TWI762592B - Defect inspection system, film manufacturing apparatus, film manufacturing method, printing apparatus and printing method - Google Patents

Abstract

An objective of the present invention is to provide a defect inspection system capable of reducing the influence of fluttering occurring in a film being conveyed and appropriately recording defect information on the film. A defect inspection system includes a conveying line for conveying a long strip-shaped film, a defect inspection device for inspecting defect inspection of the film being conveyed by the conveying line, and a recording device 13 for recording defect information based on the result of the defect inspection on the film F105 being conveyed by the conveying line, wherein the recording device 13 has a printing head 13a for printing defect information by ejecting ink i on a recording area along an edge portion of the film F105, and the printing head 13a is disposed to face a guide roller 153c which is in contact with the film F105.

Description

Defect inspection system, film manufacturing apparatus, film manufacturing method, printing apparatus, and printing method

The present invention relates to a defect inspection system, a film manufacturing apparatus, a film manufacturing method, a printing apparatus, and a printing method.

For example, an optical film such as a polarizing plate is wound around a core material after being inspected for defects such as foreign matter defects and concave-convex defects. Information related to the position and type of defects (hereinafter referred to as defect information) is recorded on the optical film by printing a barcode on the end of the optical film or printing a mark on the defect site. When the winding amount of the optical film wound around the core material reaches a certain amount, it is cut from the optical film from the upstream side and shipped as a roll of the optical film. For example, Patent Document 1 discloses a defect inspection system in which a defect inspection device and a recording device for recording defect information on the film are provided on a conveyance line of an optical film.

[Prior Art Literature] [Patent Literature]

[Patent Document 1] Japanese Patent Laid-Open No. 2011-7779

However, in the above-mentioned defect inspection system, when the defect information is recorded on the optical film, the optical film during conveyance may jump depending on the state of the optical film, conveyance conditions, and the like. If the optical film jumps like this, the defect information printed by the ink ejected from the printing head will not be correctly recorded in the recording area along the edge of the optical film, and the printing will not be clear. (typographical error).

The present invention has been made in view of the above-mentioned conventional problems, and an object of the present invention is to provide a defect inspection system capable of appropriately recording defect information on the film while reducing the influence of the slaps that occur in the film being conveyed. , Film manufacturing apparatus, film manufacturing method, printing apparatus and printing method.

As means for solving the above-mentioned problems, according to an aspect of the present invention, there is provided a defect inspection system including: a conveying line for conveying a long-belt-shaped film; and a defect inspection device for inspecting defects of the film conveyed on the conveying line inspection; and a recording device for recording the defect information obtained based on the result of the defect inspection on the film conveyed on the conveying line, wherein the recording device has a printing head, and the printing head prints the defect information along the edge In the recording area of the edge portion of the film, the print head is arranged to face the guide roller in contact with the film, and prints are performed from the side opposite to the side where the film is in contact with the guide roller.

In the defect inspection system of the aforementioned aspect, the film may be wound around the outer peripheral surface of the guide roller at an angle ranging from 40° to 130°.

In the defect inspection system of the above aspect, the printing head may be configured to print the defect information by ejecting ink to the recording area of the film.

In the defect inspection system of the aforementioned aspect, the recording device may have a cover configured to prevent ink from adhering to at least an area of the film that is closer to the inner side than the recording area.

The defect inspection system of the above-described aspect may include a static electricity removing device for removing static electricity from the surface of the film at a position upstream of the recording device in the film conveying direction.

Furthermore, according to an aspect of the present invention, there is provided a film manufacturing apparatus including the defect inspection system of any one of the aforementioned aspects.

Moreover, according to the aspect of this invention, there is provided the film manufacturing method which includes the process of performing a defect inspection using the defect inspection system of any one of the above-mentioned aspects.

Further, according to an aspect of the present invention, there is provided a printing apparatus including a printing head for printing information on the film while conveying a long strip-shaped film, and the printing head is in contact with a guide that is in contact with the film. The rolls are arranged to face each other, and printing is performed from the opposite side of the position where the film and the guide roll are in contact with each other.

Further, according to an aspect of the present invention, there is provided a printing method comprising the step of printing information on the film using a printing head while conveying a long strip-shaped film, wherein the printing head and the film are made to The guide rollers in contact are arranged to face each other, and printing is performed from the opposite side of the position where the film and the guide roller are in contact.

As described above, according to the aspect of the present invention, it is possible to provide a defect inspection system, a film manufacturing apparatus, a film manufacturing apparatus, a defect inspection system, a film production apparatus, a film production apparatus, a defect inspection system, a film production apparatus, a film production apparatus, a defect inspection system, a film production apparatus, a film production apparatus, a defect inspection system, a film production apparatus, and a Film manufacturing method, printing device and printing method.

