WO2012029110A1 - 表示パネルの製造方法及びその製造システム - Google Patents
表示パネルの製造方法及びその製造システム Download PDFInfo
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- WO2012029110A1 WO2012029110A1 PCT/JP2010/064734 JP2010064734W WO2012029110A1 WO 2012029110 A1 WO2012029110 A1 WO 2012029110A1 JP 2010064734 W JP2010064734 W JP 2010064734W WO 2012029110 A1 WO2012029110 A1 WO 2012029110A1
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- substrate
- optical panel
- liquid adhesive
- unit
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- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
- G02F1/1303—Apparatus specially adapted to the manufacture of LCDs
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- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
- G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
- G02F1/1333—Constructional arrangements; Manufacturing methods
- G02F1/1339—Gaskets; Spacers; Sealing of cells
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J5/00—Adhesive processes in general; Adhesive processes not provided for elsewhere, e.g. relating to primers
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- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
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- G—PHYSICS
- G09—EDUCATION; CRYPTOGRAPHY; DISPLAY; ADVERTISING; SEALS
- G09F—DISPLAYING; ADVERTISING; SIGNS; LABELS OR NAME-PLATES; SEALS
- G09F9/00—Indicating arrangements for variable information in which the information is built-up on a support by selection or combination of individual elements
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J2203/00—Applications of adhesives in processes or use of adhesives in the form of films or foils
- C09J2203/318—Applications of adhesives in processes or use of adhesives in the form of films or foils for the production of liquid crystal displays
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- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
- G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
- G02F1/1333—Constructional arrangements; Manufacturing methods
- G02F1/133308—Support structures for LCD panels, e.g. frames or bezels
- G02F1/133325—Assembling processes
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- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
- G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
- G02F1/1333—Constructional arrangements; Manufacturing methods
- G02F1/133308—Support structures for LCD panels, e.g. frames or bezels
- G02F1/133331—Cover glasses
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- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
- G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
- G02F1/1333—Constructional arrangements; Manufacturing methods
- G02F1/133354—Arrangements for aligning or assembling substrates
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- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
- G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
- G02F1/1333—Constructional arrangements; Manufacturing methods
- G02F1/13338—Input devices, e.g. touch panels
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- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F2202/00—Materials and properties
- G02F2202/28—Adhesive materials or arrangements
Definitions
- a substrate having an additional function is newly attached to an electro-optical panel including an FPD (flat panel display) or the like such as a touch panel, 3D (three-dimensional) display, electronic book, etc.
- the present invention relates to a method of manufacturing a display panel and a manufacturing system used to implement the method. More specifically, the present invention relates to a method of manufacturing a display panel by bonding an electro-optical panel and a light-transmissive substrate which emits light emitted from the electro-optical panel to a viewing side with a liquid adhesive, and a manufacturing system thereof. .
- Electro-optical panel and the substrate by performing a main curing process may method of manufacturing an electro-optical device that is present bonded after (e.g., see Patent Document 1).
- the electro-optical panel and the substrate are vacuum-adsorbed on the table and the pressure plate of the temporary UV curing device and pressed in a direction in which they approach each other and alignment is performed.
- the holding of the electro-optical panel and the substrate by adsorption can not be performed reliably unless in the air.
- the electro-optical panel and the substrate are pressed in the air in the direction toward each other in the atmosphere, and accordingly, the adhesive is crushed in the thickness direction, and the liquid crystal panel and the substrate are deformed and flowed. It flows and spreads along the opposite surface of the.
- the present invention has an object to address such a problem, and has an object to adhere the electro-optical panel and the substrate in a perfect non-bubble state and with a uniform gap.
- a method of manufacturing a display panel comprises: bonding an electro-optical panel and a substrate having light transmitting property and emitting light emitted from the electro-optical panel to a viewing side
- the liquid adhesive is naturally stretched for a predetermined time along the opposing surfaces of the electro-optical panel and the substrate superposed in the bonding step, and the layer thickness of the liquid adhesive is set to the electro-optical panel
- a liquid crystal adhesive is used to bond an electro-optical panel and a substrate having a light-transmitting property and emitting light emitted from the electro-optical panel to the viewing side.
- a bonding unit having a vacuum chamber, holding the electro-optical panel and the substrate in the vacuum chamber, and overlapping in the Z direction so that the liquid adhesive is sandwiched therebetween
- a transport unit for releasably holding the electro-optical panel and the substrate stacked in the bonding unit and transporting the inside of the vacuum chamber to the atmosphere; and a transport unit provided in the atmosphere and transported by the transport unit
- a bubble-free alignment unit for mutually aligning and aligning either of the electro-optical panel or the substrate relative to the other in the XY ⁇ direction;
- the electro-optical panel aligned in a row unit and a curing unit configured to cure the liquid adhesive disposed between the opposing surfaces of the substrate, the transport unit is configured to stack the electricity from the inside of the vacuum chamber.
- the liquid adhesive naturally spreads along the facing surfaces of the electro-optical panel and the substrate during a predetermined time until the optical panel and the substrate are transported and set to the bubble-free alignment unit in the atmosphere.
