next attaching mechanism. The conveying direction of the liquid crystal panel is horizontally rotated by 90°, and the side corresponding to the film width of the optical film wound around the continuous roll is the first side, and the first side is orthogonal to the first side. When the side of the length of the cutting interval is the second side, the first side of the sheet before the layer is rotated before the horizontal rotating portion corresponds to the second side of the next sheet. Forming the next piece of the sheet on the front piece of the sheet in a manner in which the second side of the preceding sheet corresponds to the first side of the next sheet; and a side width smaller than the second side of the front sheet, the film width of the optical film wound around the continuous roll for forming the next sheet; and the aforementioned sheet of the next sheet The second side is smaller than the aforementioned first piece of the preceding piece of sheet Manner, setting the cutting interval and the cutting means cutting the optical film based on the cutting interval, the next piece of sheet material is formed.
如圖6、7所示,該構成係在前一片片材之貼附處理後,使液晶面板相對搬送方向D水平旋轉90°,將下一片片材進行貼附處理。由於下一片片材之膜寬(第1邊)小於前一片片材之切斷間隔(第2邊),且下一片片材之切斷間隔(第2邊)小於前一片片材之膜寬(第1邊),故下一片片材不會溢出,亦不會產生所積層之片材間之粘著劑之溢出(露出)。As shown in FIGS. 6 and 7, this configuration is such that after the attachment process of the preceding sheet, the liquid crystal panel is horizontally rotated by 90° with respect to the conveyance direction D, and the next sheet is attached. Since the film width (the first side) of the next sheet is smaller than the cutting interval (the second side) of the previous sheet, and the cutting interval (the second side) of the next sheet is smaller than the film width of the previous sheet (1st side), so the next sheet does not overflow, and there is no overflow (exposure) of the adhesive between the sheets.
作為上述發明之一實施形態,用於積層第2片以後之片材之前述片材積層步驟之貼附機構,較佳為以使第1片片材之膜寬方向中心軸線,與和該膜寬方向正交之方向之中心軸線之交叉線,與第2片以後之片材之膜寬方向中心軸線,與和該膜寬方向正交之方向之中心軸線之交叉線一致的方式,積層該片材。根據該構成,由於可以使片材彼此之交叉線一致或實質上一致的方式,積層片材彼此,故接下來所積層之片材不會從先前所積層之片材溢出。According to an embodiment of the invention, it is preferable that the attaching means for the sheet stacking step of the sheet after the second sheet is formed so that the central axis of the first sheet in the film width direction and the film are The intersection line of the central axis in the direction orthogonal to the width direction is laminated so as to coincide with the line connecting the central axis of the sheet in the film width direction of the second sheet and the film in the direction orthogonal to the film width direction. Sheet. According to this configuration, since the sheets can be laminated so that the intersecting lines of the sheets can be aligned or substantially identical, the sheets to be laminated next do not overflow from the sheets stacked previously.
貼附機構可適用前述面板基準之對準方式、片材基準之對準方式中之任一者,貼附片材。The attaching mechanism can be attached to any one of the alignment method of the panel reference and the alignment method of the sheet reference.
又,作為上述發明之一實施形態,係將前述2個以上之片材積層裝置配置於連續生產線。藉此,由於可連續製造於液晶面板依序積層光學膜之片材而成之液晶顯示元件,故可提高生產率。又,作為其他實施形態,亦可將2個以上片材積層裝置配置於連續生產線,將與其不同之1個以上片材積層裝置配置於其他之(連續)生產線。Moreover, as one embodiment of the invention, the two or more sheet laminating apparatuses are disposed in a continuous production line. Thereby, since the liquid crystal display element in which the sheet of the optical film is sequentially laminated on the liquid crystal panel can be continuously manufactured, productivity can be improved. In addition, as another embodiment, two or more sheet laminating apparatuses may be disposed in a continuous production line, and one or more sheet laminating apparatuses different from each other may be disposed in another (continuous) production line.
又,作為前述發明之一實施形態,前述光學膜之一為2色偏光膜,另一光學膜為反射偏光膜;且2色偏光膜之片材積層裝置係於前述液晶面板上積層前述2色偏光膜之片材;反射偏光膜之片材積層裝置係以使前述2色偏光膜之片材之透射軸與前述反射偏光膜之片材之透射軸為相同方向的方式,將該反射偏光膜之片材貼附於該2色偏光膜之片材,而於前述液晶面板上積層該反射偏光膜之片材。在該構成中,前述反射偏光膜及貼附有該反射偏光膜之前述2色偏光膜,較佳為於與膜寬正交之長度方向上具有透射軸。Further, in one embodiment of the invention, one of the optical films is a two-color polarizing film, and the other optical film is a reflective polarizing film; and the two-color polarizing film sheet laminating device is formed by laminating the two colors on the liquid crystal panel a sheet for a polarizing film; a sheet stacking device for reflecting a polarizing film, wherein the reflective polarizing film is formed such that a transmission axis of the sheet of the two color polarizing film and a transmission axis of the sheet of the reflective polarizing film are in the same direction The sheet is attached to the sheet of the two-color polarizing film, and the sheet of the reflective polarizing film is laminated on the liquid crystal panel. In this configuration, the reflective polarizing film and the two-color polarizing film to which the reflective polarizing film is attached preferably have a transmission axis in a longitudinal direction orthogonal to the film width.
藉此,可使用長度方向(MD方向)具有透射軸,膜寬方向具有吸收軸之2色偏光膜。由於該等之長度方向(MD方向)具有2色偏光膜及反射偏光膜之透射軸,且可使2色偏光膜、反射偏光膜、液晶面板之搬送方向為相同方向,故無需採用旋轉機構等之複雜之機構,即可使生產線為直線路線。Thereby, a two-color polarizing film having a transmission axis in the longitudinal direction (MD direction) and an absorption axis in the film width direction can be used. Since the longitudinal direction (MD direction) has the transmission axes of the two-color polarizing film and the reflective polarizing film, and the two-color polarizing film, the reflective polarizing film, and the liquid crystal panel can be transported in the same direction, it is not necessary to use a rotating mechanism or the like. The complex mechanism allows the production line to be a straight line.
又,作為上述發明之一實施形態,進而包含檢查裝置,其係以2個前述2色偏光膜之片材積層裝置,於前述液晶面板之兩面積層2色偏光膜之片材後,將該液晶面板進行光學檢查;且前述反射偏光膜之片材積層裝置係在藉由前述檢查裝置檢查後,在積層於前述液晶面板之一面之2色偏光膜之片材上,以使該2色偏光膜之片材之透射軸之方向與反射偏光膜之片材之透射軸之方向相同的方式,貼附該反射偏光膜之片材。藉此,介隔2色偏光膜,將反射偏光膜積層於液晶面板上。Further, in an embodiment of the invention, the inspection apparatus further includes a sheet stacking device of the two color-shifting films, and the liquid crystal panel has a two-area layer 2 color-polarizing film sheet. The panel is optically inspected; and the sheet laminate device of the reflective polarizing film is placed on a sheet of a two-color polarizing film laminated on one surface of the liquid crystal panel after being inspected by the inspection device to make the two-color polarizing film The sheet of the reflective polarizing film is attached in such a manner that the direction of the transmission axis of the sheet is the same as the direction of the transmission axis of the sheet of the reflective polarizing film. Thereby, the reflective polarizing film is laminated on the liquid crystal panel via the two-color polarizing film.
該構成由於在積層反射偏光膜之前,檢查於兩面積層有2色偏光膜之液晶面板,於判斷為良品之液晶面板積層反射偏光膜,而於判斷為不良品之液晶面板無需積層反射偏光膜即可,故可提高反射偏光膜之良率。In this configuration, the liquid crystal panel having the two-color polarizing film in the two-layer layer is inspected before the laminated layer is reflected, and the liquid crystal panel is judged to be a good reflection of the polarizing film, and it is determined that the liquid crystal panel of the defective product does not need to have a reflective polarizing film. Yes, it can improve the yield of the reflective polarizing film.
又,另一發明之液晶顯示元件之製造方法,其包含2個以上光學膜之片材積層步驟,該步驟包含:從將相鄰積層有複數片之含有粘著劑之特定膜寬之光學膜之片材之襯膜捲繞而成之連續輥,搬送該襯膜之襯膜搬送子步驟;搬送液晶面板之搬送子步驟;及一面搬送前述液晶面板,一面將已從前述襯膜剝離之前述片材介隔前述粘著劑,積層於該液晶面板側之貼附子步驟;且藉由該2個以上之片材積層步驟,將2片以上之片材按每片片材依序積層於液晶面板側而形成液晶顯示元件,且,積層於前述液晶面板之一面之2片以上之片材中,使接下來要積層之片材之4條邊各者小於其前已積層之片材之4條邊中在積層狀態下所對應之邊的方式,設定前述2片以上捲繞於連續輥之光學膜之片材之膜寬及與該膜寬正交之方向之長度。藉此,由於可使用所謂的缺口嵌入連續輥,故可省略如上所述之切斷子步驟。Further, in another method of producing a liquid crystal display device of the present invention, there is provided a sheet stacking step of two or more optical films, which comprises: an optical film having a specific film width containing a plurality of adhesives from adjacent layers. a continuous roll wound with a lining film of the sheet, a step of transporting the lining film of the lining film, a transfer sub-step of transporting the liquid crystal panel, and a step of detaching the lining film from the lining film while transporting the liquid crystal panel The sheet is laminated on the liquid crystal panel side by the adhesion agent, and two or more sheets are sequentially laminated on the liquid crystal panel by the two or more sheet stacking steps. The liquid crystal display element is formed on the panel side, and is laminated on two or more sheets of one surface of the liquid crystal panel, so that the four sides of the sheet to be laminated next are smaller than the four sides of the sheet which has been laminated before. In the method of the side corresponding to the laminated state, the film width of the sheet of the optical film wound on the continuous roll of two or more sheets and the length in the direction orthogonal to the film width are set. Thereby, since the continuous roll can be embedded using a so-called notch, the cutting sub-step described above can be omitted.
作為上述發明之一實施形態,前述片材中,將相當於捲繞於前述連續輥之光學膜之片材之膜寬之邊設為第1邊,將相當於與該膜寬正交之方向之長度之邊設為第2邊時,以對先前所積層之前一片片材之前述第1邊對應接下來要積層之下一片片材之前述第1邊,而對該前一片片材之前述第2邊對應該下一片片材之前述第2邊的方式,於該前一片片材上積層該下一片片材;且,積層於前述液晶面板之一面之2片以上之片材中,以使最初積層之片材之膜寬及與該膜寬正交之方向之長度最大,其後積層之片材之膜寬及與該膜寬正交之方向之長度依序縮小的方式,設定前述2片以上捲繞於連續輥之光學膜之片材之膜寬,及與該膜寬正交之方向之長度。According to an embodiment of the invention, in the sheet, a side corresponding to a film width of a sheet wound around the optical film of the continuous roll is referred to as a first side, and corresponds to a direction orthogonal to the film width. When the side of the length is set to the second side, the first side of one sheet before the previous layer is formed, and the first side of the sheet to be laminated next is laminated, and the front side of the sheet is formed. The second side is formed by laminating the next sheet on the front sheet, and the second sheet is laminated on the sheet of one or more of the liquid crystal panels. The film width of the first laminated sheet and the length in the direction orthogonal to the film width are maximized, and the film width of the subsequently laminated sheet and the length in the direction orthogonal to the film width are sequentially reduced. The film width of two or more sheets of the optical film wound on the continuous roll and the length in the direction orthogonal to the film width.