10‧‧‧Defect Inspection System

11‧‧‧First Defect Inspection Device

12‧‧‧Second defect inspection device

13‧‧‧Recording device

13a‧‧‧Print head

14‧‧‧First Length Gauge

15‧‧‧Second length measuring device

16‧‧‧Control device

21a, 22a, 23a, 24a, 25a‧‧‧Lighting

21b, 22b, 23b, 24b, 25b‧‧‧Light detection part

30‧‧‧Cover

30a‧‧‧First side plate

30b‧‧‧Second side plate

30c‧‧‧The third side plate

30d‧‧‧The fourth side plate

31‧‧‧Covering

32‧‧‧covering

32a‧‧‧Window

40‧‧‧Static removal device

100‧‧‧Membrane manufacturing equipment

101‧‧‧First transfer line

102‧‧‧Second transfer line

103‧‧‧The third transfer line

104‧‧‧The fourth conveying line

105‧‧‧Fifth transfer line

106‧‧‧Coiler

111a, 111b‧‧‧First nip roll

112‧‧‧First accumulator

112a, 112b‧‧‧First Tensioner Roller

113‧‧‧First guide roller

121a, 121b‧‧‧Second nip roll

122‧‧‧Second accumulator

122a, 122b‧‧‧Second tensioning roller

123a, 123b‧‧‧Second guide roller

131a, 131b‧‧‧The third nip roll

141a, 141b‧‧‧The fourth nip roll

142‧‧‧Third accumulator

142a, 142b‧‧‧The third dancer roller

143a, 143b‧‧‧The fourth guide roller

151a, 151b‧‧‧Fifth nip roll

152‧‧‧Fourth accumulator

152a, 152b‧‧‧The fourth dancer roller

153a‧‧‧Fifth guide roller

153b‧‧‧Sixth guide roller

153c‧‧‧Seventh guide roller

P‧‧‧LCD panel (optical display device)

F1X‧‧‧Optical Film

F10X‧‧‧Optical Film

F101‧‧‧First Film

F102‧‧‧Second film

F103‧‧‧Third film

F104‧‧‧Single-sided lamination film

F105‧‧‧Double-sided lamination film

FIG. 1 is a plan view showing an example of a liquid crystal display panel.

FIG. 2 is a cross-sectional view of the liquid crystal display panel shown in FIG. 1 .

Fig. 3 is a cross-sectional view showing an example of an optical film.

FIG. 4 is a side view showing the configuration of a film manufacturing apparatus and a defect inspection system.

Fig. 5 is a side view showing an example of a recording device.

Fig. 6 shows an example of the mask, Fig. 6(a) is a plan view of the mask as seen from the upper side of the film, Fig. 6(b) is a side view of the mask as seen from the upstream side of the film, and Fig. 6 ( c) is a side view of the mask as seen from the outside of the membrane.

Fig. 7 is a plan view showing a modification of the mask.

Fig. 8 shows a modification of the cover, Fig. 8(a) is a perspective view of the cover, and Fig. 8(b) is a side view of the cover.

Fig. 9 shows another embodiment of the cover, Fig. 9(a) is a plan view of the cover, and Fig. 9(b) is a side view of the cover.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

In the present embodiment, a film manufacturing apparatus constituting a part of a production system of an optical display device, and a film manufacturing method using the film manufacturing apparatus will be described.

The film manufacturing apparatus manufactures, for example, a polarizing film, a retardation film, a brightness enhancement film, etc., for lamination on a panel-shaped optical display element (optical display panel) such as a liquid crystal display panel (panel) and an organic EL display panel (optical display panel). A device for film-like optical components (optical films). The film manufacturing apparatus constitutes a part of a production system for producing an optical display device including such an optical display element and optical components.

In this embodiment, a transmissive liquid crystal display device will be described as an example of an optical display device. A transmissive liquid crystal display device generally includes a liquid crystal display panel and a backlight. In this liquid crystal display device, the illumination light emitted from the backlight is incident from the back side of the liquid crystal display panel, and the light modulated by the liquid crystal display panel is emitted from the front side of the liquid crystal display panel to display an image.

(optical display device)

First, the configuration of the liquid crystal display panel P shown in FIGS. 1 and 2 will be described with respect to an optical display device. FIG. 1 is a plan view showing the configuration of the liquid crystal display panel P. As shown in FIG. Fig. 2 is a cross-sectional view of the liquid crystal display panel P taken along the section line A-A shown in Fig. 1 . In Fig. 2, the hatched line showing the cross section is omitted.

As shown in FIGS. 1 and 2, the liquid crystal display panel P generally includes a first substrate P1, a second substrate P2 arranged opposite to the first substrate P1, and a second substrate P2 arranged between the first substrate P1 and the second substrate P2 the liquid crystal layer P3.