- the layer thickness of the liquid adhesive is substantially uniform in the Z direction over the entire facing surface.
- the opposing surfaces of the electro-optical panel and the substrate are overlapped in the Z direction with the liquid adhesive in the vacuum atmosphere. , Force the liquid adhesive to extend along the opposite surface.
- the liquid adhesive is naturally stretched between the electro-optical panel and the substrate, so that the local vacuum etc. in the liquid adhesive disappears, and the liquid adhesive becomes in a nearly stationary stable state.
- the layer thickness of the liquid adhesive becomes substantially uniform in the Z direction over the entire facing surface of the electro-optical panel and the substrate, so that no further gap adjustment is necessary.
- the opposing surfaces of the electro-optical panel and the substrate are overlapped in the Z direction with the liquid adhesive in the vacuum chamber by the bonding unit.
- the liquid adhesive is forced to extend along the opposite surface.
- the electro-optical panel and the substrate are transported and set by the carrier unit to the bubble-free alignment unit in the atmosphere.
- the entire opposing surface becomes substantially uniform in the Z direction, and no further gap adjustment is necessary.
- the electric adhesive on the liquid adhesive having a substantially uniform layer thickness is aligned. It is only necessary to slide either the optical panel or the substrate smoothly along the interface of the liquid adhesive, and since no pressure is applied, the liquid adhesive does not deform and flow and does not entrain air. Therefore, the electro-optical panel and the substrate can be bonded in a perfect non-bubble state and at a uniform gap.
- the bubble-free performance is achieved even if the size of the electro-optical panel is increased.
- the yield can be significantly improved.
- a manufacturing system of a display panel A according to an embodiment of the present invention is a bonding unit in which the electro-optical panel 1 and the substrate 2 are superimposed in the Z direction so as to sandwich the liquid adhesive 3.
- a transport unit 20 for transporting the stacked electro-optical panel 1 and the substrate 2 into the atmosphere
- a bubble-free alignment unit 30 for aligning the electro-optical panel 1 and the substrate 2 in the XY ⁇ direction
- the aligned electro-optical panel 1 A curing unit 40 for curing the liquid adhesive 3 disposed between the substrates 2, and a control unit 50 for controlling the operation of the bonding unit 10, the transport unit 20, the bubble-free alignment unit 30, the curing unit 40 and the like. It is equipped as a main component.
- the electro-optical panel 1 includes an electro-optical material layer and means for applying a voltage to the electro-optical material layer, and changes the state of the electro-optical material layer by applying a voltage based on an electrical signal to extract desired light.
- the electro-optical panel 1 include, for example, a liquid crystal display (LCD), an organic EL display (OLED), a plasma display (PDP), and a flexible display, which are used for touch panels, 3D (three-dimensional) displays, electronic books, etc.
- LCD liquid crystal display
- OLED organic EL display
- PDP plasma display
- FPD Flat panel display
- the electro-optical panel 1 is formed in a rectangular shape or the like, and that an alignment mark (not shown) used for alignment with the substrate 2 described later is provided on the periphery thereof. Moreover, as the electro-optical panel 1, it is also possible to use one sheet before separation in which a plurality of the electro-optical panels 1 are juxtaposed in the manufacturing stage.
- the substrate 2 is made of a translucent material such as glass, quartz, or plastic, and transmits light emitted from the electro-optical panel 1 and emits the light to the Z direction side (viewing side). Have functions according to their application.
- Specific examples of the substrate 2 include cover glass and barrier glass used in touch panels, 3D (three-dimensional) displays, electronic books, etc.
- cover glass and barrier glass used in touch panels, 3D (three-dimensional) displays, electronic books, etc.
- patterns such as patterns and symbols are It is printed on the surface which is the adhesive surface.
- the size and the planar shape of the substrate 2 are formed in the same rectangular shape as that of the electro-optical panel 1, and it is preferable to provide an alignment mark (not shown) used for alignment with the electro-optical panel 1 .
- the substrate 2 it is also possible to use one substrate before separation in which a plurality of substrates 2 are juxtaposed in the manufacturing stage.
- the liquid adhesive 3 is made of a photo-curable adhesive, a thermosetting adhesive, a two-component mixture-curable adhesive, or the like, which absorbs light energy and hardens as polymerization proceeds to develop adhesiveness.
- degree of polymerization hardening degree
- the degree of polymerization hardening degree
- the liquid adhesive 3 is partially applied to the opposing surfaces (surfaces) 1a and 2a of the electro-optical panel 1 and the substrate 2, and the opposing surfaces of the electro-optical panel 1 and the substrate 2 are combined in a bonding unit 10 described later.
- the liquid adhesive 3 is extended along the facing surfaces 1a and 2a, and finally, substantially the entire facing surfaces 1a and 2a are filled.
- an ultraviolet curing adhesive or the like is used.
- the dots are drawn on the opposing surfaces 1 a and 2 a in a line or a line,
- the point-like or linear liquid adhesive 3 is extended so that the interfaces are in contact and mutually connected. It is preferable to distribute them.
- the bonding unit 10 is entirely or partially shown in the Z direction in the vacuum chamber 11 and the vacuum chamber 11 formed in the Z direction (FIGS. 2A and 2B).