作為上述發明之一實施形態,進而包含水平旋轉步驟,其係使藉由前述貼附子步驟而積層有片材之液晶面板,在藉由下一個貼附子步驟積層下一片片材之前,相對於該液晶面板之搬送方向水平旋轉90°;且前述片材中,將相當於捲繞於前述連續輥之光學膜之膜寬之邊設為第1邊,將相當於與該膜寬正交之方向之長度之邊設為前述第2邊時,以對在前述水平旋轉步驟之前所積層之前一片片材之前述第1邊對應前述下一片片材之前述第2邊,而對該前一片片材之前述第2邊對應該下一片片材之前述第1邊的方式,於該前一片片材上積層該下一片片材;且以使前述下一片片材之前述第1邊小於前述前一片片材之前述第2邊的方式,設定捲繞於前述連續輥之光學膜之片材之膜寬;及以使前述下一片片材之前述第2邊小於前述前一片片材之前述第1邊的方式,設定與捲繞於前述連續輥之光學膜之片材之膜寬正交的方向之長度。According to an embodiment of the invention, the method further includes a horizontal rotation step of laminating the liquid crystal panel with the sheet by the attaching sub-step, and before laminating the next sheet by the next attaching sub-step, The conveyance direction of the liquid crystal panel is horizontally rotated by 90°; and in the sheet, the side corresponding to the film width of the optical film wound around the continuous roll is referred to as a first side, and corresponds to a direction orthogonal to the film width. When the side of the length is the second side, the first side of the one sheet before the layer is stacked before the horizontal rotation step corresponds to the second side of the next sheet, and the front sheet is The second side of the lower sheet corresponds to the first side of the next sheet, and the next sheet is laminated on the front sheet; and the first side of the next sheet is smaller than the front sheet In the second aspect of the sheet, the film width of the sheet wound around the optical film of the continuous roll is set; and the second side of the next sheet is smaller than the first sheet of the front sheet Side way, set and wrap around The optical film of the length of the film roll of said continuous sheet of a direction perpendicular to the width.
又,另一發明之液晶顯示元件之製造系統,其包含2個以上光學膜之片材積層裝置,該裝置包含:從將相鄰積層有複數片之含有粘著劑之特定膜寬之光學膜之片材之襯膜捲繞而成之連續輥,搬送該襯膜之襯膜搬送機構;搬送液晶面板之搬送機構;及一面搬送前述液晶面板,一面將已從前述襯膜剝離之前述片材介隔前述粘著劑而積層於該液晶面板側之貼附機構;且藉由該2個以上之片材積層裝置,將2片以上之片材按每片片材依序積層於液晶面板側而形成液晶顯示元件,且,積層於前述液晶面板之一面之2片以上之片材中,以使接下來要積層之片材之4條邊各者小於其前已積層之片材之4條邊中在積層狀態下所對應之邊的方式,設定前述2片以上捲繞於連續輥之光學膜之片材之膜寬,及與該膜寬正交之方向之長度。藉此,由於可使用所謂的缺口嵌入連續輥,故可省略如上所述之切斷子步驟。Further, a manufacturing system of a liquid crystal display device according to another aspect of the invention includes a sheet stacking device comprising two or more optical films, the device comprising: an optical film having a specific film width containing a plurality of adhesives from adjacent layers. a continuous roll wound with a lining film of the sheet, a lining film conveying mechanism that transports the lining film, a conveying mechanism that transports the liquid crystal panel, and the sheet that has been peeled off from the lining film while conveying the liquid crystal panel An attachment mechanism that is laminated on the liquid crystal panel side with the above-mentioned adhesive; and two or more sheets are laminated on the liquid crystal panel side for each sheet by the two or more sheet laminating devices And forming a liquid crystal display element, and laminating the two or more sheets of one surface of the liquid crystal panel such that the four sides of the sheet to be laminated next are smaller than the four sides of the sheet which has been laminated before In the manner of the side corresponding to the laminated state, the film width of the sheet of the optical film wound on the continuous roll of two or more sheets and the length in the direction orthogonal to the film width are set. Thereby, since the continuous roll can be embedded using a so-called notch, the cutting sub-step described above can be omitted.
作為上述發明之一實施形態,前述片材中,將相當於捲繞於前述連續輥之光學膜之片材之膜寬之邊設為第1邊,將相當於與該膜寬正交之方向之長度之邊設為第2邊時,以對先前所積層之前一片片材之前述第1邊對應接下來要積層之下一片片材之前述第1邊,而對該前一片片材之前述第2邊對應該下一片片材之前述第2邊的方式,於該前一片片材上積層該下一片片材;且,積層於前述液晶面板之一面之2片以上之片材中,以使最初積層之片材之膜寬及與該膜寬正交之方向之長度最大,其後積層之片材之膜寬及與該膜寬正交之方向之長度依序縮小的方式,設定前述2片以上捲繞於連續輥之光學膜之片材之膜寬,及與該膜寬正交之方向之長度。According to an embodiment of the invention, in the sheet, a side corresponding to a film width of a sheet wound around the optical film of the continuous roll is referred to as a first side, and corresponds to a direction orthogonal to the film width. When the side of the length is set to the second side, the first side of one sheet before the previous layer is formed, and the first side of the sheet to be laminated next is laminated, and the front side of the sheet is formed. The second side is formed by laminating the next sheet on the front sheet, and the second sheet is laminated on the sheet of one or more of the liquid crystal panels. The film width of the first laminated sheet and the length in the direction orthogonal to the film width are maximized, and the film width of the subsequently laminated sheet and the length in the direction orthogonal to the film width are sequentially reduced. The film width of two or more sheets of the optical film wound on the continuous roll and the length in the direction orthogonal to the film width.
作為上述發明之一實施形態,進而包含水平旋轉部,其係使藉由前述貼附機構積層有片材之液晶面板,在藉由下一個貼附機構積層下一片片材之前,相對於該液晶面板之搬送方向水平旋轉90°;且前述片材中,將相當於捲繞於前述連續輥之光學膜之膜寬之邊設為第1邊,將相當於與該膜寬正交之方向之長度之邊設為前述第2邊時,以對在藉由前述水平旋轉部旋轉之前所積層之前一片片材之前述第1邊對應前述下一片片材之前述第2邊,而對該前一片片材之前述第2邊對應該下一片片材之前述第1邊的方式,於該前一片片材上積層該下一片片材;且以使前述下一片片材之前述第1邊小於前述前一片片材之前述第2邊的方式,設定捲繞於前述連續輥之光學膜之片材之膜寬;及以使前述下一片片材之前述第2邊小於前述前一片片材之前述第1邊的方式,設定與捲繞於前述連續輥之光學膜之片材之膜寬正交的方向之長度。According to an embodiment of the invention, the horizontal rotating portion further includes a liquid crystal panel in which a sheet is laminated by the attaching means, and the liquid crystal panel is laminated with respect to the liquid crystal before the next sheet is laminated by the next attaching means. The conveying direction of the panel is horizontally rotated by 90°; and in the sheet, the side corresponding to the film width of the optical film wound around the continuous roll is referred to as a first side, and corresponds to a direction orthogonal to the film width. When the side of the length is the second side, the first side of the one sheet before the layer is laminated before the horizontal rotating unit is rotated corresponds to the second side of the next sheet, and the front sheet is The second side of the sheet corresponds to the first side of the next sheet, and the next sheet is laminated on the front sheet; and the first side of the next sheet is smaller than the aforementioned The film width of the sheet wound around the optical film of the continuous roll is set to be the second side of the first sheet; and the second side of the next sheet is smaller than the front sheet The first side of the way, set and wrapped before Length of the film roll of the continuous optical film of the width direction of the sheet perpendicular.
又,作為上述任一製造方法之一實施形態,前述片材積層步驟進而包含檢查光學膜之膜檢查子步驟,且前述切斷子步驟較佳為根據膜檢查子步驟之檢查結果,切斷該光學膜。檢查是指檢查光學膜之缺陷。又,根據檢查結果切斷光學膜之情形,可以避開缺陷部份予以切斷的方式構成。較佳的是,將缺陷部份作為不良品,切斷成特定尺寸,並以例如排除裝置等進行排除,以便不會貼附於液晶面板。Further, in one embodiment of any one of the above manufacturing methods, the sheet stacking step further includes a film inspection substep of inspecting the optical film, and the cutting substep is preferably performed according to the inspection result of the film inspection substep. Optical film. Inspection refers to checking for defects in the optical film. Further, in the case where the optical film is cut according to the result of the inspection, it is possible to avoid the fact that the defective portion is cut. Preferably, the defective portion is cut into a specific size as a defective product, and is removed by, for example, a removing device so as not to be attached to the liquid crystal panel.
又,在上述之實施形態中,較佳的是在前述膜檢查子步驟中,在將前述襯膜從前述光學膜剝離之狀態下,進行前述光學膜之檢查,檢查後,介隔前述粘著劑,將襯膜貼附於前述光學膜。藉此,無需考慮襯膜內在之相位差,及襯膜上附著或內在之異物或瑕疵等之缺陷,即可進行光學膜之缺陷檢查。Further, in the above-described embodiment, preferably, in the film inspection sub-step, the optical film is inspected in a state where the liner film is peeled off from the optical film, and after the inspection, the adhesion is interposed. The film is attached to the aforementioned optical film. Thereby, the defect inspection of the optical film can be performed without considering the phase difference inherent in the liner film and the defects such as foreign matter or flaws adhering to the liner film or the like.
又,在上述之實施形態中,較佳的是前述切斷子步驟進一步包含排除子步驟,其係將膜檢查子步驟之檢查結果判斷為不良品之光學膜,切斷成特定尺寸,並將判斷為不良品之光學膜之片材排除。缺陷檢查中判斷為不良品之情形,係以避開光學膜之缺陷部份的方式,切斷成特定尺寸(有稱為跳躍切割之情形),而含有判斷為不良品之缺陷之片材藉由例如已知之排除裝置排除(除去)。藉此,可大幅提高光學膜之良率。Further, in the above-described embodiment, preferably, the cutting step further includes an exclusion sub-step of determining an optical film of the defective product by the inspection result of the film inspection sub-step, cutting into a specific size, and The sheet of the optical film judged to be defective was excluded. In the case of the defect inspection, the defective product is cut into a specific size (referred to as a jump cut) in a manner avoiding the defective portion of the optical film, and the sheet containing the defect determined to be defective is borrowed. It is excluded (removed) by, for example, a known exclusion device. Thereby, the yield of the optical film can be greatly improved.