The first substrate P1 is formed of a transparent substrate having a rectangular shape in plan view. The second substrate P2 is formed of a rectangular transparent substrate smaller than the first substrate P1. The periphery between the 1st board|substrate P1 and the 2nd board|substrate P2 is sealed with the sealing material (not shown), and the liquid crystal layer P3 is arrange|positioned inside the area|region which is rectangular in plan view surrounded by the sealing material. In the liquid crystal display panel P, the area limited to the inner side of the outer periphery of the liquid crystal layer P3 in plan view is the display area P4, and the area surrounding the outer periphery of the display area P4 is the frame edge portion G.

On the back surface (backlight side) of the liquid crystal display panel P, the first film F11 as a polarizing film is bonded. On the surface (display surface side) of the liquid crystal display panel P, the second film F12 as a polarizing film and the third film F13 as a brightness enhancement film are laminated and bonded on the second film F12. Hereinafter, the first film, the second film, and the third film F11, F12, and F13 are collectively referred to as the optical film F1X.

(optical film)

Next, an example of the optical sheet FX which comprises the optical film F1X shown in FIG. 3 is demonstrated. Fig. 3 is a cross-sectional view showing the structure of the optical sheet FX. In Fig. 3, the hatched line showing the cross section is omitted.

The optical film F1X is obtained by cutting out a piece (chip) of a predetermined length from the long-belt-shaped optical sheet (roll) FX shown in FIG. 3 . Specifically, this optical sheet FX has a base material sheet F4, an adhesive layer F5 provided on one side of the base sheet F4 (upper side in FIG. 3 ), and provided on the base sheet through the adhesive layer F5 A separator sheet (separator sheet) F6 on one surface of F4, and a surface protection sheet F7 provided on the other surface (lower surface in FIG. 3 ) of the base sheet F4.

In the case of a polarizing film, for example, the base sheet F4 has a structure in which a polarizer F4a is sandwiched between a pair of protective films F4b and F4c. The adhesive layer F5 is a layer for adhering the optical sheet (optical film F1X) on the liquid crystal display panel P. As shown in FIG. The separator F6 is a film which protects the adhesive layer F5, and is peeled off from the adhesive layer F5 before sticking the optical sheet (optical film F1X) to the liquid crystal display panel P. As shown in FIG. Hereinafter, the part where the optical film F1X of the separator F6 has been torn off is referred to as a bonding sheet F8. The surface protection sheet F7 is a film for protecting the surface of the base material sheet F4, and the surface protection sheet F7 is peeled from the surface of the optical sheet (optical film F1X) after the optical sheet (optical film F1X) has been pasted to the liquid crystal display panel P .

In the aspect of the base material sheet F4, it is possible to omit either one of the pair of protective films F4b and F4c. For example, the protective film F4b on the side of the adhesive layer F5 may be omitted, and the adhesive layer F5 may be directly provided on the polarizer F4a. In addition, the protective film F4c on the surface protective sheet F7 side may be subjected to, for example, a hard coating treatment for protecting the outermost surface of the liquid crystal display panel P, an antiglare treatment for obtaining an antiglare effect, or the like. Surface treatment. In addition, the base material sheet F4 is not limited to the above-mentioned laminated structure sheet, and may be a single-layer structure sheet. In addition, the surface protection sheet F7 can also be abbreviate|omitted.

(Film manufacturing apparatus and film manufacturing method)

Next, the film manufacturing apparatus 100 shown in FIG. 4 is demonstrated. FIG. 4 is a side view showing the configuration of the film manufacturing apparatus 100 .

The film manufacturing apparatus 100 is, as shown in FIG. 4 , for example, after sticking a long strip-shaped second film F102 as a surface protection film on one side of a long strip-shaped first film F101 as a polarizing film, and then on the first film The other side of F101 is bonded to the long strip-shaped third film F103 as a surface protection film, and a device in which the optical film F10X of the second film F102 and the third film F103 is bonded to both sides of the first film F101 is manufactured in this way.

Specifically, this film manufacturing apparatus 100 is roughly equipped with the 1st conveyance line 101, the 2nd conveyance line 102, the 3rd conveyance line 103, the 4th conveyance line 104, the 5th conveyance line 105, and the winding part 106.