- a pair of holding plates 12 and 13 are provided facing each other in the vertical direction and detachably hold the electro-optical panel 1 and the substrate 2, and one or both of the holding plates 12 and 13
- An elevation drive unit 14 is provided to move the electro-optical panel 1 and the substrate 2 in close proximity to each other in the Z direction.
- the pair of holding plates 12 and 13 is formed of, for example, a rigid body such as metal or ceramic in a flat plate shape having a thickness that is not distorted (flexed), and the electro-optical panel 1 or the substrate 2
- As holding means (not shown) for detachably holding the adhesive for example, an adhesive chuck or a combination with an electrostatic chuck or a suction chuck, etc. are provided, and either or both of the holding surfaces 12a and 13a with respect to the vacuum chamber 11 Are reciprocally supported so as to approach or separate from each other in a parallel state in the Z direction.
- the electro-optical panel 1 is held by the holding surface 12a of the holding plate 12 disposed below, and the substrate 2 is held by the holding surface 13a of the holding plate 13 disposed above.
- the upper holding plate 13 with respect to the lower holding plate 12 is moved up and down by the raising and lowering drive unit 14.
- the lower holding plate 12 holds the substrate 2
- the upper holding plate 13 holds the electro-optical panel 1 or the lower holding plate 12 with respect to the upper holding plate 13. It is also possible to move up and down only by the lifting drive unit 14 or to move up and down by the lifting drive unit 14 both the lower holding plate 12 and the upper holding plate 13.
- a closed space S capable of adjusting the air pressure is formed around the holding plates 12 and 13 inside the vacuum chamber 11, and the closed space S is maintained under an environment of vacuum or a pressure reduced to a state close thereto. It is preferable to move the surfaces 12 a and 13 a close to each other to overlap the electro-optical panel 1 and the substrate 2.
- the transport unit 20 is, for example, a transport robot having a suction pad as a means for detachably holding the electro-optical panel 1 and the substrate 2, and at least the vacuum chamber 11 of the bonding unit 10 and the bubble-free alignment unit described later
- the electro-optical panel 1 and the substrate 2 stacked in the bonding unit 10 are conveyed to the bubble-free alignment unit 30 and delivered.
- the transfer unit 20 the electric elements stacked in the vacuum chamber 11 by operating in cooperation with liftable lift pins (not shown) provided on the holding plates 12 and 13 of the bonding unit 10, etc.
- the optical panel 1 and the substrate 2 are received from the holding surfaces 12a and 13a, taken out from the inside of the vacuum chamber 11 to the outside atmosphere, and a bubble-free alignment unit 30 described later while maintaining the overlapping state of the electro-optical panel 1 and the substrate 2. It is conveyed toward the center and set at a predetermined position on the holding chuck 31. Furthermore, if necessary, the electro-optical panel 1 and the substrate 2 are directed into the vacuum chamber 11 of the bonding unit 10 from the external area where the coating unit comprising a liquid metering dispenser such as a dispenser is disposed by the transport unit 20.
- the electro-optical panel 1 and the substrate 2 are unloaded from the bubble-free alignment unit 30 It is preferable to control the movement as follows.
- the transport unit 20 in order to promote the natural extension of the liquid adhesive 3 sandwiched in the opposing surfaces 1a and 2a with respect to the electro-optical panel 1 and the substrate 2 during transport, It is also possible to provide means for giving a proper vibration including fine vibration, or to provide buffer means for holding and holding the electro-optical panel 1 and the substrate 2 during transport for a certain period of time.
- the bubble-free alignment unit 30 is disposed in the atmosphere, and holds a pair of holding chucks 31 and 32 for detachably holding the electro-optical panel 1 and the substrate 2 conveyed by the conveyance unit 20, and the holding chucks 31 and 32.
- Horizontal drive unit 33 which aligns the electro-optical panel 1 and the substrate 2 by moving one of them in the XY.theta. Direction (up and down, left and right and diagonal direction in the example shown in FIG. 3A) with respect to the other;
- the optical panel 1 and a position detection unit 34 for detecting alignment marks and the like arranged on the peripheral edge of the substrate 2 are provided.
- the pair of holding chucks 31 and 32 are formed of, for example, a rigid body such as metal or ceramic and formed in a flat plate shape having a thickness that is not distorted (flexible), and the electro-optical panel 1 or the substrate 2
- a suction chuck, an electrostatic chuck, an adhesive chuck, a friction chuck, or a combination thereof is provided as holding means (not shown) for detachably holding the holding surface 31a and 32a.
- One of the surfaces 12a and 13a is supported movably in the XY ⁇ direction while maintaining a parallel state with respect to the other. In the example shown in FIGS.
- a camera as the position detection unit 34 is provided at the peripheral edge portion of the upper holding chuck 32 on which the substrate 2 is held. Furthermore, the lower holding chuck 31 holding the electro-optical panel 1 is supported movably in the XY ⁇ direction with respect to the upper holding chuck 32 holding the substrate 2. Further, although not shown as another example, the upper holding chuck 32 holding the substrate 2 can be supported movably in the XY ⁇ direction with respect to the lower holding chuck 31 holding the electro-optical panel 1 It is.