光學膜只要為於最外層含有粘著劑層者即可,可為單層之光學膜,亦可為積層有光學膜之積層光學膜。又,亦可為於光學膜積層有其他膜構件之構成。又,作為光學膜,可舉出例如偏光子、偏光膜,偏光膜係在偏光子與其兩面或單面積層偏光子保護膜而成。又,亦有積層用於保護偏光子或偏光膜避免輸送上之缺陷之表面保護膜之情形。又,作為其他之光學膜,示例有相位差膜、亮度提高膜等之光學補償膜。作為經積層之光學膜,亦可於偏光子或偏光膜上積層相位差膜及/或亮度提高膜。The optical film may be an optical film of a single layer as long as it contains an adhesive layer on the outermost layer, or may be a laminated optical film in which an optical film is laminated. Further, it is also possible to have a structure in which another film member is laminated on the optical film. Further, examples of the optical film include a polarizer and a polarizing film, and the polarizing film is formed by a polarizer and a double-sided or single-layer polarizer protective film. Further, there is also a case where a surface protective film for protecting a polarizer or a polarizing film from transport defects is laminated. Further, as another optical film, an optical compensation film such as a retardation film or a brightness enhancement film is exemplified. As the laminated optical film, a retardation film and/or a brightness enhancement film may be laminated on the polarizer or the polarizing film.
偏光膜可舉出例如2色偏光膜。2色偏光膜係藉由包含(A)將實施過染色、交聯及拉伸處理之聚乙烯醇系膜進行乾燥,而獲得偏光子之步驟;(B)於該偏光子之單側或兩側貼合保護層之步驟;(C)貼合後進行加熱處理之步驟之製造方法而製造。聚乙烯醇系膜之染色、交聯、拉伸之各處理無需分別進行,可同時進行,且各處理之順序亦可任意。再者,作為聚乙烯醇系膜,亦可使用實施過膨潤處理之聚乙烯醇系膜。一般而言,係將聚乙烯醇系膜浸漬於含有碘或二色性色素之溶液,吸附碘或二色性色素進行染色後清洗,並在含有硼酸或硼砂等之溶液中,以拉伸倍率3倍~7倍單軸拉伸後進行乾燥。在含有碘或二色性色素之溶液中進行拉伸後,在含有硼酸或硼砂等之溶液中進一步拉伸(二段拉伸)後,而進行乾燥,藉此,由於使碘之配向增高,偏光度特性變佳,故而較佳。The polarizing film may, for example, be a two-color polarizing film. The two-color polarizing film is a step of obtaining a polarizer by (A) drying a polyvinyl alcohol-based film subjected to dyeing, crosslinking, and stretching treatment; (B) unilateral or two of the polarizer The step of bonding the protective layer on the side; (C) the manufacturing method of the step of performing heat treatment after bonding. The respective processes of dyeing, crosslinking, and stretching of the polyvinyl alcohol-based film need not be carried out separately, and may be carried out simultaneously, and the order of each treatment may be arbitrary. Further, as the polyvinyl alcohol-based film, a polyvinyl alcohol-based film which has been subjected to swelling treatment can also be used. In general, a polyvinyl alcohol-based film is immersed in a solution containing iodine or a dichroic dye, and is immersed in iodine or a dichroic dye to be dyed, washed, and stretched in a solution containing boric acid or borax. Drying is carried out after stretching 3 times to 7 times uniaxially. After stretching in a solution containing iodine or a dichroic dye, it is further stretched (two-stage stretching) in a solution containing boric acid or borax or the like, and then dried, whereby the alignment of iodine is increased. The polarizing property is improved, so that it is preferable.
亮度提高膜可舉出例如具有反射軸與透射軸之反射偏光膜。反射偏光膜係藉由例如將2種不同之材料之聚合物膜A、B相互複數片積層拉伸而獲得。在拉伸方向僅材料A之折射率增加變化,發現雙折射率,材料AB界面具有折射率差之拉伸方向為反射軸,而未產生折射率差之方向(非拉伸方向)為透射軸。The brightness enhancement film may, for example, be a reflective polarizing film having a reflection axis and a transmission axis. The reflective polarizing film is obtained by, for example, stretching a plurality of polymer films A and B of two different materials into a plurality of layers. In the direction of stretching, only the refractive index of the material A increases, and the birefringence is found. The stretching direction of the material AB interface having the refractive index difference is the reflection axis, and the direction in which the refractive index difference is not generated (non-stretching direction) is the transmission axis. .
又,光學膜所含之粘著劑並無特別限制,可舉出例如丙烯系粘著劑、矽系粘著劑、聚氨酯系粘著劑等。襯膜可使用例如塑膠膜(例如,聚對苯二甲酸乙酯系膜、聚烯烴系膜等)等之膜。又,因應所需可使用矽系或長鏈烷基系、氟系或硫化鉬等之以適當之剝離劑經塗層處理者等之適宜者。Moreover, the adhesive agent contained in the optical film is not particularly limited, and examples thereof include a propylene-based pressure-sensitive adhesive, an oxime-based pressure-sensitive adhesive, and a urethane-based pressure-sensitive adhesive. As the liner film, for example, a film of a plastic film (for example, a polyethylene terephthalate film, a polyolefin film, or the like) can be used. Further, if necessary, those which are subjected to coating treatment with a suitable release agent such as a lanthanide or a long-chain alkyl group, a fluorine-based or a molybdenum sulfide, or the like can be used.
(光學膜及連續輥)(optical film and continuous roll)
本實施形態,並不限制於在襯膜上形成有光學膜之形態。例如,亦可以捲繞成輥狀之連續輥構成。作為連續輥可舉出例如(1)將具有襯膜與含有形成於該襯膜上之粘著劑之光學膜的光學膜積層體捲繞成輥狀者。該情形,液晶顯示元件之製造系統為從光學膜形成光學膜之片材而具有切斷機構,其不切斷襯膜而將其留下,將該光學膜(含有粘著劑)以特定之切斷間隔切斷(半切斷)。在該切斷中,亦可例如以基於製造系統內之缺陷檢查裝置之檢查結果,將良品之片材,與不良品之片材進行區別的方式,進行切斷。This embodiment is not limited to the form in which an optical film is formed on the liner film. For example, it may be formed by winding a continuous roll in the form of a roll. The continuous roll may, for example, be one in which (1) an optical film laminate having a liner film and an optical film containing an adhesive formed on the liner film is wound into a roll. In this case, the manufacturing system of the liquid crystal display element has a cutting mechanism for forming a sheet of the optical film from the optical film, which is left without cutting the liner film, and the optical film (containing the adhesive) is specified. The cutting interval is cut (half cut). In the cutting, for example, the sheet of the good product may be cut off from the sheet of the defective product based on the inspection result of the defect inspection device in the manufacturing system.
又,作為連續輥,可舉出例如(2)將具襯膜與含有形成於該襯膜上之粘著劑之光學膜之片材的光學膜積層體捲繞成輥狀者(所謂的缺口嵌入光學膜之連續輥)。Moreover, as a continuous roll, for example, (2) the optical film laminated body which has a sheet|seat and the sheet|membrane containing the optical film of the adhesive agent formed on this lining film is wound into the roll shape (so-called gap. A continuous roll embedded in an optical film).
(液晶顯示元件)(liquid crystal display element)
液晶顯示元件為於液晶面板之單面或兩面至少形成有(2色)偏光膜之片材者,且因應所需裝入驅動電路。液晶面板可使用例如,垂直配向(VA)型、平面開關(IPS)型等之任意類型者。圖1所示之液晶面板4之構成為將液晶層密封於對向配置之一對基板(第1基板、第2基板)間。The liquid crystal display element is a sheet in which at least one (two colors) polarizing film is formed on one side or both sides of the liquid crystal panel, and a driving circuit is required to be mounted as needed. As the liquid crystal panel, for example, any of a vertical alignment (VA) type, a planar switch (IPS) type, or the like can be used. The liquid crystal panel 4 shown in FIG. 1 is configured such that the liquid crystal layer is sealed between the pair of substrates (the first substrate and the second substrate).
(實施形態1)(Embodiment 1)
(液晶顯示元件之製造方法)(Method of Manufacturing Liquid Crystal Display Element)
以下說明實施形態1。液晶顯示元件之製造方法包含2個以上光學膜之片材積層步驟,該步驟包含:從將積層有含有粘著劑之特定膜寬之光學膜之襯膜捲繞而成之連續輥,搬送該襯膜之襯膜搬送子步驟;留下該襯膜,在與光學膜之長度方向正交之膜寬方向以特定之切斷間隔將該光學膜切斷而形成光學膜之片材之切斷子步驟;搬送液晶面板之搬送子步驟;及一面搬送前述液晶面板,一面將已從前述襯膜剝離之前述片材介隔前述粘著劑而積層於該液晶面板側之貼附子步驟;且藉由該2個以上之片材積層步驟,將2片以上之片材按每片片材依序積層於液晶面板側而形成液晶顯示元件。且,積層於前述液晶面板之一面之2片以上片材中,以使最初積層之片材之膜寬最大,其後積層之片材之膜寬依序縮小的方式,設定前述2片以上捲繞於連續輥之光學膜之膜寬。以使在前述切斷子步驟中形成之前述最初積層之片材之切斷間隔最大,其後積層之片材之切斷間隔依序縮小的方式,實行前述切斷子步驟。在本實施形態中,於片材中,將相當於捲繞於連續輥之光學膜之膜寬之邊設為第1邊,將與該第1邊正交且相當於前述切斷間隔之長度之邊設為第2邊時,以對先前所積層之前一片片材之前述第1邊對應接下來要積層之下一片片材之前述第1邊,而對該前一片片材之前述第2邊對應該下一片片材之前述第2邊的方式,於該前一片片材上積層該下一片片材。Embodiment 1 will be described below. The method for producing a liquid crystal display device includes a sheet stacking step of two or more optical films, and the step includes: transferring a continuous roll obtained by winding a liner film of an optical film having a specific film width containing a pressure-sensitive adhesive layer thereon a lining film transporting sub-step of the lining film; leaving the lining film, cutting the optical film at a specific cutting interval in a film width direction orthogonal to the longitudinal direction of the optical film to form a sheet of the optical film a sub-step; a transfer sub-step of transporting the liquid crystal panel; and a step of attaching the sheet which has been peeled from the liner film to the liquid crystal panel side via the adhesive while transferring the liquid crystal panel; In the two or more sheet stacking steps, two or more sheets are sequentially laminated on the liquid crystal panel side for each sheet to form a liquid crystal display element. Further, two or more sheets laminated on one surface of the liquid crystal panel are set so that the film width of the first laminated sheet is maximized, and the film width of the laminated sheet is sequentially reduced. The film width of the optical film wound around the continuous roll. The cutting step is carried out so that the cutting interval of the sheet of the first layer formed in the cutting step is maximized, and the cutting interval of the sheet after the layer is sequentially reduced. In the present embodiment, the side corresponding to the film width of the optical film wound around the continuous roll is referred to as a first side, and is orthogonal to the first side and corresponds to the length of the cutting interval. When the side is set to the second side, the first side of one sheet before the previous layer is formed, and the first side of the sheet next to the next sheet is laminated, and the second sheet of the previous sheet is used. The next piece of the sheet is laminated on the front piece of the sheet in a manner corresponding to the second side of the next sheet.
以下,將光學膜之一作為2色偏光膜,而另一光學膜作為反射偏光膜進行說明。再者,積層於液晶面板之光學膜並不限制於此,亦可為其他光學膜,第3片(以後)之光學膜亦可以相同之片材積層步驟積層。Hereinafter, one of the optical films will be described as a two-color polarizing film, and the other optical film will be described as a reflective polarizing film. Further, the optical film laminated on the liquid crystal panel is not limited thereto, and may be another optical film, and the third (later) optical film may be laminated in the same sheet stacking step.