Among them, the first conveyance line 101 forms a conveyance path for conveying the first film F101, the second conveyance line 102 forms a conveyance path for conveying the second film F102 drawn from the first reel R1, and the third conveyance line 103 forms The conveyance path of the single-sided bonding film F104 after laminating the second film F102 on one side of the first film F101 is conveyed, and the fourth conveyance line 104 forms a conveyance path for conveying the third film F103 drawn from the second roll R2 The fifth conveyance line 105 is formed to convey the double-sided lamination film F105 (optical film F10X) after laminating the third film F103 on the surface of the single-sided lamination film F104 on the first film F101 side (the other side of the first film F101). ) of the transport path. The manufactured optical film F10X is wound around the core material in the winding part 106, and becomes the 3rd roll R3.

The first conveying line 101 applies dyeing treatment, cross-linking treatment, stretching treatment, etc. to a film such as PVA (Polyvinyl Alcohol), which is a base material of a polarizer, and then sticks TAC (three) on both sides of the film. The long-belt-shaped 1st film F101 obtained by the protective film, such as cellulose acetate: Triacetylcellulose), is conveyed to the 3rd conveyance line 103.

Specifically, on the first conveyance line 101, a pair of first nip rollers ( nip rollers) 111a, 111b, a first accumulator 112 including a plurality of first dancer rollers 112a, 112b, and a first guide roller 113.

A pair of 1st nip rolls 111a and 111b hold|maintain the 1st film F101, and rotate in the opposite direction at the same time, and by this, the 1st film F101 is pulled in the arrow direction (right side) shown in FIG. 4. FIG.

The first accumulator 112 is used to absorb the difference caused by the fluctuation of the feed amount of the first film F101 and reduce the fluctuation of the tension applied to the first film F101. Specifically, the first accumulator 112 has a plurality of dancer rollers 112a located on the upper side and a plurality of dancer rollers 112b located on the lower side alternately between the first nip rollers 111a, 111b and the first guide roller 113 The composition of the arrangement configuration.

The first accumulator 112 is in a state in which the first film F101 is alternately passed around the dancer roll 112a on the upper side and the dancer roll 112b on the lower side, and the first film F101 is conveyed while the upper side is conveyed. The dancer roller 112a and the dancer roller 112b on the lower side relatively move up and down in the vertical direction. In this way, the first film F101 can be temporarily accumulated without stopping the first conveyance line 101 . For example, the first accumulator 112 can increase the distance between the dancer roller 112a on the upper side and the dancer roller 112b on the lower side to increase the accumulation of the first film F101. Conversely, the dancer roller 112a on the upper side can be increased. By reducing the distance from the dancer roller 112b on the lower side, the accumulation of the first film F101 can be reduced. The first accumulator 112 is actuated, for example, at the time of work such as connection of sheet tapes after replacing the core materials of the reels R1 to R3.

The first guide roller 113 rotates to guide the first film F101 pulled by the first nip rollers 111 a and 111 b and conveyed toward the upstream side of the third conveyance line 103 . The first guide roller 113 is not limited to a configuration in which only one is arranged, and a configuration in which a plurality of first guide rollers are arranged may be used.

The second transfer line 102 pulls out the long strip-shaped second film F102 as a surface protective film such as PET (Polyethylene Terephthalate) from the first reel R1, and transfers it to The third conveying line 103 conveys.

Specifically, on this second conveyance line 102, a pair of second nip rollers are arranged in sequence in the horizontal direction from the other side upstream of the third conveyance line 103 toward the direction of the third conveyance line 103. 121a, 121b, a second accumulator 122 including a plurality of second dancer rollers 122a, 122b, and a plurality of second guide rollers 123a, 123b.

The pair of second nip rolls 121a and 121b sandwich the second film F102 while rotating in opposite directions, thereby pulling the second film F102 in the direction of the arrow (leftward) shown in FIG. 4 .

The second accumulator 122 is used to absorb the difference caused by the fluctuation of the feed amount of the second film F102 and reduce the fluctuation of the tension applied to the second film F102. Specifically, the second accumulator 122 has a plurality of dancer rollers 122a located on the upper side and a plurality of dancer rollers 122b located on the lower side alternately between the second nip rollers 121a, 121b and the second guide roller 123a The composition of the arrangement configuration.

The second accumulator 122 is in a state in which the second film F102 is alternately passed around the dancer roller 122a on the upper side and the dancer roller 122b on the lower side, and the second film F102 is conveyed while conveying the second film F102. The dancer roller 122a and the dancer roller 122b on the lower side relatively move up and down in the vertical direction. In this way, the second film F102 can be accumulated without stopping the second conveyance line 102 . For example, the second accumulator 122 increases the distance between the dancer roller 122a on the upper side and the dancer roller 122b on the lower side to increase the accumulation of the second film F102, and conversely increases the distance between the dancer roller 122a on the upper side and the dancer roller 122b on the lower side. By reducing the distance from the dancer roller 122b on the lower side, the accumulation of the second film F102 can be reduced. The second accumulator 122 is actuated, for example, at the time of work such as connection of sheet tapes after replacing the core materials of the reels R1 to R3.