- the curing unit 40 irradiates light energy to increase the degree of polymerization (degree of curing) of the liquid adhesive 3, and immediately after the alignment of the electro-optical panel 1 and the substrate 2 by the non-bubble alignment unit 30, Increase the degree of polymerization (degree of curing) of the liquid adhesive 3 without moving it.
- the curing unit 40 when the liquid adhesive 3 is an ultraviolet-curable adhesive or the like, it becomes a UV irradiation unit that irradiates ultraviolet light, between the opposing surfaces 1a and 2a of the electro-optical panel 1 and the substrate 2. Ultraviolet rays are directed to a part or all of the liquid adhesive 3 extended along the same. In the example shown in FIGS.
- a UV irradiation head is disposed as a curing unit 40 at the periphery of the upper holding chuck 32 where the substrate 2 is held, and the electro-optical panel 1 and the substrate 2 are By partially curing several parts of the peripheral portion of the liquid adhesive 3 extended along the space between the facing surfaces 1a and 2a, temporary minimum curing is performed, and from the bubble-free alignment unit 30 to the electro-optical panel After the substrate 1 and the substrate 2 are carried out, the main curing is performed.
- a thermosetting adhesive, a two-component mixed curing adhesive, or the like instead of the ultraviolet curing adhesive, or to fully cure the entire liquid adhesive 3 is there.
- the control unit 50 is electrically connected to the opening / closing drive unit 11a, the lift drive unit 14, the transport unit 20, the horizontal drive unit 33, the position detection unit 34, the curing unit 40, etc. It is a controller that connects in sequence and is controlled to operate sequentially according to a preset program. In particular, the control unit 50 adjusts the operating speed of the transfer unit 20, etc., from the time when the superposition of the electro-optical panel 1 and the substrate 2 in the vacuum chamber 11 is completed by the bonding unit 10, The time until the alignment of the electro-optical panel 1 with the substrate 2 is started can be arbitrarily set.
- the time when the alignment by the bubble-free alignment unit 30 is started can be arbitrarily set. ing. That is, the liquid adhesive 3 partially applied to the opposing surfaces 1a and 2a of the electro-optical panel 1 and the substrate 2 is naturally extended along the opposing surfaces 1a and 2a of the electro-optical panel 1 and the substrate 2, While filling substantially the entire facing surfaces 1a and 2a, the local vacuum in the liquid adhesive 3 disappears and the liquid adhesive 3 becomes substantially stationary and the layer thickness of the liquid adhesive 3 is opposed After the surfaces 1a and 2a are substantially uniform in the Z direction, alignment of the electro-optical panel 1 and the substrate 2 by the bubble-free alignment unit 30 is started.
- a bonding step for overlapping the electro-optical panel 1 and the substrate 2 includes a leveling step for naturally extending 3, a bubble-free alignment step for aligning the electro-optical panel 1 and the substrate 2, and a curing step for curing the liquid adhesive 3.
- the facing surfaces 1a and 2a of the electro-optical panel 1 and the substrate 2 are in the Z direction so that the liquid adhesive 3 is sandwiched therebetween. Superimpose and temporarily bond.
- the electro-optical panel 1 and the substrate 2 which have been completely stacked are taken out from the vacuum chamber 11 by the transfer unit 20 or the like, and they are stacked in the bonding step for a predetermined time before setting in the bubbleless alignment unit 30.
- the liquid adhesive 3 is naturally stretched along the facing surfaces 1a and 2a of the electro-optical panel 1 and the substrate 2 for a predetermined time to fill substantially the entire facing surfaces 1a and 2a, and a layer of the liquid adhesive 3
- the thickness is made substantially uniform in the Z direction across the opposing surfaces 1 a and 2 a of the electro-optical panel 1 and the substrate 2.
- either the electro-optical panel 1 or the substrate 2 is slid relative to the other in the atmosphere in the XY ⁇ direction and aligned by the bubble-free alignment unit 30 with respect to the other.
- the facing surfaces of the electro-optical panel 1 and the substrate 2 in the vacuum chamber 11 by the bonding unit 10 1a and 2a are superimposed on each other in the Z direction with the liquid adhesive 3 interposed therebetween.
- the liquid adhesive 3 is forcibly extended along the facing surfaces 1a and 2a, and the liquid adhesive 3 fills the majority of the facing surfaces 1a and 2a.
- the transport unit 20 transports the electro-optical panel 1 and the substrate 2 completed in the vacuum chamber 11 from the inside of the vacuum chamber 11 to the bubble-free alignment unit 30 in the atmosphere for a predetermined time.
- the liquid adhesive 3 is naturally stretched between the electro-optical panel 1 and the substrate 2.
- the local vacuum or the like in the liquid adhesive 3 disappears, and the liquid adhesive 3 is in a substantially stationary stable state, and the layer thickness of the liquid adhesive 3 becomes the opposing surface of the electro-optical panel 1 and the substrate 2
- the whole of 1a and 2a becomes substantially uniform in proportion to the volume of the liquid adhesive 3 applied in the Z direction.
