JP2012053349A - Continuous roll and method and system for manufacturing liquid crystal display element - Google Patents

Abstract

A continuous roll that can be used in a roll-type laminating system and can prevent deformation of an optical film laminate, and a method and a system for manufacturing a liquid crystal display element.
SOLUTION: Continuous rolls R1 and R2 used in a roll laminating system in an environment having a temperature of 23 ± 5 ° C. and a humidity of 35 to 80% are drawn out of the optical film laminates F1 and F2 in the environment. Is adjusted so that the water content per 1 m ^{2 of the} optical film laminates F1 and F2 when starting the process is 7.8 g or less. This effectively prevents the moisture content of the optical film laminates F1 and F2 including the polarizing film from increasing and deforming until all of the optical film laminates F1 and F2 are drawn from the continuous rolls R1 and R2. be able to.
[Selection] Figure 2

Description

  The present invention is formed by winding a long optical film laminate in which an optical functional film including at least a polarizing film, an adhesive layer, and a carrier film are laminated in this order, and the optical film laminate is pulled out. The present invention also relates to a continuous roll for bonding the optical functional film to the surface of a liquid crystal panel via the adhesive layer, and a method and a system for manufacturing a liquid crystal display element.

  Conventionally, an optical functional film to be bonded to the surface of a liquid crystal panel is packed in a state in which the optical functional film is punched into a size corresponding to the liquid crystal panel in advance, and is transported from an optical functional film manufacturer to a panel processing manufacturer. In the case of an optical functional film including a polarizing film, the polarizing film is hygroscopic, so it is punched, degassed and packed in a relatively low humidity environment, and the optical functional film is opened just before being attached to the liquid crystal panel. By doing, it can prevent that the quality of a polarizing film deteriorates by the influence of external humidity. Moreover, in order to prevent a polarizing film from curling, adjusting the moisture content of a polarizing film is proposed (for example, patent document 1).

  On the other hand, as a method for producing a liquid crystal display element, by pulling out the optical film laminate from a continuous roll formed by winding a long optical film laminate including an optical functional film, and cutting it to a predetermined size A method of forming a single-wafer optical functional film and bonding the optical functional film to the surface of a liquid crystal panel has been proposed (for example, Patent Document 2). In such a roll-type laminating system, even if the continuous roll is delivered in a packed state, after the continuous roll is opened and set in the system, unless there are special circumstances, the continuous roll is optically Until the film laminate is pulled out, the continuous roll is used while being exposed to the outside air.

JP 2005-326531 A Japanese Patent Laid-Open No. 2007-140046

  In the roll-type bonding system as described above, the hygroscopic polarizing film is exposed to the outside air for a long time until the entire optical film laminate is drawn from the continuous roll. Therefore, there exists a problem that the moisture content of the optical film laminated body containing the said polarizing film increases and deform | transforms, and the quality of an optical functional film deteriorates.

  In the roll-type bonding system, the liquid crystal panel is transported through the system in which the continuous roll is set, and the optical functional film contained in the optical film laminate pulled out from the continuous roll is pasted on the liquid crystal panel in the system. Be matched. Since the liquid crystal panel may be damaged due to the influence of static electricity, it is desirable that the liquid crystal panel be transported in a humid environment. However, in such a wet environment system, the humidity around the continuous roll set in the system becomes high, so that the moisture content of the optical film laminate tends to increase, and the optical properties due to the deformation of the optical film laminate can be increased. There is a problem that the quality of the functional film is likely to deteriorate.

  Furthermore, in the optical film laminate wound in a roll shape, since both ends in the width direction are always exposed to the outside air, the polarizing film absorbs moisture contained in the outside air at both ends, and the both ends are It may be deformed into a wavy and wavy state. When the optical film laminate having both ends deformed in this way is bonded to a liquid crystal panel without cutting off both ends of the optical function film included in the optical film laminate, the optical function is applied to both ends. There is a problem that bubbles are easily generated between the film and the liquid crystal panel.

  The present invention has been made in view of the above circumstances, and is used in a roll-type laminating system, and is capable of preventing the optical film laminate from being deformed, and a method for producing a liquid crystal display element and An object is to provide a manufacturing system. Moreover, this invention is used with a roll-type bonding system, and provides a continuous roll which can bond an optical function film favorably with respect to a liquid crystal panel, and the manufacturing method and manufacturing system of a liquid crystal display element. Objective.

The continuous roll according to the present invention is formed by winding a long optical film laminate in which an optical functional film including at least a polarizing film, an adhesive layer, and a carrier film are laminated in this order, and the optical film A continuous roll for pulling out the laminate and bonding the optical functional film to the surface of the liquid crystal panel through the adhesive layer, and is used in an environment where the temperature is 23 ± 5 ° C. and the humidity is 35-80%. The moisture content per 1 m ^{2 of the} optical film laminate when starting to draw out the optical film laminate in the environment is adjusted to be 7.8 g or less.

According to the present invention, when the continuous roll used in the roll-type laminating system is started in the environment where the temperature is 23 ± 5 ° C. and the humidity is 35 to 80%, the drawing of the optical film laminate is started from the continuous roll. By adjusting the moisture content per 1 m ^{2 of the} optical film laminate to be 7.8 g or less, the moisture content of the optical film laminate including the polarizing film until the entire optical film laminate is drawn from the continuous roll. It is possible to effectively prevent the amount from increasing and deforming.