2色偏光膜之片材積層步驟係於液晶面板上積層2色偏光膜之片材,而反射偏光膜之片材積層步驟係於該2色偏光膜之片材上積層反射偏光膜之片材。該情形,2色偏光膜及反射偏光膜係作為於與該膜寬方向正交之長度方向上具有透射軸者進行說明。又,在本實施形態中,連續進行2色偏光膜之片材積層步驟及反射偏光膜之片材積層步驟。The sheet stacking step of the two-color polarizing film is performed by laminating a sheet of two color polarizing films on the liquid crystal panel, and the sheet laminating step of the reflective polarizing film is a sheet of the reflective polarizing film laminated on the sheet of the two-color polarizing film. . In this case, the two-color polarizing film and the reflective polarizing film are described as having a transmission axis in the longitudinal direction orthogonal to the film width direction. Further, in the present embodiment, the sheet stacking step of the two-color polarizing film and the sheet stacking step of the reflective polarizing film are continuously performed.
圖1係顯示液晶顯示元件之製造方法之一例之流程圖。就最初積層於液晶面板之2色偏光膜之片材積層步驟進行說明。準備2色偏光膜之連續輥(S1)。2色偏光膜之膜寬W1大於積層於該2色偏光膜上之反射偏光膜之膜寬W2(W1>W2)。將2色偏光膜及襯膜從連續輥送出,搬送至下游側(襯膜搬送子步驟、S2)。作為該搬送機構,係以例如進給輥、張力輥、調節輥、用於檢查進給量之感測器、控制該等之搬送速度或進給量等之控制部等構成。Fig. 1 is a flow chart showing an example of a method of manufacturing a liquid crystal display element. The step of laminating the sheets of the two color polarizing films laminated on the liquid crystal panel will be described. A continuous roll (S1) of a 2-color polarizing film was prepared. The film width W1 of the two-color polarizing film is larger than the film width W2 (W1>W2) of the reflective polarizing film laminated on the two-color polarizing film. The two-color polarizing film and the liner film are sent out from the continuous roll, and are conveyed to the downstream side (film transfer sub-step, S2). The conveying means is constituted by, for example, a feed roller, a tension roller, a regulating roller, a sensor for inspecting the feed amount, a control unit for controlling the conveyance speed or the feed amount, and the like.
留下襯膜,在與2色偏光膜之長度方向正交之膜寬方向以特定之切斷間隔L1,將該2色偏光膜切斷,形成2色偏光膜之片材(切斷子步驟、S3)。作為切斷機構,可舉出例如雷射裝置、切割器、其他之切斷機構等。The liner film is left, and the two-color polarizing film is cut at a specific slit width L1 orthogonal to the longitudinal direction of the two-color polarizing film to form a sheet of the two-color polarizing film (cutting step) , S3). Examples of the cutting mechanism include a laser device, a cutter, and other cutting mechanisms.
使襯膜作為內側,在剝離機構前端部折返,將2色偏光膜從該襯膜剝離,並供給至貼附位置。且,一面搬送液晶面板,一面將已從襯膜剝離之2色偏光膜之片材介隔粘著劑而積層於液晶面板側(貼附子步驟、S4)。作為貼附機構,可舉出例如貼附用對輥。再者,具有捲繞已剝離片材之襯膜之捲繞子步驟,與將液晶面板搬送至貼附位置之搬送子步驟。又,搬送子步驟係將貼附有2色偏光膜之液晶面板搬送至與下一個反射偏光膜貼附之位置。作為液晶面板之搬送機構,以例如貼附用對輥、搬送用輥、吸附板、用於控制該等之搬送速度或進給量等之控制部等構成。The lining film was set to the inside, and was folded back at the tip end portion of the peeling mechanism, and the two-color polarizing film was peeled off from the lining film and supplied to the attaching position. When the liquid crystal panel is conveyed, the sheet of the two-color polarizing film which has been peeled off from the lining film is laminated on the liquid crystal panel side via an adhesive (attachment substep, S4). As the attaching means, for example, a pair of rollers for attachment can be mentioned. Further, there is a winding sub-step of winding a liner film of the peeled sheet, and a transport sub-step of transporting the liquid crystal panel to the attaching position. Further, in the transport sub-step, the liquid crystal panel to which the two-color polarizing film is attached is transported to a position where it is attached to the next reflective polarizing film. The conveying means of the liquid crystal panel is configured, for example, by a pairing roller for the attachment, a conveying roller, an adsorption plate, a control unit for controlling the conveying speed or the feed amount, and the like.
其次,說明積層於2色偏光膜上之反射偏光膜之片材積層步驟。準備反射偏光膜之連續輥(S11)。使反射偏光膜之膜寬W2小於已積層之2色偏光膜之寬度W1(參照圖4A、圖4B,W2<W1)。將反射偏光膜及襯膜從連續輥送出,搬送至下游側(襯膜搬送子步驟、S12)。Next, a step of laminating a sheet of a reflective polarizing film laminated on a two-color polarizing film will be described. A continuous roll (S11) for reflecting the polarizing film is prepared. The film width W2 of the reflective polarizing film is made smaller than the width W1 of the laminated two color polarizing film (see FIGS. 4A and 4B, and W2 < W1). The reflective polarizing film and the liner film are sent out from the continuous roll and conveyed to the downstream side (liner transfer substep, S12).
留下襯膜,在與反射偏光膜之長度方向正交之膜寬方向,以特定之切斷間隔L2,將該反射偏光膜切斷,形成反射偏光膜之片材(切斷子步驟、S13)。此處,反射偏光膜之切斷間隔L2小於前述2色偏光膜之切斷間隔L1(參照圖4A、圖4B,L2<L1)。The liner film is left, and the reflective polarizing film is cut at a specific slit width L2 in the film width direction orthogonal to the longitudinal direction of the reflective polarizing film to form a sheet for reflecting the polarizing film (cutting step, S13) ). Here, the cutting interval L2 of the reflective polarizing film is smaller than the cutting interval L1 of the two-color polarizing film (see FIGS. 4A and 4B and L2 < L1).
使襯膜為內側,在剝離機構前端部折返,將反射偏光膜從該襯膜剝離,供給至貼附位置。且,一面搬送液晶面板,一面將已從襯膜剝離之反射偏光膜之片材,介隔粘著劑貼附於2色偏光膜(貼附子步驟、S14)。貼附機構與前述貼附機構相同。搬送子步驟係將貼附有反射偏光膜之液晶面板,搬送至下一個步驟。The lining film was placed inside, and was folded back at the tip end portion of the peeling mechanism, and the reflective polarizing film was peeled off from the lining film and supplied to the attaching position. Further, while the liquid crystal panel is being conveyed, the sheet of the reflective polarizing film which has been peeled off from the liner film is adhered to the two-color polarizing film via the adhesive (the attaching step, S14). The attachment mechanism is the same as the attachment mechanism described above. In the transfer sub-step, the liquid crystal panel to which the reflective polarizing film is attached is transported to the next step.
作為上述實施形態之其他實施形態,在膜寬方向具有透射軸之2色偏光膜上,積層於與膜寬方向正交之長度方向具有透射軸之反射偏光膜的情形下,將液晶面板之搬送路線構成為L字狀,於液晶面板積層2色偏光膜之片材後,沿著L字狀之搬送路線搬送該液晶面板,將反射偏光膜之片材以使該等之透射軸方向為相同之方向的方式,積層於該2色偏光膜之片材上。In another embodiment of the above-described embodiment, when a reflective polarizing film having a transmission axis in a longitudinal direction orthogonal to the film width direction is laminated on a two-color polarizing film having a transmission axis in the film width direction, the liquid crystal panel is transported. The route is formed in an L shape, and after the liquid crystal panel laminates the sheets of the two color polarizing films, the liquid crystal panel is transported along the L-shaped transport path, and the sheet of the polarizing film is reflected so that the transmission axis directions are the same. The direction of the layer is laminated on the sheet of the two-color polarizing film.
又,作為上述實施形態之其他實施形態,片材積層步驟進一步包含檢查光學膜之膜檢查子步驟,切斷子步驟係根據膜檢查子步驟之檢查結果,切斷該光學膜。再者,切斷子步驟進一步包含排除子步驟,其係以膜檢查子步驟之檢查結果,將判斷為不良品之光學膜切斷成特定尺寸(以避開缺陷的方式予以切斷(所謂的跳躍切割)),排除判斷為不良品之光學膜之片材。又,膜檢查子步驟亦可讀取預先附著於光學膜或襯膜之缺陷資訊,基於該缺陷資訊,以避開缺陷的方式予以切斷。作為缺陷檢查方法,有例如對光學膜拍攝透射光或反射光產生之圖像,將該圖像進行圖像處理,解析缺陷,判斷是良品還是不良品之方法。再者,圖像處理之運算法可適用已知之方法,可藉由例如利用二值化處理之濃淡判斷檢測缺陷。將缺陷檢查中獲得之缺陷之資訊與其位置資訊(例如,位置座標)一起連接,發送至控制裝置(未圖示),有助於切斷子步驟之切斷處理。Further, in another embodiment of the above embodiment, the sheet stacking step further includes a film inspection substep of inspecting the optical film, and the cutting substep is performed by cutting the optical film according to the inspection result of the film inspection substep. Furthermore, the cutting sub-step further includes an exclusion sub-step of cutting the optical film judged to be defective into a specific size by using the inspection result of the film inspection sub-step (cutting in a manner avoiding the defect (so-called Jump cutting)), excluding the sheet of the optical film judged to be defective. Further, the film inspection sub-step can also read the defect information previously attached to the optical film or the liner film, and cut off the defect in a manner avoiding the defect based on the defect information. As a defect inspection method, for example, an image in which transmitted light or reflected light is imaged on an optical film, and the image is subjected to image processing, and the defect is analyzed to determine whether it is a good product or a defective product. Furthermore, the image processing algorithm can be applied to a known method, and the defect can be detected by, for example, using the shading of the binarization process. The information on the defect obtained in the defect inspection is connected to the position information (for example, the position coordinate) and transmitted to the control device (not shown), which helps to cut off the sub-step cutting process.
又,進而作為其他實施形態,較佳為在膜檢查子步驟中,在將襯膜從光學膜剝離之狀態下,進行光學膜之檢查,檢查後,將襯膜介隔粘著劑貼合於光學膜。Further, as another embodiment, in the film inspection sub-step, it is preferable to perform inspection of the optical film in a state where the liner film is peeled off from the optical film, and after the inspection, the liner film is interposed with the adhesive. Optical film.
又,在上述實施形態中,雖已說明於液晶面板之一面依序積層2色偏光膜與反射偏光膜之方法,但本實施形態並不限制於該構成。亦可於液晶面板之另一面,同樣地積層2色偏光膜。該情形,係以使積層於液晶面板之一面之2色偏光膜之透射軸,與積層於另一面之2色偏光膜之透射軸為正交偏光鏡的方式進行積層。Further, in the above-described embodiment, a method of sequentially laminating a two-color polarizing film and a reflective polarizing film on one surface of a liquid crystal panel has been described, but the present embodiment is not limited to this configuration. A two-color polarizing film may be laminated on the other side of the liquid crystal panel. In this case, the transmission axis of the two-color polarizing film laminated on one surface of the liquid crystal panel is laminated so that the transmission axis of the two-color polarizing film laminated on the other surface is a crossed polarizer.