The plurality of second guide rollers 123a and 123b respectively rotate to guide the second film F102 pulled by the second nip rollers 121a and 121b and conveyed to the upstream side of the third conveyance line 103 . The second guide rollers 123a and 123b are not limited to a configuration in which a plurality of the second guide rollers are arranged, and a configuration in which only one is arranged may be used.

The third conveyance line 103 conveys, to the fifth conveyance line 105, the long-belt-shaped single-sided bonding film F104 formed by bonding the second film F102 to one surface of the first film F101.

Specifically, a pair of third nip rollers 131 a and 131 b are arranged on the third conveyance line 103 . A pair of third nip rolls 131a and 131b are located at the junction of the downstream side of the first conveyance line 101 and the downstream side of the second conveyance line 102, and the first film F101 and the second film F102 are sandwiched and moved in opposite directions at the same time. By rotating, the single-sided bonding film F104 in which both the 1st film F101 and the 2nd film F102 were bonded together is pulled in the direction of the arrow (downward) shown in FIG. 4 .

The 4th conveyance line 104 draws out the long-belt-shaped 3rd film F103 which is a surface protective film, such as PET (Polyethylene Terephthalate), from the 2nd roll R2, and conveys it to the 5th conveyance line 105.

Specifically, on the fourth conveyance line 104, a pair of fourth nip rollers 141a are arranged in sequence in the horizontal direction from the downstream side of the third conveyance line 103 toward the direction of the third conveyance line 103. , 141b, a third accumulator 142 including a plurality of third dancer rollers 142a, 142b, and a plurality of fourth guide rollers 143a, 143b.

The pair of fourth nip rolls 141a and 141b rotate in opposite directions to each other while sandwiching the third film F103, thereby moving the third film F103 in the direction of the arrow (right) shown in FIG. 4. pull.

The third accumulator 142 is used to absorb the difference caused by the fluctuation of the feed amount of the third film F103 and reduce the fluctuation of the tension applied to the third film F103. Specifically, the third accumulator 142 has a plurality of dancer rollers 142a located on the upper side and a plurality of dancer rollers 142b located on the lower side alternately between the fourth nip rollers 141a, 141b and the fourth guide roller 143a The composition of the arrangement configuration.

The third accumulator 142 is in a state in which the third film F103 is alternately passed around the upper dancer roll 142a and the lower dancer roll 142b, and conveys the third film F103 while making the upper part. The dancer roller 142a and the dancer roller 142b on the lower side relatively move up and down in the vertical direction. In this way, the third film F103 can be temporarily accumulated without stopping the fourth conveyance line 104 . For example, the third accumulator 142 can increase the distance between the dancer roller 142a on the upper side and the dancer roller 142b on the lower side to increase the accumulation of the third film F103. Conversely, the dancer roller 142a on the upper side can be increased By reducing the distance from the dancer roller 142b on the lower side, the accumulation of the third film F103 can be reduced. The third accumulator 142 is actuated, for example, at the time of work such as connection of sheet tapes after replacing the core materials of the reels R1 to R3.

The plurality of fourth guide rollers 143a and 143b are respectively rotated to guide the third film F103 pulled and conveyed by the fourth nip rollers 141a and 141b to the downstream side of the third conveyance line 103 (upstream of the fifth conveyance line 105 ). side). The fourth guide rollers 143a and 143b are not limited to a configuration in which a plurality of them are arranged, and a configuration in which only one is arranged may be used.

The fifth conveyance line 105 is a long-belt-shaped double-sided bonding film F105 ( Optical film F10X) is conveyed to the 3rd roll R3.

Specifically, on this fifth conveyance line 105, a pair of fifth nip rolls are arranged in order in the horizontal direction from the other side downstream of the third conveyance line 103 toward the third web R3. 151a, 151b, a fifth guide roller 153a, a pair of sixth nip rollers 151c, 151d, a fourth accumulator 152 including a plurality of fourth dancer rollers 152a, 152b, and a sixth guide roller 153b.

A pair of fifth nip rolls 151a and 151b are located at the junction of the downstream side of the third conveyance line 103 and the upstream side of the fifth conveyance line 105, and sandwich the single-sided bonding film F104 and the third film F103 while moving toward each other. By turning in the opposite direction, the double-sided bonding film F105 formed by bonding both the single-sided bonding film F104 and the third film F103 is pulled in the direction of the arrow (downward) shown in FIG. 4 .

The 5th guide roller 153a rotates, and guides the double-sided bonding film F105 which the 5th nip rollers 151a and 151b pulled and conveyed to the 4th accumulator 152. The fifth guide roller 153a is not limited to a configuration in which only one is arranged, and a configuration in which a plurality of fifth guide rollers are arranged may be used.