  Moreover, even when a continuous roll is used in a somewhat high range where the humidity is 80% or less, the optical film laminate can be prevented from being deformed. Therefore, even when the liquid crystal panel is transported in a wet environment, the optical film laminate can be effectively prevented from being deformed by the influence of the humidity.

The method for producing a liquid crystal display device according to the present invention is a method for producing a liquid crystal display device having a liquid crystal panel and an optical functional film bonded to the surface of the liquid crystal panel, and includes at least a polarizing film. And from the continuous roll formed by winding a long optical film laminate in which the adhesive layer and the carrier film are laminated in this order, the optical film laminate is pulled out via the adhesive layer. Including a bonding step of bonding the optical functional film to a surface of a liquid crystal panel, and the continuous roll is used in an environment having a temperature of 23 ± 5 ° C. and a humidity of 35 to 80%. It is characterized in that the water content of the optical film laminate 1 m ² per at the start of withdrawal of the laminate is adjusted to be equal to or less than 7.8g .

According to the present invention, when the continuous roll used in the roll-type laminating system is started in the environment where the temperature is 23 ± 5 ° C. and the humidity is 35 to 80%, the drawing of the optical film laminate is started from the continuous roll. By adjusting the moisture content per 1 m ^{2 of the} optical film laminate to be 7.8 g or less, the moisture content of the optical film laminate including the polarizing film until the entire optical film laminate is drawn from the continuous roll. It is possible to effectively prevent the amount from increasing and deforming.

  Moreover, even when a continuous roll is used in a somewhat high range where the humidity is 80% or less, the optical film laminate can be prevented from being deformed. Therefore, even when the liquid crystal panel is transported in a wet environment, the optical film laminate can be effectively prevented from being deformed by the influence of the humidity.

The continuous roll is preferably adjusted so that the amount of water per 1 m ^{2 of the} optical film laminate is 7.8 g or less after being stored for 12 hours or more in an environment where the humidity is 40% or less.

According to the present invention, the continuous roll is stored for 12 hours or more in an environment with a humidity of 40% or less, thereby sufficiently drying the optical film laminate wound in the form of a roll, per 1 m ^{2 of the} optical film laminate. The amount of water can be adjusted to 7.8 g or less. Thereby, it can prevent more effectively that an optical film laminated body deform | transforms.

  The continuous roll is formed by winding the optical film laminate obtained by slitting a long raw fabric into a width corresponding to the short side or the long side of the rectangular liquid crystal panel, Pulling out the optical film laminate from the continuous roll, cutting at least the optical functional film of the optical film laminate into a length corresponding to a long side or a short side of the liquid crystal panel, The optical functional film may be bonded to the surface of the liquid crystal panel.

  According to the present invention, an optical film laminate obtained by slitting a long original fabric into a width corresponding to a short side or a long side of a rectangular liquid crystal panel is pulled out from a continuous roll, and the optical film laminate is obtained. By cutting at least the optical functional film into a length corresponding to the long side or short side of the liquid crystal panel, an optical functional film having a shape corresponding to the liquid crystal panel is formed, and the optical functional film is formed on the surface of the liquid crystal panel. Can be pasted together. Thus, even when both ends of the optical functional film included in the optical film laminate are bonded to the liquid crystal panel without cutting off, the both ends can be prevented from being deformed. Can prevent bubbles from being generated between the optical functional film and the liquid crystal panel, and the optical functional film can be satisfactorily bonded to the liquid crystal panel.

  The continuous roll has the optical function, except for the carrier film, the optical film laminate obtained by slitting a long original fabric into a width corresponding to a short side or a long side of the rectangular liquid crystal panel. It is formed by winding the film and the adhesive layer in a state of being cut to a length corresponding to the long side or the short side of the liquid crystal panel, and pulling out the optical film laminate from the continuous roll, The optical functional film may be bonded to the surface of the liquid crystal panel via a layer.

  According to the present invention, an optical film laminate obtained by slitting a long original fabric into a width corresponding to a short side or a long side of a rectangular liquid crystal panel, except for the carrier film, the optical functional film. And by cutting the adhesive layer into a length corresponding to the long side or the short side of the liquid crystal panel, an optical functional film having a shape corresponding to the liquid crystal panel is formed, and the optical functional film is attached to the surface of the liquid crystal panel. Can be combined. Thus, even when both ends of the optical functional film included in the optical film laminate are bonded to the liquid crystal panel without cutting off, the both ends can be prevented from being deformed. Can prevent bubbles from being generated between the optical functional film and the liquid crystal panel, and the optical functional film can be satisfactorily bonded to the liquid crystal panel.

A liquid crystal display element manufacturing system according to the present invention is a liquid crystal display element manufacturing system having a liquid crystal panel and an optical functional film bonded to the surface of the liquid crystal panel, and includes at least a polarizing film. And from the continuous roll formed by winding a long optical film laminate in which the adhesive layer and the carrier film are laminated in this order, the optical film laminate is pulled out via the adhesive layer. Including a laminating apparatus for laminating the optical functional film to the surface of the liquid crystal panel, and the continuous roll is used in an environment having a temperature of 23 ± 5 ° C. and a humidity of 35 to 80%. that water content of the optical film laminate 1 m ² per at the start of withdrawal of the laminate is adjusted to be equal to or less than 7.8g And butterflies.

The continuous roll is preferably adjusted so that the amount of water per 1 m ^{2 of the} optical film laminate is 7.8 g or less after being stored for 12 hours or more in an environment where the humidity is 40% or less.