- the opposing surfaces 1a and 2a of the electro-optical panel 1 and the substrate 2 become parallel to each other, and no further gap adjustment is necessary.
- the bubble-free alignment unit 3 aligns one of the electro-optical panel 1 and the substrate 2 in the atmosphere with respect to the other in the XY ⁇ direction.
- the liquid adhesive 3 does not deform and flow, it does not involve air.
- a pattern such as a pattern or a symbol is printed on the adhesive surface like the cover glass of a touch panel, for example, and the substrate 2 has slight unevenness between the printed portion and the non-printed portion, slight unevenness is generated.
- the liquid adhesive 3 bites in a non-bubble state and the interface between the solid and the liquid conforms, the liquid adhesive 3 moves smoothly as the fluid operation of the liquid adhesive 3 itself. Therefore, the electro-optical panel 1 and the substrate 2 can be bonded in a perfect non-bubble state and at a uniform gap.
- the bonding unit 10 and the bubble-free alignment unit 30 are separately provided, and a plurality of sets of the electro-optical panel 1 and the substrate 2 are simultaneously provided in the vacuum chamber 11. These are stacked and transported by the transport unit 20, and the plurality of sets of the electro-optical panel 1 and the substrate 2 are sequentially aligned. That is, the bonding unit 10 holds the plurality of sets of the electro-optical panel 1 and the substrate 2 so as to face each other by the holding plates 12 and 13 in the vacuum chamber 11 and moves them close to each other at the same time.
- a plurality of sets of electro-optical panels 1 and substrates 2 are detachably held and sequentially aligned.
- the vacuum chamber 11 of the bonding unit 10 is configured to be entirely divisible in the Z direction, and the closed space S formed therein is a predetermined vacuum. After reaching the predetermined temperature, the plurality of electro-optical panels 1 and the substrate 2 are stacked, and thereafter the closed space S is an open-type vacuum chamber in which the open space S is open to the atmosphere.
- the vacuum chamber 11 is inseparable and an entrance is opened in a part of the side wall, and a door is supported so as to cover the entrance so as to cover the entrance.
- the electro-optical panel 1 and the substrate 2 can be moved in and out by the transport unit 20 when the door is opened.
- the plurality of electro-optical panels 1 one sheet before the separation in which the plurality of electro-optical panels 1 are juxtaposed in the manufacturing stage is held on the lower holding plate 12;
- the plurality of separated substrates 2 are held on the upper holding plate 13 so as to face the panel 1 respectively.
- a plurality of substrates 2 are held one by one before separation in which a plurality of substrates 2 are juxtaposed in the manufacturing stage. It is also possible to hold a plurality of separated electro-optical panels 1 facing each other.
- the upper holding chuck 32 for holding the substrate 2 with respect to the lower holding chuck 31 for holding the electro-optical panel 1 corresponds to each electro-optical panel 1 and
- the horizontal drive unit 33 movably supports the respective substrates 2 in the XY ⁇ directions (upper and lower, left and right directions and oblique directions in the example shown in FIG. 3A) such that the respective substrates 2 face each other.
- the plurality of sets of the electro-optical panel 1 and the respective substrates 2 can be stacked only once with respect to the bonding unit 10. Alignment and alignment are performed. Thereby, there is an advantage that the plurality of sets of electro-optical panels 1 and the substrate 2 can be efficiently bonded. As a result, the productivity of the display panel A can be improved and the cost can be reduced, as compared with the conventional manufacturing system and method in which the electro-optical panel and the substrate are superposed and aligned one by one.
- the bonding unit 10 and the bubble-free alignment unit 30 are separately disposed, and are transported by the transport unit 20 between the two, but the present invention is not limited thereto.
- the bubble alignment unit 30 may be integrally disposed, and may be transported by the transport unit 20 therein.