(液晶顯示元件之製造系統)(Manufacturing system of liquid crystal display element)
以下一面參照圖3一面說明實施形態1之液晶顯示元件之製造系統。液晶顯示元件之製造系統具備2個以上光學膜之片材積層裝置,該裝置具備:從捲繞積層有含有粘著劑之特定之膜寬之光學膜的襯膜而成之連續輥,搬送該襯膜之襯膜搬送機構;留下該襯膜,在與光學膜之長度方向正交之膜寬方向,以特定之切斷間隔將該光學膜切斷而形成光學膜之片材之切斷機構;搬送液晶面板之搬送機構;及一面搬送前述液晶面板,一面將已從前述襯膜剝離之前述片材介隔前述粘著劑,積層於該液晶面板側之貼附機構。藉由該2個以上之片材積層裝置,將2片以上之片材,每片片材依序積層於液晶面板側,形成液晶顯示元件。且製造系統具有以使最初積層之片材之前述切斷間隔最大,其後積層之片材之切斷間隔依序縮小的方式,控制前述切斷機構及襯膜搬送機構之控制部;前述片材積層裝置之切斷機構係以使前述最初積層之片材之前述切斷間隔最大,其後積層之片材之切斷間隔依序縮小的方式,切斷光學膜。即,依序積層於液晶面板之片材(第1片、第2片、第n片、第n+1片、‥)之切斷間隔L之大小關係為Ln>Ln+1。Hereinafter, a manufacturing system of a liquid crystal display element of the first embodiment will be described with reference to Fig. 3 . A manufacturing system of a liquid crystal display device includes a sheet stacking device of two or more optical films, and the apparatus includes a continuous roll formed by winding a film of a film having a specific film width including a pressure-sensitive adhesive, and transporting the film a lining film conveying mechanism for the lining film; the lining film is cut, and the optical film is cut at a specific cutting interval in a film width direction orthogonal to the longitudinal direction of the optical film to form a sheet of the optical film. The mechanism for transporting the liquid crystal panel; and the attachment mechanism that laminates the sheet that has been peeled off from the liner film to the liquid crystal panel side while interposing the sheet that has been peeled off from the liner film. By the two or more sheet stacking apparatuses, two or more sheets, each of which is sequentially laminated on the liquid crystal panel side to form a liquid crystal display element. Further, the manufacturing system has a method of controlling the cutting mechanism and the control unit of the liner conveying mechanism so that the cutting interval of the sheet to be laminated first is maximized, and then the cutting interval of the laminated sheets is sequentially reduced; The cutting mechanism of the material layering apparatus cuts the optical film so that the cutting interval of the first laminated sheet is maximized, and the cutting interval of the laminated sheet is sequentially reduced. In other words, the relationship between the cutting intervals L of the sheets (the first sheet, the second sheet, the nth sheet, the n+1th sheet, and the . . ) laminated in the liquid crystal panel in this order is L n > L n+1 .
以下,積層於液晶面板之一面之2片片材為2色偏光膜及反射偏光膜,但並不限制於此,亦可為其他之光學膜,亦可以相同之片材積層裝置積層第3片(以後)之光學膜。Hereinafter, the two sheets laminated on one surface of the liquid crystal panel are a two-color polarizing film and a reflective polarizing film. However, the present invention is not limited thereto, and may be another optical film, or the same sheet stacking device may be used to laminate the third sheet. (after) optical film.
2個片材積層裝置為用於積層2色偏光膜之片材之片材積層裝置301,與用於在2色偏光膜之片材上積層反射偏光膜之片材之片材積層裝置302。在本實施形態中,2色偏光膜之片材積層裝置301及反射偏光膜之片材積層裝置302係配置於連續生產線。2色偏光膜之膜寬W1大於反射偏光膜之膜寬W2(參照圖4A~4B)。在本實施形態中,2色偏光膜其長度方向具有透射軸,膜寬方向具有吸收軸。又,反射偏光膜其長度方向具有透射軸,膜寬方向具有反射軸。且,為2色偏光膜之膜寬W1>反射偏光膜之膜寬W2之關係。The two sheet stacking devices are a sheet stacking device 301 for laminating a sheet of two color polarizing films, and a sheet stacking device 302 for laminating a sheet of a polarizing film on a sheet of a two-color polarizing film. In the present embodiment, the sheet stacking device 301 of the two-color polarizing film and the sheet stacking device 302 of the reflective polarizing film are disposed in a continuous production line. The film width W1 of the two-color polarizing film is larger than the film width W2 of the reflective polarizing film (see FIGS. 4A to 4B). In the present embodiment, the two-color polarizing film has a transmission axis in the longitudinal direction and an absorption axis in the film width direction. Further, the reflective polarizing film has a transmission axis in the longitudinal direction and a reflection axis in the film width direction. Further, the film width W1 of the two-color polarizing film is related to the film width W2 of the reflective polarizing film.
圖3所示之2色偏光膜之片材積層裝置301具有襯膜搬送機構101、液晶面板搬送機構102、及貼附機構103(貼附輥50a、驅動輥50b)。又,反射偏光膜之片材積層裝置302具有液晶面板搬送機構202、襯膜搬送機構201、貼附機構203(貼附輥、驅動輥)。在本實施形態中,從液晶面板4之上側貼附2色偏光膜之片材131,其次,從液晶面板4之上側貼附反射偏光膜之片材231。再者,並不限制於該貼附方法,可例如從液晶面板之下側,貼附2色偏光膜之片材,從液晶面板之下側貼附反射偏光膜之片材,亦可從液晶面板之上側貼附一光學膜,而從液晶面板之下側貼附另一光學膜。The sheet stacking apparatus 301 of the two-color polarizing film shown in FIG. 3 has a liner conveyance mechanism 101, a liquid crystal panel conveyance mechanism 102, and an attachment mechanism 103 (adhesion roller 50a and drive roller 50b). Further, the sheet stacking device 302 that reflects the polarizing film includes a liquid crystal panel transport mechanism 202, a liner transport mechanism 201, and an attaching mechanism 203 (adhesive roller, drive roller). In the present embodiment, the sheet 131 of the two-color polarizing film is attached from the upper side of the liquid crystal panel 4, and the sheet 231 on which the polarizing film is reflected is attached from the upper side of the liquid crystal panel 4. Furthermore, it is not limited to the attachment method, and for example, a sheet of a two-color polarizing film may be attached from the lower side of the liquid crystal panel, and a sheet of the reflective polarizing film may be attached from the lower side of the liquid crystal panel, or may be a liquid crystal. An optical film is attached to the upper side of the panel, and another optical film is attached from the lower side of the liquid crystal panel.
(液晶面板搬送機構)(liquid crystal panel transport mechanism)
液晶面板搬送機構102係將液晶面板4搬送供給至貼附機構103。在本實施形態中,液晶面板搬送機構102之構成為具有搬送輥80及吸附板等。藉由旋轉搬送輥80,或轉移吸附板,將液晶面板4搬送至生產線下游側。The liquid crystal panel transport mechanism 102 transports and supplies the liquid crystal panel 4 to the attaching mechanism 103. In the present embodiment, the liquid crystal panel transport mechanism 102 is configured to include a transport roller 80, an adsorption plate, and the like. The liquid crystal panel 4 is transported to the downstream side of the production line by rotating the transfer roller 80 or transferring the adsorption plate.
(襯膜搬送機構)(liner transport mechanism)
襯膜搬送機構101係從連續輥1送出積層有含有粘著劑之2色偏光膜13之襯膜12,並留下襯膜12,將2色偏光膜13以特定之切斷間隔L1切斷,於襯膜12上形成2色偏光膜之片材131,並使襯膜12為內側,在剝離機構40之前端折返,將2色偏光膜之片材131(含粘著劑)從襯膜12剝離,供給至貼附機構103。因此,襯膜搬送機構101具有切斷機構20、調節輥30、剝離機構40、及捲繞機構60。The lining film transport mechanism 101 sends a lining film 12 in which a two-color polarizing film 13 containing an adhesive is laminated from the continuous roll 1, and leaves the lining film 12, and cuts the two color polarizing film 13 at a specific cutting interval L1. A sheet 131 of a two-color polarizing film is formed on the backing film 12, and the backing film 12 is inside, and is folded back at the front end of the peeling mechanism 40, and the sheet 131 (containing an adhesive) of the two color polarizing film is removed from the backing film. 12 is peeled off and supplied to the attaching mechanism 103. Therefore, the liner conveying mechanism 101 has the cutting mechanism 20, the regulating roller 30, the peeling mechanism 40, and the winding mechanism 60.
切斷機構20係以吸附機構20a固定襯膜12,留下襯膜,將2色偏光膜13以特定間隔L1予以切斷,於襯膜12上形成2色偏光膜之片材131。作為切斷機構20,可舉出例如切割器、雷射裝置等。The cutting mechanism 20 fixes the liner film 12 by the suction mechanism 20a, leaves a liner film, cuts the two-color polarizing film 13 at a predetermined interval L1, and forms a sheet 131 of a two-color polarizing film on the liner film 12. Examples of the cutting mechanism 20 include a cutter, a laser device, and the like.
調節輥30具有保持襯膜12之張力之功能。襯膜搬送機構101係經由調節輥30搬送襯膜12。The dancer roller 30 has a function of maintaining the tension of the liner film 12. The liner conveying mechanism 101 conveys the liner 12 via the regulating roller 30.
剝離機構40在於液晶面板4貼附片材131之情形時,使襯膜12在其前端部向內側折返,將片材131從襯膜12剝離。在本實施形態中,作為剝離機構40,是於前端部使用尖銳刀口部,但並不限定於此。In the case where the liquid crystal panel 4 is attached to the sheet 131, the peeling mechanism 40 folds the backing film 12 inward at the front end portion thereof, and peels the sheet 131 from the backing film 12. In the present embodiment, the peeling mechanism 40 uses a sharp knife edge portion at the distal end portion, but the present invention is not limited thereto.
捲繞機構60係捲繞已剝離片材131之襯膜12。再者,亦可於貼附機構103與捲繞機構60之間,進一步具備進給輥。The winding mechanism 60 winds the liner film 12 of the peeled sheet 131. Further, a feed roller may be further provided between the attaching mechanism 103 and the winding mechanism 60.
(貼附機構)(attachment mechanism)
貼附機構103係介隔粘著劑,從由液晶面板搬送機構102供給之液晶面板4之上側,貼附由襯膜搬送機構101供給之2色偏光膜之片材131。在本實施形態中,貼附機構103係由貼附輥50a、驅動輥50b構成。The attaching mechanism 103 is provided with a pressure-sensitive adhesive, and a sheet 131 of a two-color polarizing film supplied from the film transport mechanism 101 is attached from the upper side of the liquid crystal panel 4 supplied from the liquid crystal panel transport mechanism 102. In the present embodiment, the attaching mechanism 103 is constituted by the attaching roller 50a and the driving roller 50b.