  The continuous roll is formed by winding the optical film laminate obtained by slitting a long raw fabric into a width corresponding to the short side or the long side of the rectangular liquid crystal panel, Pulling out the optical film laminate from the continuous roll, cutting at least the optical functional film of the optical film laminate into a length corresponding to a long side or a short side of the liquid crystal panel, The optical functional film may be bonded to the surface of the liquid crystal panel.

  The continuous roll has the optical function, except for the carrier film, the optical film laminate obtained by slitting a long original fabric into a width corresponding to a short side or a long side of the rectangular liquid crystal panel. It is formed by winding the film and the adhesive layer in a state of being cut to a length corresponding to the long side or the short side of the liquid crystal panel, and pulling out the optical film laminate from the continuous roll, The optical functional film may be bonded to the surface of the liquid crystal panel via a layer.

5 is a flowchart illustrating an example of a method for manufacturing a liquid crystal display element according to an embodiment of the present invention. It is the schematic plan view which showed an example of the manufacturing system of a liquid crystal display element. It is sectional drawing which showed an example of the aspect at the time of bonding an optical function film on a liquid crystal panel.

  One embodiment of the present invention will be described below. FIG. 1 is a flowchart showing an example of a method for manufacturing a liquid crystal display element according to an embodiment of the present invention. FIG. 2 is a schematic plan view showing an example of a liquid crystal display device manufacturing system.

(LCD panel)
The liquid crystal panel W used for the liquid crystal display element manufactured by this invention is a glass substrate unit by which the liquid crystal is arrange | positioned between a pair of glass substrates which oppose, for example. The liquid crystal panel W is formed in a rectangular shape, for example.

(Optical function film)
The optical function film used for the liquid crystal display element manufactured by this invention has a polarizing film. An adhesive layer for bonding to the liquid crystal panel W is formed on one surface of the optical functional film, and a carrier film for protecting the adhesive layer is provided. That is, the optical function film, the adhesive layer, and the carrier film are laminated in this order. Moreover, a surface protective film is provided on the other surface of the optical functional film via an adhesive layer. Hereinafter, an optical functional film in which a surface protective film and a carrier film are laminated may be referred to as an optical film laminate.

  FIG. 3 is a cross-sectional view showing an example of an aspect when the optical functional film is bonded to the liquid crystal panel W. In the present embodiment, the first optical film laminate F1 including the first optical functional film F11 bonded to one surface of the liquid crystal panel W and the second optical functional film F21 bonded to the other surface of the liquid crystal panel W are included. A second optical film laminate F2 is used. However, the present invention is not limited to the configuration in which the optical functional film is bonded to both surfaces of the liquid crystal panel W, but can also be applied to a configuration in which the optical functional film is bonded to only one surface of the liquid crystal panel W. .

  The first optical film laminate F1 has a structure in which a first optical functional film F11, a first carrier film F12, and a surface protective film F13 are laminated. In the present embodiment, the first optical functional film F11 has a polarizing film. The first optical function film F11 includes a first polarizer F11a, a first film F11b bonded to one surface of the first polarizer F11a via an adhesive layer (not shown), and an adhesive layer (not shown) on the other side. It is comprised with the 2nd film F11c bonded together. The first polarizer F11a is formed, for example, by stretching a polyvinyl alcohol (PVA) film. The first polarizer F11a may be formed using a film other than the polyvinyl alcohol film, but in the present invention, the first polarizer F11a is formed of a material having a moisture absorption rate of 10% or more. It is more effective. Here, the “moisture absorption rate” is a value when the saturated moisture absorption rate is measured at a temperature of 23 ° C. and a relative humidity of 45%.

  The first and second films F11b and F11c are, for example, protective films (for example, triacetyl cellulose film, PET film, etc.). The second film F11c is bonded to the liquid crystal panel W via the first adhesive layer F14. A surface treatment can be applied to the first film F11b. Examples of the surface treatment include a hard coat treatment, an antireflection treatment, a treatment for the purpose of prevention of sticking, diffusion or antiglare, and the like. The first carrier film F12 is bonded to the second film F11c via the first adhesive layer F14. Further, the surface protective film F13 is bonded to the first film F11b via the adhesive layer F15.

  Moreover, although the laminated structure of the 2nd optical film laminated body F2 is the structure similar to the 1st optical film laminated body F1, it is not limited to this. The second optical film laminate F2 has a structure in which a second optical functional film F21, a second carrier film F22, and a surface protective film F23 are laminated. In the present embodiment, the second optical functional film F21 has a polarizing film. The second optical functional film F21 includes a second polarizer F21a, a third film F21b bonded to one surface of the second polarizer F21a via an adhesive layer (not shown), and an adhesive layer (not shown) on the other side. It is comprised with the 4th film F21c bonded together. The second polarizer F21a is formed, for example, by drying a polyvinyl alcohol (PVA) film. The second polarizer F21a may be formed using a film other than the polyvinyl alcohol film. However, in the present invention, the second polarizer F21a is formed of a material having a moisture absorption rate of 10% or more. It is more effective.

  The third and fourth films F21b and F21c are, for example, protective films (for example, triacetyl cellulose film, PET film, etc.). The fourth film F21c is bonded to the liquid crystal panel W via the second adhesive layer F24. The third film F21b can be subjected to a surface treatment. Examples of the surface treatment include a hard coat treatment, an antireflection treatment, a treatment for the purpose of prevention of sticking, diffusion or antiglare, and the like. The second carrier film F22 is bonded to the fourth film F21c via the second adhesive layer F24. Further, the surface protective film F23 is bonded to the third film F21b via the adhesive layer F25.