The pair of sixth nip rolls 151c and 151d rotate in opposite directions to each other while sandwiching the double-sided bonding film F105, thereby moving the double-sided bonding film F105 in the direction of the arrow (right) shown in FIG. 4 . square) pull.

The fourth accumulator 152 is in a state in which the double-sided bonding film F105 is alternately passed around the dancer roller 152a on the upper side and the dancer roller 152b on the lower side, while conveying the double-sided bonding film F105, the upper part is conveyed. The dancer roller 152a on the side and the dancer roller 152b on the lower side relatively move up and down in the vertical direction. In this way, the double-sided bonding film F105 can be accumulated without stopping the fifth conveyance line 105 . For example, the fourth accumulator 152 can increase the distance between the dancer roller 152a on the upper side and the dancer roller 152b on the lower side to increase the accumulation of the double-sided bonding film F105. Conversely, the dancer roller on the upper side can be increased When the distance between 152a and the dancer roller 152b on the lower side is reduced, the accumulation of the double-sided bonding film F105 can be reduced. The fourth accumulator 152 is actuated, for example, at the time of work such as connection of sheet tapes after replacing the core materials of the reels R1 to R3.

The 6th guide roller 153b rotates, and guides the double-sided bonding film F105 to the 3rd web R3. The sixth guide roller 153b is not limited to a configuration in which only one is arranged, and a configuration in which a plurality of the sixth guide rollers are arranged may be used.

After the double-sided bonding film F105 is wound around the core material by the winding unit 106, it is sent to the next step as the third roll R3 of the optical film F10X.

(Defect Inspection System)

Next, the defect inspection system 10 included in the film manufacturing apparatus 100 described above will be described.

As shown in FIG. 4 , the defect inspection system 10 generally includes a conveyance line L, a first defect inspection device 11 and a second defect inspection device 12 , a recording device 13 , a first length measuring device 14 and a second length measuring device 15 . , and the control device 16 .

The conveyance line L forms a conveyance path for conveying the film to be inspected, and in this embodiment, the conveyance line L is constituted by the above-mentioned first conveyance line 101 , third conveyance line 103 , and fifth conveyance line 105 .

The first defect inspection apparatus 11 is an apparatus for inspecting the defects of the first film 101 before bonding the second film F102 and the third film F103. Specifically, the first defect inspection apparatus 11 detects various defects such as foreign matter defects, uneven defects, and bright spot defects, which are generated when the first film F101 is produced or when the first film F101 is conveyed. The first defect inspection apparatus 11 performs inspection processing such as reflection inspection, transmission inspection, oblique transmission inspection, crossed Nichol transmission inspection, etc. on the first film F101 conveyed on the first conveyance line 101, to detect the defect of the first film F101.

The first defect inspection device 11 includes a plurality of illumination units 21a, 22a, 23a for irradiating the first film F101 with light, and a plurality of illumination units 21a, 22a, and 23a for irradiating light to the first film F101 on the upstream side of the first nip rolls 111a and 111b, and for detecting A plurality of light detection parts 21b, 22b, 23b of light transmitted through the first film F101 (transmitted light) or light reflected by the first film F101 (reflected light).

In the present embodiment, the structure for detecting transmitted light is that a plurality of illumination units 21a, 22a, 23a and a plurality of light detection units are arranged in a row in the conveyance direction of the first film F101 and face each other with the first film F101 interposed therebetween. 21b, 22b, 23b. In addition, the first defect inspection apparatus 11 is not limited to such a configuration for detecting transmitted light, and may be a configuration for detecting reflected light, or a configuration for detecting transmitted light and reflected light.

The illumination parts 21a, 22a, and 23a irradiate the first film F101 with illumination light whose intensity, wavelength, polarization state, and the like have been adjusted according to the type of defect inspection. The light detection parts 21b, 22b, and 23b use imaging elements such as CCDs to capture images of the positions where the illumination light is irradiated on the first film F101. The images (defect inspection results) captured by the photodetectors 21 b , 22 b , and 23 b are output to the control device 16 .

The 2nd defect inspection apparatus 12 is an apparatus which performs defect inspection of the 1st film 101 after bonding the 2nd film F102 and the 3rd film F103, ie, the double-sided bonding film F105. Specifically, this 2nd defect inspection apparatus 12 detects the foreign material which generate|occur|produces when the 1st film F101 bonds the 2nd film F102 and the 3rd film F103, when the single-sided bonding film F104 and the double-sided bonding film F105 are conveyed Various defects such as defects, uneven defects, bright spot defects, etc. The second defect inspection apparatus 12 performs inspection processing such as reflection inspection, transmission inspection, oblique transmission inspection, cross-polarized light transmission inspection, etc. on the double-sided bonding film F105 conveyed on the fifth conveyance line 105 to detect Defects of double-sided bonding film F105.