(控制部)(Control Department)
控制部300係控制切斷機構20及襯膜搬送機構101,控制2色偏光膜之片材131之切斷間隔L1。切斷間隔L1為與2色偏光膜之片材131之膜寬方向正交之方向的長度(參照圖4A~4C)。控制部300係以使2色偏光膜之切斷間隔L1最大,接下來積層之反射偏光膜之切斷間隔L2小於L1的方式,控制切斷機構20及襯膜搬送機構101。例如,控制部300係以將切斷間隔L1、L2預先儲存於控制部300之記憶體,並以該特定間隔L1、L2進行切斷的方式,控制襯膜之進給量及切斷處理。進給量可藉由例如測定構成襯膜搬送機構101、201之一部份之進給輥等之旋轉量的編碼器之檢測進行測定。The control unit 300 controls the cutting mechanism 20 and the liner transport mechanism 101 to control the cutting interval L1 of the sheet 131 of the two-color polarizing film. The cutting interval L1 is a length in a direction orthogonal to the film width direction of the sheet 131 of the two-color polarizing film (see FIGS. 4A to 4C). The control unit 300 controls the cutting mechanism 20 and the liner transport mechanism 101 so that the cutting interval L1 of the two-color polarizing film is maximized, and the cutting interval L2 of the reflective polarizing film is less than L1. For example, the control unit 300 controls the feed amount and the cutting process of the liner film so that the cutting intervals L1 and L2 are stored in advance in the memory of the control unit 300 and the cutting is performed at the specific intervals L1 and L2. The feed amount can be measured by, for example, detecting an encoder that measures the amount of rotation of a feed roller or the like that forms part of the film transport mechanisms 101, 201.
其次,說明反射偏光膜之片材積層裝置302。反射偏光膜之片材積層裝置302係在積層於液晶面板4之2色偏光膜之片材131上,貼附反射偏光膜之片材231之裝置,由於為與2色偏光膜之片材積層裝置相同之構成,故簡單地進行說明。Next, a sheet laminating apparatus 302 that reflects a polarizing film will be described. The sheet stacking device 302 of the reflective polarizing film is attached to the sheet 131 of the two color polarizing film laminated on the liquid crystal panel 4, and is attached to the sheet 231 which reflects the polarizing film, and is laminated with the sheet of the two color polarizing film. Since the configuration of the device is the same, it will be briefly described.
液晶面板搬送機構202係搬送由貼附機構103貼附有片材131之液晶面板4,供給至貼附機構203。The liquid crystal panel transport mechanism 202 transports the liquid crystal panel 4 to which the sheet 131 is attached by the attaching mechanism 103, and supplies it to the attaching mechanism 203.
襯膜搬送機構201可以與襯膜搬送機構101相同之裝置構成,貼附機構203可以與貼附機構103相同之裝置構成。例如,調節輥可以與調節輥30相同之裝置構成,捲繞機構可以與捲繞機構60相同之裝置構成,貼附輥及驅動輥可以與貼附輥50a及驅動輥50b相同之機構構成。The lining film transport mechanism 201 can be configured similarly to the lining membrane transport mechanism 101, and the affixing mechanism 203 can be configured similarly to the attaching mechanism 103. For example, the adjustment roller may be configured in the same manner as the adjustment roller 30, and the winding mechanism may be configured in the same manner as the winding mechanism 60. The attachment roller and the driving roller may be configured in the same manner as the attachment roller 50a and the driving roller 50b.
切斷機構20係以吸附機構20a固定襯膜22,留下襯膜22,將反射偏光膜23以特定間隔L2(L1>L2)切斷,並於襯膜22上形成反射偏光膜之片材231。The cutting mechanism 20 fixes the liner 22 with the adsorption mechanism 20a, leaves the liner 22, cuts the reflective polarizing film 23 at a specific interval L2 (L1>L2), and forms a sheet of the reflective polarizing film on the liner film 22. 231.
貼附機構203係介隔粘著劑,從由液晶面板搬送機構202供給之液晶面板4之上側,於2色偏光膜之片材131,貼附由襯膜搬送機構201供給之反射偏光膜之片材231。貼附機構203較佳為以使2色偏光膜之片材131之寬度方向中心軸線,與和該寬度方向正交之方向之中心軸線之交叉線(圖4A之虛線P1),與反射偏光膜之片材231之寬度方向中心軸線,與和該寬度方向正交之方向之中心軸線之交叉線(圖4B之虛線P2)一致或大致一致的方式,於2色偏光膜之片材131積層反射偏光膜之片材231。其原因為較佳為考慮貼附偏差量(X方向偏差、Y方向偏差、θ偏差),積層片材彼此。The attaching mechanism 203 is provided with an adhesive, and the reflective polarizing film supplied from the liner transport mechanism 201 is attached to the upper surface of the liquid crystal panel 4 supplied from the liquid crystal panel transport mechanism 202 to the sheet 131 of the two-color polarizing film. Sheet 231. The attaching mechanism 203 is preferably such that the central axis of the width direction of the sheet 131 of the two-color polarizing film intersects with the central axis of the direction orthogonal to the width direction (the broken line P1 of FIG. 4A), and the reflective polarizing film. The central axis of the width direction of the sheet 231 is aligned or substantially coincident with the line of intersection with the central axis of the direction orthogonal to the width direction (the broken line P2 of FIG. 4B), and is laminated on the sheet 131 of the two-color polarizing film. A sheet 231 of a polarizing film. The reason for this is that it is preferable to consider the amount of deviation (X-direction deviation, Y-direction deviation, θ deviation), and laminate sheets.
控制部300係控制切斷機構20及襯膜搬送機構201,控制反射偏光膜之片材231之切斷間隔L2。切斷間隔L2為與反射偏光膜之片材231之膜寬方向正交之方向的長度(參照圖4A~4C)。控制部300係以使反射偏光膜之L2小於2色偏光膜之L1的方式,控制切斷機構20及襯膜搬送機構201。The control unit 300 controls the cutting mechanism 20 and the liner transport mechanism 201 to control the cutting interval L2 of the sheet 231 that reflects the polarizing film. The cutting interval L2 is a length in a direction orthogonal to the film width direction of the sheet 231 of the reflective polarizing film (see FIGS. 4A to 4C). The control unit 300 controls the cutting mechanism 20 and the liner transport mechanism 201 such that L2 of the reflective polarizing film is smaller than L1 of the two-color polarizing film.
液晶面板搬送機構204係將積層有2色偏光膜之片材131及反射偏光膜之片材231之液晶面板,搬送至下游側。In the liquid crystal panel transport mechanism 204, the liquid crystal panel in which the sheet 131 of the two color polarizing film and the sheet 231 which reflects the polarizing film are laminated is conveyed to the downstream side.
又,在搬送下游側,亦可於未積層有片材之液晶面板之另一面,使用其他之片材積層裝置,貼附2色偏光膜之片材等之光學膜。In addition, on the other side of the liquid crystal panel on which the sheet is not laminated, an optical film such as a sheet of a two-color polarizing film may be attached to another surface of the liquid crystal panel on which the sheet is not laminated.
又,在搬送下游側,亦可設置用於檢查於兩面積層有2色偏光膜等之液晶顯示元件之檢查裝置。該檢查裝置之檢查目的、檢查方法並無特別限制。Further, an inspection device for inspecting a liquid crystal display element having a two-color polarizing film or the like in two area layers may be provided on the downstream side of the conveyance. The inspection purpose and inspection method of the inspection apparatus are not particularly limited.
(實施形態2)(Embodiment 2)
實施形態2之製造方法係藉由2個2色偏光膜之片材積層步驟,於液晶面板之兩面積層2色偏光膜之片材後,實行將該液晶面板進行光學檢查之檢查步驟。且,藉由檢查步驟檢查後,實行反射偏光膜之片材積層步驟,並於積層於液晶面板之一面之2色偏光膜之片材上,積層具有與該2色偏光膜之片材之透射軸之方向相同方向之透射軸的反射偏光膜之片材。在本實施形態中,係連續進行前述2個2色偏光膜之片材積層步驟、前述檢查步驟及前述反射偏光膜之片材積層步驟,但並不特別限制於此,作為其他實施形態,可連續進行2個2色偏光膜之片材積層步驟;可連續進行2個2色偏光膜之片材積層步驟及檢查步驟;亦可連續進行檢查步驟及反射偏光膜之片材積層步驟。In the manufacturing method of the second embodiment, the sheet-layering process of the two color-shifting films is performed on the sheet of the two-layer color-polarizing film of the liquid crystal panel, and then the inspection step of optically inspecting the liquid crystal panel is performed. After the inspection step is inspected, the sheet stacking step of the reflective polarizing film is carried out, and the sheet having the two color polarizing film laminated on one surface of the liquid crystal panel is laminated to have a transmission layer of the sheet having the two color polarizing film. A sheet of a reflective polarizing film having a transmission axis in the same direction as the direction of the axis. In the present embodiment, the sheet stacking step of the two two-color polarizing films, the inspection step, and the sheet stacking step of the reflective polarizing film are continuously performed, but the present invention is not particularly limited thereto. The sheet laminating step of two two-color polarizing films is continuously performed; the sheet laminating step and the inspecting step of two two-color polarizing films may be continuously performed; and the inspecting step and the sheet laminating step of the reflective polarizing film may be continuously performed.
於圖2顯示實施形態2之製造流程圖。首先,於液晶面板之一面貼附2色偏光膜之片材(2色偏光膜之片材積層步驟、S21)。其次,於液晶面板之另一面貼附2色偏光膜之片材(2色偏光膜之片材積層步驟、S22)。2色偏光膜之片材積層步驟與上述實施形態1之步驟S1至步驟S4之各步驟相同。再者,以使積層於液晶面板之一面之2色偏光膜之透射軸,與積層於其另一面之2色偏光膜之透射軸為正交偏光鏡的方式進行積層。A manufacturing flow chart of the second embodiment is shown in Fig. 2 . First, a sheet of two color polarizing films (a sheet laminating step of two color polarizing films, S21) is attached to one surface of a liquid crystal panel. Next, a sheet of two color polarizing films (a sheet laminating step of two color polarizing films, S22) is attached to the other surface of the liquid crystal panel. The sheet stacking step of the two-color polarizing film is the same as the steps of the steps S1 to S4 of the above-described first embodiment. Further, the transmission axis of the two-color polarizing film laminated on one surface of the liquid crystal panel is laminated so that the transmission axis of the two-color polarizing film laminated on the other surface thereof is a crossed polarizing mirror.