(Manufacturing flowchart)
(1) First continuous roll preparation step (FIG. 1, S1). A first continuous roll R1 formed by winding a long first optical film laminate F1 into a roll is prepared. The width of the first continuous roll R1 depends on the bonding size of the liquid crystal panel W. That is, the first continuous roll R1 is formed by winding the first optical film laminate F1 having the first optical functional film F11 having a width corresponding to the short side or the long side of the liquid crystal panel W. More specifically, the first continuous roll R1 is a short side of the liquid crystal panel W formed of a long original fabric in which the first optical functional film F11, the first adhesive layer F14, and the first carrier film F12 are laminated in this order. Or it is formed by winding the elongate 1st optical film laminated body F1 obtained by slitting to the width | variety corresponding to a long side. It is preferable that the polarizing film contained in the said long original fabric is formed by extending | stretching along a longitudinal direction, and in this case, the absorption axis of a polarizing film is formed along a longitudinal direction. By slitting the long original fabric in parallel with the longitudinal direction, it is possible to form the first optical film laminate F1 in which the absorption axis extends accurately along the longitudinal direction. In the present embodiment, the first continuous roll R1 having a width corresponding to the short side of the liquid crystal panel W is used.

  (2) Transport process (FIG. 1, S2). The 1st conveyance apparatus 12 pays out the 1st optical film laminated body F1 from 1st continuous roll R1 prepared and installed, and conveys it downstream.

  (3) First inspection step (FIG. 1, S3). The first optical film laminate F1 is inspected for defects using the first defect inspection device 14. The defect inspection method here includes a method of photographing and processing images with transmitted light and reflected light on both surfaces of the first optical film laminate F1, and a polarizing film for inspection between the CCD camera and the inspection object. , A method of taking an image and processing an image by arranging it so that the absorption axis of the polarizing film to be inspected is crossed Nicols (sometimes referred to as 0 degree cross), and a polarizing film for inspection with a CCD camera and an inspection object. Between the absorption axis of the polarizing film to be inspected and a predetermined angle (for example, a range of greater than 0 degrees and within 10 degrees) (sometimes referred to as x-degree crossing). The method of processing is mentioned. As an image processing algorithm, for example, a defect can be detected by density determination by binarization processing.

  The defect information obtained by the first defect inspection device 14 is linked with the position information (for example, position coordinates), transmitted to the control device, and can contribute to the cutting method by the first cutting device 16. .

  (4) 1st cutting process (FIG. 1, S4). The 1st cutting device 16 cut | disconnects at least 1st optical function film F11 among the 1st optical film laminated bodies F1 pulled out from 1st continuous roll R1. In this example, without cutting the first carrier film F12, the first optical function film F11 bonded to the first carrier film F12 and the surface protection film bonded to the first optical function film F11. F13 is cut into a predetermined size. However, the configuration is not limited to such a configuration, and for example, a configuration in which the first optical film laminate F1 is completely cut to form the first optical film laminate F1 as a single wafer may be employed. Examples of the cutting means include a laser device and a cutter. It is preferable that the apparatus is configured to cut so as to avoid the defect based on the defect information obtained by the first defect inspection apparatus 14. Thereby, the yield of the 1st optical film laminated body F1 improves significantly. The first optical film laminate F1 including the defects is excluded by a first rejection device (not shown), and is not attached to the liquid crystal panel W. In the present embodiment, the first optical functional film F11 is cut at a length corresponding to the long side of the liquid crystal panel W, but the width of the first continuous roll R1 corresponds to the long side of the liquid crystal panel W. If it is, it may be cut at a length corresponding to the short side of the liquid crystal panel W.

  Each of the first continuous roll preparation step, the first inspection step, and the first cutting step is preferably a continuous production line. In the series of manufacturing steps described above, the cut first optical functional film F11 for bonding to one surface of the liquid crystal panel W is formed. Below, the process of forming the cut | disconnected 2nd optical function film F21 for bonding on the other surface of the liquid crystal panel W is demonstrated.

  (5) 2nd continuous roll preparation process (FIG. 1, S11). A second continuous roll R2 formed by winding the long second optical film laminate F2 into a roll is prepared. The width of the second continuous roll R2 depends on the bonding size of the liquid crystal panel W. That is, the second continuous roll R2 is formed by winding the second optical film laminate F2 having the second optical functional film F21 having a width corresponding to the long side or the short side of the liquid crystal panel W. More specifically, the second continuous roll R2 has a long original fabric in which the second optical functional film F21, the second adhesive layer F24, and the second carrier film F22 are laminated in this order on the long side of the liquid crystal panel W. Or it forms by winding the elongate 2nd optical film laminated body F2 obtained by slitting to the width | variety corresponding to a short side. It is preferable that the polarizing film contained in the said long original fabric is formed by extending | stretching along a longitudinal direction, and in this case, the absorption axis of a polarizing film is formed along a longitudinal direction. By slitting the long original fabric in parallel with the longitudinal direction, the second optical film laminate F2 in which the absorption axis extends with high accuracy along the longitudinal direction can be formed. The second continuous roll R2 is formed with a width different from that of the first continuous roll R1, for example. That is, when the first continuous roll R1 is formed with a width corresponding to the long side of the liquid crystal panel W, the second continuous roll R2 is formed with a width corresponding to the short side of the liquid crystal panel W. When one continuous roll R1 is formed with a width corresponding to the short side of the liquid crystal panel W, the second continuous roll R2 is formed with a width corresponding to the long side of the liquid crystal panel W. In the present embodiment, the second continuous roll R2 having a width corresponding to the long side of the liquid crystal panel W is used. In the present embodiment, “corresponding to the long side or short side of the liquid crystal panel W” means the length of bonding of the optical functional films F11 and F21 corresponding to the length of the long side or short side of the liquid crystal panel W ( The length of the liquid crystal panel W is not necessarily the same as the length of the optical function films F11 and F21.