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Abstract
Description
詳しくは、電気光学パネルと、透光性を有し前記電気光学パネルから射出された光を視認側に射出する基板とを液状接着剤で貼り合わせる表示パネルの製造方法、及び、その製造システムに関する。
そうしてみると、大気中で電気光学パネルと基板が互いに接近する方向に押圧されることになり、それに伴って、接着剤が厚さ方向へ押し潰され、変形流動しながら液晶パネル及び基板の対向面に沿って流動し押し広げられる。
しかし乍ら、大気中における接着剤の変形流動は、その変形流動の過程で空気を巻き込み易くなることが避けられず、完全な無気泡で接着できないことから不良品が発生し易く歩留まりが悪いという問題があった。
すなわち、接着剤の変形流動中、例えば接着剤と基板の間に空隙が全く生じない状態で流動すれば空気が混入することはないが、押圧中に電気光学パネルの表面に対して基板が僅かでも傾斜すると空隙が生じ、空気の巻き込みが発生するいう問題があった。大気中で加圧板を使用する場合には、加圧板を支持する軸機構の精度、加圧板の歪み等が存在し、これらが基板に伝わるため、空気の巻き込みの問題は避け得ないものであった。
また、基板が例えばタッチパネルのカバーガラスのように模様や記号などが接着面に印刷される場合には、印刷部と非印刷部との間に僅かな凹凸が生ずるため、空気の巻き込みがさらに助長されるという問題もあった。
バネで電気光学パネル及び基板の周縁部を中央部側よりも強い力で押圧しても、大気中における接着剤の変形流動に伴う空気の巻き込みを減らすことはできず、電気光学パネルと基板の間を完全な無気泡状態にすることはできなかった。
特に、基板サイズが大型化すると、加圧方式では信頼性を得ることは難しかった。
また、電気光学パネルと基板を一組ずつ重ね合わせて位置合わせするため、生産性に劣るという問題があった。
したがって、電気光学パネルと基板を完全な無気泡状態で且つ均一なギャップで接着することができる。
その結果、真空吸着された電気光学パネルと基板を大気中で互いに接近する方向に押圧するとともに位置合わせを行う従来の製造方法に比べ、電気光学パネルのサイズが大きくなっても、無気泡の性能を向上させることができ、歩留まりが大幅に良くなる。
したがって、電気光学パネルと基板を完全な無気泡状態で且つ均一なギャップで接着することができる。
その結果、真空吸着された電気光学パネルと基板を大気中で互いに接近する方向に押圧するとともに位置合わせを行う従来の製造システムに比べ、電気光学パネルのサイズが大きくなっても、無気泡の性能を向上させることができ、歩留まりが大幅に良くなる。
本発明の実施形態に係る表示パネルAの製造システムは、図1~図3に示すように、電気光学パネル1と基板2を液状接着剤3が挟まれるようにZ方向へ重ね合わせる合着ユニット10、重ね合わされた電気光学パネル1及び基板2を大気中に搬送する搬送ユニット20、電気光学パネル1と基板2をXYθ方向へ位置合わせする無気泡整列ユニット30、位置合わせされた電気光学パネル1及び基板2の間に配置される液状接着剤3を硬化させる硬化ユニット40、これら合着ユニット10,搬送ユニット20,無気泡整列ユニット30及び硬化ユニット40などをそれぞれ作動制御する制御部50を、主要な構成要素として備えている。
電気光学パネル1の具体例としては、タッチパネルや3D(3次元)ディスプレイや電子書籍などに用いられる、例えば液晶ディスプレイ(LCD)、有機ELディスプレイ(OLED)、プラズマディスプレイ(PDP)、フレキシブルディスプレイなどのフラットパネルディスプレイ(FPD)などが挙げられる。
さらに、電気光学パネル1は、矩形などに形成され、その周縁部には、後述する基板2との位置合わせに用いるアライメントマーク(図示しない)を設けることが好ましい。
また、電気光学パネル1としては、その製作段階で複数の電気光学パネル1が並設される分離前の一枚ものを使用することも可能である。
基板2の具体例としては、タッチパネルや3D(3次元)ディスプレイや電子書籍などに用いられる、カバーガラスやバリアガラスなどが挙げられ、例えばタッチパネルとして用いられる場合には、模様や記号などのパターンが接着面である表面に印刷される。
基板2の大きさや平面形状は、電気光学パネル1と同程度の矩形などに形成され、その周縁部には、電気光学パネル1との位置合わせに用いるアライメントマーク(図示しない)を設けることが好ましい。
また、基板2としては、その製作段階で複数の基板2が並設される分離前の一枚ものを使用することも可能である。
さらに、液状接着剤3は、電気光学パネル1及び基板2の対向面(表面)1a,2aに対して部分的に塗布され、後述する合着ユニット10で電気光学パネル1及び基板2の対向面1a,2aを重ね合わせることにより、これら対向面1a,2aに沿って液状接着剤3が伸展して、最終的には対向面1a,2aの略全体に充満するようにしている。
液状接着剤3の具体例としては、紫外線硬化型接着剤などが用いられる。
また、液状接着剤3の塗布方法としては、例えばディスペンサなどの液体定量吐出機からなる塗布手段(図示しない)を用い、対向面1a,2aに点状や線状に描画し、後述する合着ユニット10により電気光学パネル1と基板2の対向面1a,2a同士が重ね合わされることで、点状や線状の液状接着剤3がそれぞれ伸展してその界面同士が接触し相互に繋がるように分散配置することが好ましい。