其次,對於在兩面貼附有2色偏光膜之片材之液晶面板,對作為其背面側(背光側)之2色偏光膜面照射光,拍攝其反射光學影像。又,對作為背光側(背面側)之2色偏光膜面照射光,拍攝其透射光學影像。將拍攝而獲得之圖像資料進行圖像處理,判斷是否有介存於2色偏光膜之內部或2色偏光膜與液晶面板之間之異物或氣泡等缺陷(檢查步驟、S23)。在判斷為良品(正常品)之情形,將液晶顯示面板搬送至與反射偏光膜之貼附位置。且,於作為液晶顯示面板之背面側之2色偏光膜,貼附反射偏光膜之片材(反射偏光膜之片材積層步驟、S25)。反射偏光膜之片材積層步驟與上述實施形態1之步驟S11至步驟S14之各步驟相同。再者,以使2色偏光膜之透射軸,與積層於該2色偏光膜之反射偏光膜之透射軸成為相同方向的方式進行積層。另一方面,在判斷為不良品之情形,將液晶面板搬送至不良品端口進行排除(排除步驟、S26)。Next, the liquid crystal panel in which the two-color polarizing film was attached to both surfaces was irradiated with light on the surface of the two-color polarizing film as the back side (backlight side), and the reflected optical image was taken. Further, light was irradiated onto the surface of the two-color polarizing film as the backlight side (back side), and the transmitted optical image was taken. The image data obtained by the photographing is subjected to image processing to determine whether or not there is a defect such as a foreign matter or a bubble interposed between the two-color polarizing film or between the two-color polarizing film and the liquid crystal panel (inspection step, S23). When it is judged that it is a good product (normal product), the liquid crystal display panel is conveyed to the attachment position with the reflective polarizing film. Further, a sheet of a reflective polarizing film (a step of laminating a sheet of a reflective polarizing film, S25) is attached to the two-color polarizing film on the back side of the liquid crystal display panel. The sheet stacking step of the reflective polarizing film is the same as the steps of the steps S11 to S14 of the first embodiment. In addition, the transmission axis of the two-color polarizing film is laminated so that the transmission axes of the reflective polarizing films laminated on the two color polarizing films are in the same direction. On the other hand, when it is determined that the product is defective, the liquid crystal panel is transported to the defective port to be excluded (excluding step, S26).
(製造系統)(manufacturing system)
以下一面參照圖5,一面說明實施形態2之製造系統。在本實施形態中,係將2個2色偏光膜之片材積層裝置、檢查裝置及反射偏光膜之片材積層裝置配置於連續生產線,但並不特別限制於此,可將2色偏光膜之片材積層裝置配置於連續生產線,亦可將2個2色偏光膜之片材積層裝置及檢查裝置配置於連續生產線,又可將檢查裝置及反射偏光膜之片材積層裝置配置於連續生產線。The manufacturing system of the second embodiment will be described below with reference to Fig. 5 . In the present embodiment, the sheet layering apparatus, the inspection apparatus, and the sheet-layering apparatus of the reflective polarizing film of the two two-color polarizing films are disposed in a continuous production line. However, the present invention is not particularly limited thereto, and a two-color polarizing film can be used. The sheet stacking device is disposed in a continuous production line, and the sheet stacking device and the inspection device of the two 2-color polarizing films can be disposed on the continuous production line, and the sheet stacking device of the inspection device and the reflective polarizing film can be disposed in the continuous production line. .
圖5所示之片材積層裝置501、502為與實施形態1之2色偏光膜之片材積層裝置相同之構成。片材積層裝置501係於液晶面板之目視側積層2色偏光膜之片材131,片材積層裝置502係於液晶面板之背面側(背光側)積層2色偏光膜之片材131。片材積層裝置501、502若積層於液晶面板之兩面之2色偏光膜之片材彼此之透射軸為正交偏光鏡,則與實施形態1相同,可從液晶面板之上側積層片材,亦可從液晶面板之下側積層片材。因應所需,亦可具有90°水平旋轉機構、上下反轉機構等。The sheet stacking apparatuses 501 and 502 shown in Fig. 5 have the same configuration as the sheet stacking apparatus of the two color polarizing films of the first embodiment. The sheet layering apparatus 501 is a sheet 131 of a color polarizing film which is laminated on the visual side of the liquid crystal panel, and the sheet layering apparatus 502 is a sheet 131 of a color polarizing film laminated on the back side (backlight side) of the liquid crystal panel. In the sheet stacking apparatuses 501 and 502, if the transmission axes of the sheets of the two color polarizing films laminated on both surfaces of the liquid crystal panel are orthogonal polarizers, the sheet can be laminated from the upper side of the liquid crystal panel as in the first embodiment. The sheet can be laminated from the lower side of the liquid crystal panel. According to the needs, it can also have a 90° horizontal rotation mechanism, an up-and-down reversing mechanism, and the like.
於兩面積層有2色偏光膜之片材之液晶面板,係以液晶面板搬送機構202搬送至檢查裝置400。檢查裝置400係將液晶面板進行光學檢查。檢查裝置400對作為搬送來之液晶面板之背面側之面(在圖5中從上至下方向),垂直地照射光。來自照射部401之光由半反射鏡(未圖示)反射,而照射液晶面板。該照射產生之反射光學影像由攝像機構402攝像。又,透射光學影像由攝像機構403攝像。拍攝而獲得之圖像資料係在檢查裝置400之資訊處理部進行圖像處理,解析缺陷,並由其判斷部判斷是良品還是不良品。The liquid crystal panel having a sheet of two color polarizing films on two areas is transported to the inspection apparatus 400 by the liquid crystal panel transport mechanism 202. The inspection device 400 performs optical inspection of the liquid crystal panel. The inspection device 400 vertically irradiates light to the surface on the back side of the liquid crystal panel that is transported (from the top to the bottom in FIG. 5). The light from the illuminating unit 401 is reflected by a half mirror (not shown) to illuminate the liquid crystal panel. The reflected optical image generated by the illumination is imaged by the imaging unit 402. Further, the transmission optical image is captured by the imaging unit 403. The image data obtained by the imaging is subjected to image processing by the information processing unit of the inspection apparatus 400, and the defect is analyzed, and the determination unit determines whether it is a good product or a defective product.
其次,與實施形態1相同之構成之反射偏光膜之片材積層裝置503在藉由檢查裝置400檢查後,在積層於作為液晶面板之背面側之面的2色偏光膜之片材131上,以使該2色偏光膜之片材131之透射軸之方向,與反射偏光膜之片材232之透射軸之方向相同的方式,貼附反射偏光膜之片材231。對以檢查結果判斷為良品之液晶面板,片材積層裝置503,會於2色偏光膜之片材131上貼附反射偏光膜之片材231。而將檢查結果判斷為不良品之液晶面板搬送至不良品端口進行排除。再者,不良品之液晶面板亦可藉由液晶面板搬送機構202、貼附機構203、搬送機構204,搬送至不良品端口。Then, the sheet laminated device 503 of the reflective polarizing film having the same configuration as that of the first embodiment is laminated on the sheet 131 of the two-color polarizing film which is laminated on the back surface side of the liquid crystal panel, after being inspected by the inspection apparatus 400. The sheet 231 of the reflective polarizing film is attached so that the direction of the transmission axis of the sheet 131 of the two-color polarizing film is the same as the direction of the transmission axis of the sheet 232 of the reflective polarizing film. In the liquid crystal panel which is judged to be a good result by the inspection, the sheet laminating apparatus 503 attaches the sheet 231 which reflects the polarizing film to the sheet 131 of the two-color polarizing film. The liquid crystal panel that judges the result of the inspection as a defective product is transported to the defective port to be excluded. Further, the liquid crystal panel of the defective product can be transported to the defective port by the liquid crystal panel transport mechanism 202, the attaching mechanism 203, and the transport mechanism 204.
前述之各機構、裝置之動作時序係以例如於特定之位置配置感測器進行檢測之方法計算,或以旋轉編碼器等,檢測搬送機構或搬送機構之旋轉構件的方式予以計算。控制部可藉由軟體程式與CPU、記憶體等之硬體資源之協同作用實現,該情形之程式軟體、處理程序、各種設定等被預先記憶於記憶體。又,可由專用電路或固件等構成。The operation timing of each of the above-described mechanisms and devices is calculated by, for example, a method of arranging a sensor at a specific position, or a rotary encoder or the like for detecting a rotating member of a transport mechanism or a transport mechanism. The control unit can be realized by a software program in cooperation with hardware resources such as a CPU and a memory. In this case, the program software, the processing program, various settings, and the like are stored in advance in the memory. Further, it may be constituted by a dedicated circuit, firmware, or the like.
(實施形態3)(Embodiment 3)
實施形態3之製造方法及製造系統係以上述實施形態1之構成為基本,進而包含在第1片片材之貼附子步驟(貼附機構103)後,貼附第2片片材之前,使液晶面板4相對搬送方向D水平旋轉90°之水平旋轉步驟(水平旋轉部90)(參照圖6、7)。由於實施形態3之各構成要件具有與實施形態1相同之構成要件,且圖6、7A~7C之各構成要件與和其符號一致之圖3、4A~4C之各構成要件相同,故省略各構成要件之說明,而不同之構成將在以下進行說明。The manufacturing method and the manufacturing system according to the third embodiment are basically the configuration of the first embodiment described above, and further include the attaching substep of the first sheet (the attaching mechanism 103), and then attaching the second sheet before attaching the second sheet. The horizontal rotation step (horizontal rotation portion 90) in which the liquid crystal panel 4 is horizontally rotated by 90° with respect to the conveyance direction D (see FIGS. 6 and 7). Since the constituent elements of the third embodiment have the same constituent elements as those of the first embodiment, and the constituent elements of Figs. 6 and 7A to 7C are the same as those of Figs. 3 and 4A to 4C, which are identical to the reference numerals, the respective constituent elements are omitted. The description of the constituent elements will be described below, and the different configurations will be described below.
如圖6、7A~7C所示,第1片片材131積層於液晶面板4。且,在於第1片片材131積層第2片片材231之前,使液晶面板4相對於搬送方向D水平旋轉90°。其次,將第2片片材231積層於第1片片材131上。在進行該貼附時,使第1片片材131之第1邊(捲繞於連續輥之光學膜之膜寬),與第2片片材231之第2邊(由切斷機構以特定之切斷間隔切斷之邊)上下(積層之厚度方向)對應,使第1片片材131之第2邊(由切斷機構以特定之切斷間隔切斷之邊),與第2片片材231之第1邊(捲繞於連續輥之光學膜之膜寬)上下(積層之厚度方向)對應。As shown in FIGS. 6 and 7A to 7C, the first sheet 131 is laminated on the liquid crystal panel 4. Further, before the first sheet 131 is laminated with the second sheet 231, the liquid crystal panel 4 is horizontally rotated by 90° with respect to the conveyance direction D. Next, the second sheet 231 is laminated on the first sheet 131. At the time of the attachment, the first side of the first sheet 131 (the film width of the optical film wound around the continuous roll) and the second side of the second sheet 231 are specified by the cutting mechanism. The cutting edge is cut (the side in the thickness direction of the laminate), and the second side of the first sheet 131 (the side cut by the cutting mechanism at a specific cutting interval) and the second sheet are used. The first side of the sheet 231 (the film width of the optical film wound around the continuous roll) corresponds to the upper and lower sides (the thickness direction of the laminate).
水平旋轉部90雖示例有例如,使液晶面板4朝上方向移動,從液晶面板搬送機構(例如搬送輥80)脫離,其次,使其水平旋轉90°,其後載置於搬送輥80之機構,但並不限定於此,亦可為其他機構。For example, the horizontal rotating unit 90 is configured such that the liquid crystal panel 4 is moved upward, and the liquid crystal panel transport mechanism (for example, the transport roller 80) is detached, and then horizontally rotated by 90°, and then placed on the transport roller 80. However, it is not limited thereto, and may be other institutions.