  (6) Transfer process (FIG. 1, S12). The 2nd conveyance apparatus 22 pays out the 2nd optical film laminated body F2 from 2nd continuous roll R2 prepared and installed, and conveys it downstream.

  (7) Second inspection step (FIG. 1, S13). The second optical film laminate F <b> 2 is inspected for defects using the second defect inspection device 24. The defect inspection method here is the same as the method using the first defect inspection apparatus 14 described above. However, the first inspection step (S3) and the second inspection step (S13) can be omitted. In this case, the defect inspection of the first optical film laminate F1 and the second optical film laminate F2 is performed at the stage of producing the first continuous roll R1 and the second continuous roll R2, and the defects obtained by the defect inspection. The liquid crystal display element may be configured to be manufactured using the first continuous roll R1 and the second continuous roll R2 to which the information is attached.

  (8) 2nd cutting process (FIG. 1, S14). The 2nd cutting device 26 cut | disconnects at least 2nd optical function film F21 among the 2nd optical film laminated bodies F2 pulled out from 2nd continuous roll R2. In this example, without cutting the second carrier film F22, the second optical function film F21 bonded to the second carrier film F22 and the surface protection film bonded to the second optical function film F21. F23 is cut into a predetermined size. However, the configuration is not limited to such a configuration, and for example, a configuration in which the second optical film stack F2 is completely cut to form a single-layer second optical film stack F2 may be used. Examples of the cutting means include a laser device and a cutter. Based on the defect information obtained by the second defect inspection apparatus 24, it is preferable to be configured to cut so as to avoid the defect. Thereby, the yield of 2nd optical film laminated body F2 improves significantly. The 2nd optical film laminated body F2 containing a fault is excluded by the 2nd exclusion apparatus (not shown), and it is comprised so that it may not affix on the liquid crystal panel W. FIG. In the present embodiment, the second optical functional film F21 is cut at a length corresponding to the short side of the liquid crystal panel W, but the width of the second continuous roll R2 corresponds to the short side of the liquid crystal panel W. If it is, it may be cut at a length corresponding to the long side of the liquid crystal panel W.

  The process of conveying the liquid crystal panel W is performed in parallel with the process of forming the cut first optical function film F11 and the second optical function film F21 as described above. The following processing is performed on the liquid crystal panel W during the conveyance.

  (9) Cleaning step (FIG. 1, S6). The surface of the liquid crystal panel W is cleaned by polishing cleaning, water cleaning, or the like.

  (10) 1st optical function film bonding process (FIG. 1, S5). The cut first optical functional film F11 is bonded to one surface of the liquid crystal panel W by the first bonding device 18 via the adhesive layer F14 while the first carrier film F12 is peeled off. At the time of bonding, the first optical function film F11 and the liquid crystal panel W are sandwiched between a pair of rolls facing each other and pressure bonded.

  (11) 2nd optical function film bonding process (FIG. 1, S15). The cut second optical functional film F21 is bonded to the other surface of the liquid crystal panel W through the adhesive layer F24 by the second bonding device 28 while the second carrier film F22 is peeled off. At the time of bonding, the second optical function film F21 and the liquid crystal panel W are sandwiched between a pair of rolls facing each other and pressure bonded. Before the second optical function film F21 is bonded to the liquid crystal panel W, the first optical function film F11 is pasted so that the first optical function film F11 and the second optical function film F21 have a crossed Nicols relationship. The aligned liquid crystal panel W is rotated 90 degrees by the turning mechanism 20. However, the configuration is not limited to the configuration in which the liquid crystal panel W is rotated by 90 degrees, and the first optical film laminate F1 and the second optical film laminate F2 may be transported in directions orthogonal to each other. The first optical functional film F11 and the second optical functional film F21 can be in a crossed Nicols relationship.

  (12) Liquid crystal panel inspection process (FIG. 1, S16). The liquid crystal panel W having the optical functional films F11 and F21 attached to both surfaces is inspected by an inspection device. Examples of the inspection method include a method of capturing an image and processing an image using transmitted light and reflected light on both surfaces of the liquid crystal panel W. As another method, a method of installing a polarizing film for inspection between the CCD camera and the inspection object is also exemplified. As an image processing algorithm, for example, a defect can be detected by density determination by binarization processing.

  (13) Non-defective product determination of the liquid crystal panel W is performed based on the defect information obtained by the inspection apparatus. The liquid crystal panel W determined to be non-defective is conveyed to the next mounting process. When a defective product is determined, a rework process is performed, and optical function films F11 and F21 are newly applied and then inspected. If a good product is determined, the process proceeds to a mounting process. If a defective product is determined, the rework process is performed again. Migrated or disposed of.