また、その他の例として図示しないが、下方の保持板12に基板2を保持するとともに上方の保持板13に電気光学パネル1を保持したり、上方の保持板13に対して下方の保持板12のみを昇降駆動部14で昇降移動したり、下方の保持板12及び上方の保持板13の両方を昇降駆動部14で昇降移動させることも可能である。
搬送ユニット20の具体例としては、合着ユニット10の保持板12,13に設けられる昇降自在なリフトピン(図示しない)などと協動して作動することにより、真空チャンバー11内で重ね合わされた電気光学パネル1及び基板2を保持面12a,13aから受け取り、真空チャンバー11内から外の大気中に取り出すとともに、電気光学パネル1及び基板2の重ね合わせ状態を維持しながら後述する無気泡整列ユニット30へ向け搬送し、その保持チャック31上の所定位置にセットする。
さらに必要に応じて、搬送ユニット20により、例えばディスペンサなどの液体定量吐出機からなる塗布手段が配備される外部領域から電気光学パネル1及び基板2を、合着ユニット10の真空チャンバー11内へ向け搬入し、また後述する無気泡整列ユニット30による無気泡整列工程及び後述する硬化ユニット40に液状接着剤3の硬化工程が終了した後に、無気泡整列ユニット30から電気光学パネル1及び基板2を搬出するように移動制御することが好ましい。
また必要に応じて、搬送ユニット20には、搬送中の電気光学パネル1及び基板2に対し、それぞれの対向面1a,2a中に挟まれた液状接着剤3の自然伸展を促進するために、微振動が含まれた適度な振動を与える手段を備えたり、搬送中の電気光学パネル1及び基板2を一定時間に亘り滞留保持して先入れ先出しするバッファ手段を備えることも可能である。
図3(a)(b)に示される例では、基板2が保持される上方の保持チャック32の周縁部に、位置検出部34としてカメラを設けている。さらに、基板2が保持される上方の保持チャック32に対して、電気光学パネル1が保持される下方の保持チャック31をXYθ方向へ移動自在に支持している。
また、その他の例として図示しないが、電気光学パネル1が保持される下方の保持チャック31に対して、基板2が保持される上方の保持チャック32をXYθ方向へ移動自在に支持することも可能である。
硬化ユニット40の具体例として、液状接着剤3が紫外線硬化型接着剤などが用いられる場合には、紫外線を照射するUV照射部となり電気光学パネル1及び基板2の対向面1a,2aの間に沿って伸展した液状接着剤3の一部又は全部に向け、紫外線を照射させる。
図3(a)(b)に示される例では、基板2が保持される上方の保持チャック32の周縁部に、硬化ユニット40としてUV照射ヘッドを配設し、電気光学パネル1及び基板2の対向面1a,2aの間に沿って伸展した液状接着剤3の周縁部おいて数箇所を部分的に硬化させることにより、必要最低限の仮硬化を行い、無気泡整列ユニット30から電気光学パネル1及び基板2が搬出された後に本硬化させるようにしている。
また、その他の例として図示しないが、紫外線硬化型接着剤に代えて熱硬化型接着剤や二液混合硬化型接着剤などを用いたり、液状接着剤3の全部を本硬化させることも可能である。
特に、制御部50は、搬送ユニット20の作動速度を調整するなどして、合着ユニット10により真空チャンバー11内で電気光学パネル1と基板2の重ね合わせが完了した時点から、無気泡整列ユニット30による電気光学パネル1と基板2の位置合わせが開始される時点までの時間を任意に設定可能にしている。
詳しくは、電気光学パネル1と基板2の重ね合わせが完了した時点から始まる液状接着剤3の自然伸展に対応して、無気泡整列ユニット30による位置合わせが開始される時間を任意に設定可能にしている。
つまり、電気光学パネル1及び基板2の対向面1a,2aに対して部分的に塗布された液状接着剤3を、電気光学パネル1と基板2の対向面1a,2aに沿って自然伸展させ、対向面1a,2aの略全体に充満させるとともに、液状接着剤3中における局部的な真空などが消失して液状接着剤3は略静止安定した状態になり、液状接着剤3の層厚を対向面1a,2a全体でZ方向へ略均一にしてから、無気泡整列ユニット30による電気光学パネル1と基板2の位置合わせが開始されるようにしている。
それにより、液状接着剤3が対向面1a,2aに沿って強制的に伸展され、対向面1a,2aの大部分に液状接着剤3が充満する。
それにより、液状接着剤3中における局部的な真空などが消失して、液状接着剤3は略静止安定した状態になり、液状接着剤3の層厚が電気光学パネル1及び基板2の対向面1a,2a全体で、Z方向へ塗布した液状接着剤3の体積に見合った略均一になる。それによって、電気光学パネル1と基板2の対向面1a,2aが平行になり、これ以上のギャップ調整は必要ない状態となる。
それにより、略均一な層厚の液状接着剤3上に乗った電気光学パネル1又は基板2のいずれか一方を、液状接着剤3の界面に沿ってスムーズに滑動させるだけでよく、加圧しないので液状接着剤3は変形流動せず空気を巻き込むことはない。
特に、基板2が例えばタッチパネルのカバーガラスのように模様や記号などのパターンが接着面に印刷されて、印刷部と非印刷部との間に僅かな凹凸が生じたとしても、僅かな凹凸に液状接着剤3が無気泡状態で食い込んで固体と液体の界面が馴染んでいるから、液状接着剤3自体の流体動作としてスムーズに移動する。
したがって、電気光学パネル1と基板2を完全な無気泡状態で且つ均一なギャップで接着することができる。