The second defect inspection device 12 includes a plurality of illumination units 24a and 25a for irradiating the double-sided bonding film F105 with light, and a plurality of illumination units 24a and 25a for detecting transmission on the fifth conveying line 105 downstream of the fifth nip rolls 151a and 151b. The light (transmitted light) which passed through the double-sided bonding film F105 or the light reflected on the double-sided bonding film F105 (reflected light) is a plurality of light detection parts 24b and 25b.

In the present embodiment, the structure for detecting the transmitted light is arranged in the conveyance direction of the double-sided bonding film F105, and a plurality of illuminating parts 24a and 25a and a plurality of light-detecting parts facing each other with the double-sided bonding film F105 interposed therebetween are arranged side by side. 24b, 25b. In addition, the second defect inspection device 12 is not limited to such a configuration for detecting transmitted light, and may be a configuration for detecting reflected light, or a configuration for detecting transmitted light and reflected light.

The illumination parts 24a and 25a irradiate illumination light whose intensity, wavelength, polarization state and the like are adjusted according to the type of defect inspection to the double-sided bonding film F105. The photodetectors 24b and 25b use imaging elements such as CCDs to capture images of the positions where the double-sided bonding film F105 is irradiated with the illumination light. The images (defect inspection results) captured by the photodetectors 24 b and 25 b are output to the control device 16 .

(Printing Device and Printing Method)

The recording device 13 is a device (printing device) for recording defect information obtained from the results of the defect inspections by the first defect inspection device 11 and the second defect inspection device 12 on the double-sided bonding film F105. Specifically, the defect information includes information about the location and type of the defect, and is recorded (printed) in the form of an identification code such as a barcode, a two-dimensional barcode, and a QR code (registered trademark). The identification code includes, for example, information indicating that the defect detected by the first defect inspection device 11 and the second defect inspection device 12 is present at a distance in the width direction of the film from the position where the identification code is printed (the difference between the defect and the defect). location-related information). The identification code may also contain information related to the type of detected defect. In this embodiment, the printed defect information is a two-dimensional bar code of 7mm×7mm.

The recording device 13 is provided on the downstream side of the fifth conveyance line 105 rather than the second defect inspection device 12 . The recording device 13 has a print head 13a using, for example, an ink jet method. Moreover, the 7th guide roller 153c which contacts with the double-sided bonding film F105 is arrange|positioned in the position which opposes the printing head 13a. The print head 13a ejects ink at the position (recording area) of the edge portion (recording area) along the width direction of the double-sided bonding film F105 from the opposite side of the contact position of the double-sided bonding film F105 with the seventh guide roller 153c. Print out the above defect information.

The recording device 13 can also directly record on the defective portion by printing dot-shaped, linear or frame-shaped markings of a size to contain the defect on the defective portion of the double-sided lamination film F105. In this case, in addition to the mark, information related to the type of defect may be recorded by printing a mark or pattern indicating the type of defect.

The first length measuring device 14 and the second length measuring device 15 are devices for measuring the conveyance amount of the first film F101. Specifically, in the present embodiment, on the first conveying line 101, a rotary encoder constituting the first length measuring device 14 is arranged on the first nip roller 111a located on the upstream side of the first accumulator 112. , and a rotary encoder constituting the second length measuring device 15 is disposed on the third nip roller 131 a located on the downstream side of the first accumulator 112 .

The first length measuring device 14 and the second length measuring device 15 use rotary encoders to measure the first film based on the rotational displacement of the first nip roll 111a and the third nip roll 131a that are rotated in contact with the first film F101 The conveying capacity of F101. The measurement results of the first length measuring device 14 and the second length measuring device 15 are output to the control device 16 .

In the present embodiment, there is only one accumulator between the first defect inspection device 11 and the recording device 13, so one length measuring device is arranged on the upstream side and the downstream side of the accumulator, respectively. On the other hand, when there are a plurality of accumulators between the first defect inspection device 11 and the recording device 13 , only one is provided on the upstream side of the most upstream accumulator and one on the downstream side of the most downstream accumulator. Length measurer will do.

The control apparatus 16 includes apparatuses for controlling each part of the film manufacturing apparatus 100 . Specifically, the control device 16 is provided with a computer system as an electronic control device. A computer system generally includes an arithmetic processing unit such as a CPU, and an information storage unit such as a memory and a hard disk.