  In the above series of manufacturing steps, the liquid crystal display element can be preferably manufactured by making the bonding step of the first optical functional film F11 and the bonding step of the second optical functional film F21 into a continuous production line. it can.

  In the first and second cutting steps, the method (half-cut method) for cutting other members of the optical film laminates F1 and F2 without cutting the carrier films F12 and F22 has been described. However, without being limited to such a configuration, for example, it is also possible to use a half-cut continuous roll in which members other than the carrier films F12 and F22 in the optical film laminates F1 and F2 are cut in advance. In this case, the continuous roll is obtained by slitting the long optical film laminates F1 and F2 obtained by slitting the long original fabric into a width corresponding to the short side or the long side of the rectangular liquid crystal panel W. The optical functional films F11 and F21 and the adhesive layers F14 and F24 except for F12 and F22 are formed by winding in a state of being cut to a length corresponding to the long side or the short side of the liquid crystal panel W. The optical film laminates F1 and F2 are pulled out from such a continuous roll, and the optical functional films F11 and F21 are bonded to the surface of the liquid crystal panel W through the adhesive layers F14 and F24 while peeling the carrier films F12 and F22. Thereby, a liquid crystal display element can be manufactured. Further, the configuration is not limited to the configuration in which the optical functional films F11 and F21 are bonded after being cut, and may be a configuration in which the optical functional films F11 and F21 are cut during or after bonding.

  In the present embodiment, the first optical functional film F11 is bonded to the liquid crystal panel W from above, and the second optical functional film F21 is bonded to the liquid crystal panel W from below. However, the first optical functional film F11 may be bonded to the liquid crystal panel W from below, and the second optical functional film F21 may be bonded to the liquid crystal panel W from above. In addition, when a mechanism for vertically flipping the liquid crystal panel W after the first optical functional film F11 is bonded is provided, both the first optical functional film F11 and the second optical functional film F21 are liquid crystals from the same direction. It is also possible to adopt a configuration that can be attached to the panel W. In the case of providing a mechanism for turning the liquid crystal panel W upside down, a vertical turning mechanism may be provided separately from the turning mechanism 20 for rotating the liquid crystal panel W by 90 degrees, or while turning the liquid crystal panel W upside down. A mechanism that rotates 90 degrees may be provided.

  In the roll type bonding system as described above, the hygroscopic polarizing film is exposed to the outside air for a long time until the optical film laminates F1 and F2 are all drawn out from the continuous rolls R1 and R2. Specifically, the length of the optical film laminates F1 and F2 is preferably 3000 to 15000 m, for example, and is preferably conveyed at a speed of 2 to 10 m / min, for example. The time until all the optical film laminates F1 and F2 are drawn from the continuous rolls R1 and R2 is at least 20 hours, preferably 25 hours or more, more preferably 30 hours or more. When the polarizing film is exposed to the outside air for such a long time, the moisture content of the optical film laminates F1 and F2 including the polarizing film is increased and deformed, and the quality of the optical functional films F11 and F21 is deteriorated. There is a problem.

  Further, as shown in FIG. 2, in the roll-type laminating system, the liquid crystal panel W is transported through the system in which the continuous rolls R1, R2 are set, and the optical film laminate F1, drawn out from the continuous rolls R1, R2. Optical functional films F11 and F21 included in F2 are bonded to the liquid crystal panel W in the system. The system is preferably provided inside the partition wall structure D (for example, a clean room), which allows the optical functional films F11 and F21 to be bonded to the liquid crystal panel W in an environment in which cleanliness is ensured. The liquid crystal display element can be manufactured.

  Since the liquid crystal panel W may be damaged due to the influence of static electricity, it is preferable to transport the liquid crystal panel W in a wet environment. Therefore, in this embodiment, the temperature inside the partition wall structure D is 23 ± 5 ° C. and the humidity is 35 to 80%, so that the liquid crystal panel W is not transported in a dry environment. However, even if the partition structure D is not provided, the area where the liquid crystal panel W is transported can be the environment.

  However, in the system as described above, since the humidity around the continuous rolls R1 and R2 set in the system becomes high, the moisture content of the optical film laminates F1 and F2 is likely to increase, and the optical film laminate There is a problem that the quality of the optical functional films F11 and F21 is likely to deteriorate due to the deformation of F1 and F2.

  Further, in the optical film laminates F1 and F2 wound in a roll shape, since both ends in the width direction are always exposed to the outside air, the polarizing film absorbs moisture contained in the outside air at the both ends, and There is a case where both ends are undulated and deformed into a wavy state. Using the optical film laminates F1 and F2 whose both ends are deformed in this way, the both ends of the optical functional films F11 and F21 included in the optical film laminates F1 and F2 are bonded to the liquid crystal panel W without being cut off. In this case, there is a problem that bubbles are likely to be generated between the optical function films F11 and F21 and the liquid crystal panel W at both ends.

The following reason can be considered about the problem of bubble generation as described above. That is, in the optical film laminates F1 and F2 wound in a roll shape, moisture contained in the outside air is absorbed only from the surface at the center in the width direction, whereas both the surface and the end surface are absorbed at both ends in the width direction. To absorb moisture. Therefore, the amount of moisture absorption at both ends in the width direction of the optical film laminates F1 and F2 is larger than that in the center portion in the width direction. Thereby, the expansion coefficient of the width direction both ends of optical film laminated body F1, F2 becomes large, and as a result that a wave | undulation generate | occur | produces in both ends by the area difference, it is thought that a bubble generate | occur | produces in the said both ends at the time of bonding. .