次に、本発明の一実施例を図面に基づいて説明する。
すなわち、合着ユニット10が、真空チャンバー11内で保持板12,13により電気光学パネル1と基板2を複数組それぞれが互いに対向するように保持し、それぞれ接近移動させて同時に重ね合わせ、搬送ユニット20が、合着ユニット10で重ね合わされた複数組の電気光学パネル1及び基板2を真空チャンバー11内から無気泡整列ユニット30へ搬送し、無気泡整列ユニット30が、搬送ユニット20で搬送された複数組の電気光学パネル1と基板2をそれぞれ着脱自在に保持して順次位置合わせしている。
また、その他の例として図示しないが、真空チャンバー11が分離不能でその側壁の一部に出入口を開設し、この出入口を覆うように扉が開閉動自在に支持され、この扉を開閉駆動部11aの作動により開閉動させ、該扉の開動時に電気光学パネル1及び基板2を搬送ユニット20によって出し入れさせることも可能である。
また、その他の例として図示しないが、図示例と逆に複数の基板2としてその製作段階で複数の基板2が並設される分離前の一枚ものを保持し、これら複数の基板2とそれぞれ対向して、分離された複数枚の電気光学パネル1を保持することも可能である。
また、その他の例として図示しないが、図示例と逆に上方の保持チャック32に対して下方の保持チャック31がXYθ方向へ水平駆動部33でそれぞれ移動自在に支持することも可能である。
それにより、複数組の電気光学パネル1と基板2を効率良く貼り合わせることができるという利点がある。
その結果、電気光学パネルと基板を一組ずつ重ね合わせて位置合わせする従来の製造システム及び製造方法に比べ、表示パネルAの生産性を向上できて、コストの低減化が図れる。
2 基板 3 液状接着剤
11 真空チャンバー 20 搬送ユニット
30 無気泡整列ユニット 40 硬化ユニット
Claims (4)
- 電気光学パネルと、透光性を有し前記電気光学パネルから射出された光を視認側に射出する基板とを液状接着剤で貼り合わせる表示パネルの製造方法であって、
真空雰囲気中で前記電気光学パネル及び前記基板の対向面をそれらの間に前記液状接着剤が挟まれるようにZ方向へ重ね合わせる合着工程と、
前記合着工程で重ね合わされた前記電気光学パネル及び前記基板の前記対向面に沿って前記液状接着剤を所定時間に亘り自然伸展させて、該液状接着剤の層厚を前記電気光学パネル及び前記基板の対向面全体でZ方向へ略均一にするレベリング工程と、
前記レベリング工程後に前記電気光学パネル又は前記基板のいずれか一方を他方に対し大気中でXYθ方向へ相互に滑り移動させて位置合わせする無気泡整列工程と、
前記無気泡整列工程で位置合わせされた前記電気光学パネル及び前記基板の前記対向面間に配置される前記液状接着剤を硬化させる硬化工程とを含むことを特徴とする表示パネルの製造方法。 - 前記合着工程が、前記電気光学パネルと前記基板を複数組それぞれ互いに対向するように配置して同時に重ね合わせ、
前記無気泡整列工程が、前記合着工程で重ね合わされた複数組の前記電気光学パネルと前記基板を順次位置合わせしたことを特徴とする請求項1記載の表示パネルの製造方法。 - 電気光学パネルと、透光性を有し前記電気光学パネルから射出された光を視認側に射出する基板とを液状接着剤で貼り合わせる表示パネルの製造システムであって、
真空チャンバーを有し、該真空チャンバー内で前記電気光学パネルと前記基板を保持して、それらの間に前記液状接着剤が挟まれるようにZ方向へ重ね合わせる合着ユニットと、
前記合着ユニットで重ね合わされた前記電気光学パネル及び前記基板を着脱自在に保持して、前記真空チャンバー内から大気中に搬送する搬送ユニットと、
大気中に設けられ、前記搬送ユニットで搬送された前記電気光学パネル又は前記基板のいずれか一方を他方に対しXYθ方向へ相互移動して位置合わせする無気泡整列ユニットと、
前記無気泡整列ユニットで位置合わせされた前記電気光学パネルと前記基板の対向面間に配置される前記液状接着剤を硬化させる硬化ユニットとを備え、
前記搬送ユニットは、前記真空チャンバー内から重ね合わされた前記電気光学パネル及び前記基板を大気中の前記無気泡整列ユニットへ搬送してセットするまでの所定時間中に、前記電気光学パネルと前記基板の対向面に沿って前記液状接着剤が自然伸展して、該液状接着剤の層厚が前記対向面全体でZ方向へ略均一になるようにしたことを特徴とする表示パネルの製造システム。 - 前記合着ユニットが、前記真空チャンバー内で前記電気光学パネルと前記基板を複数組それぞれが互いに対向するように保持し、これら複数組の前記電気光学パネルと前記基板をそれぞれ接近移動させて同時に重ね合わせ、
前記搬送ユニットが、前記合着ユニットで重ね合わされた複数組の前記電気光学パネル及び前記基板を、前記真空チャンバー内から前記無気泡整列ユニットへ搬送し、
前記無気泡整列ユニットが、前記搬送ユニットで搬送された複数組の前記電気光学パネルと前記基板をそれぞれ着脱自在に保持して順次位置合わせしたことを特徴とする請求項1記載の表示パネルの製造システム。
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JP2014214165A (ja) * | 2013-04-22 | 2014-11-17 | 富士通株式会社 | 接着剤による接着方法 |
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