積層第2片片材231後,亦可積層第3片片材。該情形下,在積層第3片片材之前,亦可使液晶面板再次水平旋轉90°。After laminating the second sheet 231, a third sheet may be laminated. In this case, the liquid crystal panel may be horizontally rotated by 90° again before the third sheet is laminated.
(實施例)(Example)
使用上述實施形態1之片材積層裝置,於液晶面板(32英寸)之一面,依序積層相位差膜之片材(第1片)、2色偏光膜之片材(第2片)、及反射偏光膜之片材(第3片)。在實施例1及2、比較例1之各者中,將評估樣品數設為100片(n=100)。於表1顯示實施例1及2、比較例1之直接積層於液晶面板之第1片之相位差膜、第2片之2色偏光膜、第3片之反射偏光膜各自之膜寬W1、W2、W3,切斷間隔L1、L2、L3之大小關係,而於表2顯示該等之實際尺寸。又,於表2顯示貼附偏差量之最大值(寬度方向(膜寬方向即Y方向)、長度方向(液晶面板之搬送方向即X方向)),利用目視檢查之不良產生率(%)。偏差量為第3片片材從第2片片材溢出,第3片片材之粘著劑(黏膠)露出之長度(黏膠露出量),或第2片片材從第1片片材溢出,第2片片材之粘著劑(黏膠)露出之長度之最大值,且以數位遊標卡尺進行計測。不良判斷之評估項目設為黏膠缺損、污垢、異物。Using the sheet laminating apparatus of the first embodiment, a sheet of a retardation film (first sheet), a sheet of a two-color polarizing film (second sheet), and a sheet of a retardation film are sequentially laminated on one surface of a liquid crystal panel (32 inches). A sheet of reflective polarizing film (third sheet). In each of Examples 1 and 2 and Comparative Example 1, the number of evaluation samples was set to 100 (n=100). Table 1 shows the film width W1 of each of the retardation film of the first sheet of the liquid crystal panel, the two-color polarizing film of the second sheet, and the reflective polarizing film of the third sheet of the first embodiment and the second comparative example. W2, W3, cut off the size relationship of the intervals L1, L2, L3, and the actual size of these is shown in Table 2. In addition, Table 2 shows the maximum value (the width direction (Y direction) in the film width direction and the X direction) in the longitudinal direction (the direction in which the liquid crystal panel is transported), and the defect occurrence rate (%) by visual inspection. The amount of deviation is such that the third sheet overflows from the second sheet, the length of the adhesive (viscose) of the third sheet is exposed (the amount of adhesive exposure), or the second sheet is from the first sheet. The material overflows, and the maximum length of the adhesive of the second sheet (adhesive) is exposed, and is measured by a digital vernier caliper. The evaluation items for bad judgment are set to adhesive defects, dirt, and foreign matter.
從實施例1之結果來看,可確認在片材之膜寬、切斷間隔之大小關係為W1>W2>W3、L1>L2>L3之情形,第3片片材不會從第2片片材溢出,且第2片片材不會第1片片材溢出即可貼合。另一方面,從比較例1之結果來看,在第1片、第2片及第3片片材之膜寬(W1=W2=W3)、切斷間隔(L1=L2=L3)相同之情形,為第2片片材無法不從第1片片材溢出而貼附,且第3片片材無法不從第2片片材溢出而貼附之結果。又,在比較例2中,第3片片材不會從第1片片材溢出,但較第2片片材溢出。因此,相對於在粘著劑不會露出之實施例1中不良產生率為0%,在粘著劑會露出之比較例1及2中,發現黏膠缺損、污垢、異物等不良之產生。From the results of Example 1, it was confirmed that the film width and the cutting interval of the sheet were W1>W2>W3 and L1>L2>L3, and the third sheet was not from the second sheet. The sheet overflows, and the second sheet can be bonded without overflowing the first sheet. On the other hand, from the results of Comparative Example 1, the film width (W1 = W2 = W3) and the cutting interval (L1 = L2 = L3) of the first sheet, the second sheet, and the third sheet are the same. In other words, the second sheet cannot be attached without overflowing from the first sheet, and the third sheet cannot be attached without being overflowed from the second sheet. Further, in Comparative Example 2, the third sheet did not overflow from the first sheet but overflowed from the second sheet. Therefore, in Comparative Example 1 and Example 2 in which the adhesive agent was not exposed, the defect generation rate was 0%, and defects such as adhesive defects, dirt, and foreign matter were observed.
又,從實施例1之結果來看,可確認較佳為考慮膜寬方向,及與該膜寬方向正交之方向之最大偏差量,從而設定第1片、第2片及第3片之膜寬、切斷間隔(W1≧(W2+寬度方向最大偏差量)≧(W3+寬度方向最大偏差量)、L1≧(L2+長度方向最大偏差量)≧(L3+長度方向最大偏差量)。再者,各最大偏差量可根據製造系統之長期使用運轉之結果設定。Further, from the results of Example 1, it was confirmed that it is preferable to set the first sheet, the second sheet, and the third sheet in consideration of the film width direction and the maximum deviation amount in the direction orthogonal to the film width direction. Film width, cutting interval (W1 ≧ (W2+ width direction maximum deviation amount) ≧ (W3 + width direction maximum deviation amount), L1 ≧ (L2+ length direction maximum deviation amount) ≧ (L3 + length direction maximum deviation amount). The maximum deviation amount can be set according to the result of long-term operation of the manufacturing system.
1...連續輥1. . . Continuous roll
2...連續輥2. . . Continuous roll
4...液晶面板4. . . LCD panel
12...襯膜12. . . Lining film
13...2色偏光膜13. . . 2-color polarizing film
20...切斷機構20. . . Cutting mechanism
20a...吸附機構20a. . . Adsorption mechanism
22...襯膜twenty two. . . Lining film
23...反射偏光膜twenty three. . . Reflective polarizing film
30...調節輥30. . . Adjustment roller
40...剝離機構40. . . Stripping mechanism
50a...貼附輥50a. . . Attaching roller
50b...驅動輥50b. . . Drive roller
60...捲繞機構60. . . Winding mechanism
80...搬送輥80. . . Transfer roller
90...水平旋轉部90. . . Horizontal rotation
101...襯膜搬送機構101. . . Liner conveying mechanism
102...液晶面板搬送機構102. . . Liquid crystal panel transport mechanism
103...貼附機構103. . . Attachment mechanism
131...2色偏光膜之片材131. . . 2 color polarizing film sheet
201...襯膜搬送機構201. . . Liner conveying mechanism
202...液晶面板搬送機構202. . . Liquid crystal panel transport mechanism
203...貼附機構203. . . Attachment mechanism
204...液晶面板搬送機構204. . . Liquid crystal panel transport mechanism
231...反射偏光膜之片材231. . . Sheet of reflective polarizing film
300...控制部300. . . Control department
301...2色偏光膜之片材積層裝置301. . . Two-color polarizing film sheet laminating device
302...反射偏光膜之片材積層裝置302. . . Sheet laminate device for reflecting polarizing film
400...檢查裝置400. . . Inspection device
401...照射部401. . . Irradiation department
402...攝像機構402. . . Camera mechanism
403...攝像機構403. . . Camera mechanism
501...片材積層裝置501. . . Sheet laminating device
502...片材積層裝置502. . . Sheet laminating device
503...反射偏光膜之片材積層裝置503. . . Sheet laminate device for reflecting polarizing film
圖1係實施形態1之液晶顯示元件之製造方法之流程圖。Fig. 1 is a flow chart showing a method of manufacturing a liquid crystal display element of the first embodiment.
圖2係實施形態2之液晶顯示元件之製造方法之流程圖。Fig. 2 is a flow chart showing a method of manufacturing a liquid crystal display element of the second embodiment.
圖3係用於說明實施形態1之液晶顯示元件之製造系統之圖。Fig. 3 is a view for explaining a manufacturing system of a liquid crystal display element of the first embodiment.
圖4A係在實施形態1中,將第1片片材積層於液晶面板之狀態之模式圖。Fig. 4A is a schematic view showing a state in which a first sheet is laminated on a liquid crystal panel in the first embodiment.
圖4B係在實施形態1中,將第2片片材積層於液晶面板之狀態之模式圖。Fig. 4B is a schematic view showing a state in which a second sheet is laminated on a liquid crystal panel in the first embodiment.
圖4C係在實施形態1中,將第1片及第2片片材積層於液晶面板之狀態之模式圖。Fig. 4C is a schematic view showing a state in which the first sheet and the second sheet are laminated on the liquid crystal panel in the first embodiment.
圖5係用於說明實施形態2之液晶顯示元件之製造系統之圖。Fig. 5 is a view for explaining a manufacturing system of a liquid crystal display element of the second embodiment.
圖6係用於說明實施形態3之液晶顯示元件之製造系統之圖。Fig. 6 is a view for explaining a manufacturing system of a liquid crystal display element of the third embodiment.
圖7A係在實施形態3中,將第1片片材積層於液晶面板之狀態之模式圖。Fig. 7A is a schematic view showing a state in which a first sheet is laminated on a liquid crystal panel in the third embodiment.
圖7B係在實施形態3中,將第2片片材積層於液晶面板(使液晶面板水平旋轉90°後積層)之狀態之模式圖。Fig. 7B is a schematic view showing a state in which a second sheet is laminated on a liquid crystal panel (a liquid crystal panel is horizontally rotated by 90° and then laminated).
圖7C係在實施形態3中,將第1片及第2片片材積層於液晶面板之狀態之模式圖。Fig. 7C is a schematic view showing a state in which the first sheet and the second sheet are laminated on the liquid crystal panel in the third embodiment.
圖8係用於說明光學膜之膜寬及切斷間隔之圖。Fig. 8 is a view for explaining the film width and the cutting interval of the optical film.
1...連續輥1. . . Continuous roll
2...連續輥2. . . Continuous roll
4...液晶面板4. . . LCD panel
12...襯膜12. . . Lining film
13...2色偏光膜13. . . 2-color polarizing film
20...切斷機構20. . . Cutting mechanism
20a...吸附機構20a. . . Adsorption mechanism
22...襯膜twenty two. . . Lining film
23...反射偏光膜twenty three. . . Reflective polarizing film
30...調節輥30. . . Adjustment roller
40...剝離機構40. . . Stripping mechanism
50a...貼附輥50a. . . Attaching roller
50b...驅動輥50b. . . Drive roller
60...捲繞機構60. . . Winding mechanism
80...搬送輥80. . . Transfer roller
101...襯膜搬送機構101. . . Liner conveying mechanism
102...液晶面板搬送機構102. . . Liquid crystal panel transport mechanism
103...貼附機構103. . . Attachment mechanism
131...2色偏光膜之片材131. . . 2 color polarizing film sheet
201...襯膜搬送機構201. . . Liner conveying mechanism
202...液晶面板搬送機構202. . . Liquid crystal panel transport mechanism
203...貼附機構203. . . Attachment mechanism
204...液晶面板搬送機構204. . . Liquid crystal panel transport mechanism
231...反射偏光膜之片材231. . . Sheet of reflective polarizing film
300...控制部300. . . Control department
301...2色偏光膜之片材積層裝置301. . . Two-color polarizing film sheet laminating device
302...反射偏光膜之片材積層裝置302. . . Sheet laminate device for reflecting polarizing film
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