The expansion of the polarizing film is largely due to moisture absorption by the polarizers F11a and F21a formed of PVA or the like. Some moisture absorption always occurs according to changes in the external environment, such as when the continuous rolls R1 and R2 are moved and slit, and the widthwise center and both ends of the continuous rolls R1 and R2 as described above gradually. The difference in moisture absorption will occur. When the continuous rolls R1 and R2 are set in the roll-type laminating system from that state, further moisture absorption occurs from both ends of the continuous rolls R1 and R2, and undulation is likely to occur at both ends. On the other hand, when the continuous rolls R1 and R2 have a low moisture content when set in the roll-type laminating system, the width direction central part and both end parts of the continuous rolls R1 and R2 generated in each process or in the transport path Can be forcibly eliminated (or because there is a time allowance to reach the amount of water in which undulation occurs), so that the continuous rolls R1, R2 can be used over the entire manufacturing time of the liquid crystal display element. It is presumed that undulation can be prevented from occurring at both ends in the width direction.

Further, the polarizers F11a and F21a formed of PVA or the like have a property of easily absorbing moisture once the moisture absorption starts in the initial stage of moisture absorption. For this reason, the continuous rolls R1 and R2 having a larger initial moisture content tend to absorb moisture later. That is, it is presumed that the continuous rolls R1 and R2 having a larger initial moisture content are more likely to absorb moisture at both ends in the width direction, and the difference in moisture absorption between the center portion and both ends in the width direction becomes remarkable.

  The roll type laminating system is one of the purposes of laminating the same kind of optical functional films F11 and F21 to the liquid crystal panel W at a high speed, so the continuous production time per batch is better. Swelling may occur due to moisture absorption behavior during the manufacturing time.

Therefore, in the present embodiment, the continuous rolls R1 and R2 used in the roll-type laminating system in an environment where the temperature is 23 ± 5 ° C. and the humidity is 35 to 80% are used as the optical film laminate F1, the water content of 1 m ² per of the optical film laminate F1, F2 at the start of the withdrawal of F2 is adjusted to be equal to or less than 7.8 g. This effectively prevents the moisture content of the optical film laminates F1 and F2 including the polarizing film from increasing and deforming until all of the optical film laminates F1 and F2 are drawn from the continuous rolls R1 and R2. be able to.

  Moreover, even when the continuous rolls R1 and R2 are used within a relatively high humidity range of 80% or less, the optical film laminates F1 and F2 can be prevented from being deformed. Therefore, even when the liquid crystal panel W is transported in a wet environment, the optical film laminates F1 and F2 can be effectively prevented from being deformed due to the influence of the humidity.

When producing continuous rolls R1 and R2 that exhibit the above effects, for example, through a process of storing for 12 hours or more in an environment with a humidity of 40% or less, per 1 m ^{2 of} optical film laminates F1 and F2 The amount of water is adjusted to 7.8 g or less. By storing the continuous rolls R1 and R2 for 12 hours or more in an environment with a humidity of 40% or less, the optical film laminates F1 and F2 wound in a roll are sufficiently dried, and the optical film laminates F1 and F2 The amount of water per 1 m ² can be adjusted to be 7.8 g or less. Thereby, it can prevent more effectively that optical film laminated body F1, F2 deform | transforms. The storage step is more preferably performed in a room conditioned at a temperature of 20 to 25 ° C. and a humidity of 18 to 30%.

In this embodiment, the optical functional films F11 and F21 included in the optical film laminates F1 and F2 are bonded to the liquid crystal panel W without cutting off both ends in the width direction. Even so, the deformation of both ends can be prevented, so that bubbles can be prevented from being generated between the optical function films F11 and F21 and the liquid crystal panel W at the both ends. In contrast, the optical functional films F11 and F21 can be satisfactorily bonded.

In the following, a liquid crystal display element is manufactured with a roll-type laminating system using a plurality of continuous rolls having different initial moisture amounts, and an abnormality occurs in the liquid crystal display element due to waviness occurring at both widthwise ends of each continuous roll. The results of measuring time will be described. The said measurement was performed by installing a continuous roll in the environment whose temperature is 25 degreeC, and humidity 70%, and manufacturing a liquid crystal display element with the above-mentioned roll-type bonding system using the said continuous roll. As the continuous roll, VEGQ1724DU150T manufactured by Nitto Denko Corporation is used, the optical functional film is not cut in advance, and the optical film laminate is cut in the liquid crystal display element manufacturing process. A half-cut continuous roll (raw material with cuts) in which members other than the carrier film were cut in advance was prepared.

About the initial moisture content of each continuous roll, the weight is measured in a state where a 500 cm ² region is sampled in the central portion in the width direction of each continuous roll immediately before being set in the roll-type bonding system, and the carrier film and the surface protection film are peeled off. After being measured, it was put into an oven at 120 ° C. for 2 hours and dried, and the difference in weight before and after drying was measured as the amount of moisture. Such measurement of the amount of water was performed five times for each continuous roll, and the average value was used as the initial amount of water for each continuous roll.

About the abnormality of the liquid crystal display element manufactured using each continuous roll, 300 liquid crystal display elements are manufactured using each continuous roll, and the manufacturing time when the defective rate obtained by taking the moving average exceeds 1% is calculated. Measurements were made in 0.5 hour increments. The time until the entire optical film laminate was pulled out from the continuous roll was set to 30 hours at maximum, and it was determined whether or not it could withstand 30 hours of production.

Table 1 shows the measurement results using the raw material without cuts.

Table 2 shows the measurement results using the cut raw material.

From the measurement results as described above, it is presumed that, in both the raw material without cuts and the raw material with cuts, if the initial moisture content is 7.8 g / m ² or less, it can withstand 30 hours of production.

DESCRIPTION OF SYMBOLS 12 1st conveying apparatus 14 1st fault inspection apparatus 16 1st cutting apparatus 18 1st bonding apparatus 20 turning mechanism 22 2nd conveying apparatus 24 2nd defect inspection apparatus 26 2nd cutting apparatus 28 2nd bonding apparatus F1 1st Optical film laminate F11 First optical functional film F12 First carrier film F2 Second optical film laminated body F21 Second optical functional film F22 Second carrier film R1 First continuous roll R2 Second continuous roll W Liquid crystal panel

Claims (9)

An optical functional film including at least a polarizing film, an adhesive layer, and a carrier film are formed by winding a long optical film laminate, and the optical film laminate is drawn out to form the adhesive A continuous roll for laminating the optical functional film to the surface of the liquid crystal panel through a layer,
It is used in an environment where the temperature is 23 ± 5 ° C. and the humidity is 35 to 80%, and the amount of water per 1 m ^{2 of the} optical film laminate when starting to draw out the optical film laminate in the environment is 7. It is adjusted so that it may become 8 g or less, The continuous roll characterized by the above-mentioned. A method for producing a liquid crystal display element having a liquid crystal panel and an optical functional film bonded to the surface of the liquid crystal panel,
The optical film laminate is drawn from a continuous roll formed by winding a long optical film laminate in which an optical functional film including at least a polarizing film, an adhesive layer, and a carrier film are laminated in this order. Including a bonding step of bonding the optical functional film to the surface of the liquid crystal panel via the adhesive layer,
The continuous roll is used in an environment having a temperature of 23 ± 5 ° C. and a humidity of 35 to 80%, and per 1 m ^{2 of the} optical film laminate when starting to draw out the optical film laminate in the environment. A method for producing a liquid crystal display element, wherein the water content is adjusted to 7.8 g or less. The continuous roll is adjusted so that the water content per 1 m ^{2 of the} optical film laminate is 7.8 g or less after being stored for 12 hours or more in an environment of humidity 40% or less. The manufacturing method of the liquid crystal display element of Claim 2. The continuous roll is formed by winding the optical film laminate obtained by slitting a long raw fabric into a width corresponding to the short side or the long side of the rectangular liquid crystal panel,
Pulling out the optical film laminate from the continuous roll, cutting at least the optical functional film of the optical film laminate into a length corresponding to a long side or a short side of the liquid crystal panel, The method for producing a liquid crystal display element according to claim 2, wherein the optical functional film is bonded to the surface of the liquid crystal panel. The continuous roll has the optical function, except for the carrier film, the optical film laminate obtained by slitting a long original fabric into a width corresponding to a short side or a long side of the rectangular liquid crystal panel. It is formed by winding the film and the adhesive layer in a state of being cut into a length corresponding to the long side or the short side of the liquid crystal panel,
4. The method of manufacturing a liquid crystal display element according to claim 2, wherein the optical film laminate is pulled out from the continuous roll, and the optical functional film is bonded to the surface of the liquid crystal panel through the adhesive layer. . A liquid crystal display device manufacturing system having a liquid crystal panel and an optical functional film bonded to the surface of the liquid crystal panel,
The optical film laminate is drawn from a continuous roll formed by winding a long optical film laminate in which an optical functional film including at least a polarizing film, an adhesive layer, and a carrier film are laminated in this order. Including a bonding apparatus for bonding the optical functional film to the surface of the liquid crystal panel via the adhesive layer,
The continuous roll is used in an environment having a temperature of 23 ± 5 ° C. and a humidity of 35 to 80%, and per 1 m ^{2 of the} optical film laminate when starting to draw out the optical film laminate in the environment. A liquid crystal display device manufacturing system, wherein the moisture content is adjusted to 7.8 g or less. The continuous roll is adjusted so that the water content per 1 m ^{2 of the} optical film laminate is 7.8 g or less after being stored for 12 hours or more in an environment of humidity 40% or less. The manufacturing system of the liquid crystal display element of Claim 6. The continuous roll is formed by winding the optical film laminate obtained by slitting a long raw fabric into a width corresponding to the short side or the long side of the rectangular liquid crystal panel,
Pulling out the optical film laminate from the continuous roll, cutting at least the optical functional film of the optical film laminate into a length corresponding to a long side or a short side of the liquid crystal panel, The system for manufacturing a liquid crystal display element according to claim 6, wherein the optical functional film is bonded to a surface of the liquid crystal panel. The continuous roll has the optical function, except for the carrier film, the optical film laminate obtained by slitting a long original fabric into a width corresponding to a short side or a long side of the rectangular liquid crystal panel. It is formed by winding the film and the adhesive layer in a state of being cut into a length corresponding to the long side or the short side of the liquid crystal panel,
The system for producing a liquid crystal display element according to claim 6 or 7, wherein the optical film laminate is pulled out from the continuous roll, and the optical functional film is bonded to the surface of the liquid crystal panel via the adhesive layer. .

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