In the information storage part of the control apparatus 16, the operating system (OS) which controls a computer system, the program which makes an arithmetic processing part perform various processing required by each part of the film manufacturing apparatus 100, etc. are recorded. The control device 16 may include a logic circuit such as an ASIC that performs various processing required for the control of each part of the film manufacturing apparatus 100 . In addition, the control device 16 includes an interface for performing input/output between the computer system and external devices. Input devices such as keyboards and mice, display devices such as liquid crystal displays, and communication devices can be connected to this interface.

The control device 16 analyzes the images captured by the photodetectors 21b, 22b, and 23b and the photodetectors 24b, 25b, and determines the presence or absence (position), type, and the like of defects. When the control device 16 determines that the first film F101 or the double-sided bonding film F105 is defective, the control device 16 controls the recording device 13 to record the defect information on the double-sided bonding film F105.

The defect inspection system 10 records defect information at a predetermined timing after the defect inspection so as not to cause a deviation between the defect inspection position of the double-sided laminate film F105 and the information recording position of the defect information. For example, in the present embodiment, the conveyance amount of the film conveyed on the conveyance line L after the time point when the first defect inspection apparatus 11 or the second defect inspection apparatus 12 performs defect inspection is calculated, and the calculated conveyance amount and the offset are calculated. When the distances (offset distances) match, the recording device 13 is caused to perform recording.

Here, the offset distance means the conveyance distance of the film between the first defect inspection apparatus 11 , the second defect inspection apparatus 12 , and the recording apparatus 13 . Strictly speaking, the offset distance is defined as the difference between the positions at which the first defect inspection apparatus 11 and the second defect inspection apparatus 12 perform defect inspection (defect inspection positions) and the positions at which the recording apparatus 13 records defect information (information recording positions). The conveying distance between the films. The offset distance varies when the first accumulator 112 is activated.

The offset distance (hereinafter referred to as the first offset distance) when the first accumulator 112 is not activated is stored in the information storage unit of the control device 16 in advance. Specifically, the first defect inspection apparatus 11 and the second defect inspection apparatus 12 have a plurality of photodetection units 21b, 22b, 23b, and photodetection units 24b, 25b, and each photodetection unit 21b, 22b, 23b, 24b, 25b are all inspected for defects. Therefore, the first offset distance is stored in the information storage unit of the control device 16 for each of the light detection units 21b, 22b, 23b, 24b, and 25b, respectively.

When the offset distance fluctuates due to the operation of the first accumulator 112 , a correction value of the offset distance is calculated based on the difference in the conveyance amount of the first film F101 upstream and downstream of the first accumulator 112 . That is, the control device 16 calculates the accumulation amount of the first film F101 in the first accumulator 112 from the measurement results of the first length measuring device 14 and the second length measuring device 15, and based on this accumulation amount of the first film F101 to calculate the offset distance correction value.

The defect inspection system 10 corrects the timing at which the recording device 13 records the defect information based on the correction value of the offset distance when the first accumulator 112 is activated. For example, in the present embodiment, the correction value of the offset distance is calculated based on the measurement results of the first length measuring device 14 and the second length measuring device 15 . The control device 16 calculates the offset distance when the first accumulator 112 is activated (hereinafter referred to as the second offset distance) based on the correction value and the first offset distance.

In this embodiment, based on the measurement results of the first length measuring device 14 and the second length measuring device 15, the time point when the defect inspection by the first defect inspection device 11 and the second defect inspection device 12 is carried out on the conveyance line L is calculated. When the transport amount of the film and the calculated transport amount coincide with the second offset distance, the recording device 13 records.

Furthermore, in this embodiment, when the first accumulator 112 is activated, in addition to the defect information, information indicating that the first accumulator 112 is activated (hereinafter referred to as accumulator activation information) may be recorded on the double-sided lamination film F105. ). In the case where the operation information of the accumulator is also recorded, the operator can detect the deviation of the recording position and the like by carefully inspecting the defective part of the part where the operation information of the accumulator is printed. In this way, the possibility of erroneously determining a good part as a defective part is reduced, and the yield is improved.

However, in the defect inspection system 10 of this embodiment, the double-sided sticking film F105 during conveyance may bounce depending on the state of the double-sided sticking film F105, conveying conditions, and the like. In particular, both ends in the width direction of the double-sided bonding film F105 tend to curl due to moisture absorption of the film, drying conditions, and the like, and this curling is thought to be one of the causes of the jumping during conveyance.

In view of this, as shown in FIG. 5, the defect inspection system 10 of the present embodiment arranges the print head 13a so as to face the seventh guide roller 153c in contact with the above-mentioned double-sided lamination film F105.

Thereby, even in the case where the double-sided bonding film F105 has the both ends in the width direction during conveyance, the double-sided bonding film F105 can be restrained from jumping at the position where the double-sided bonding film F105 is in contact with the seventh guide roller 153c. . Therefore, the defect inspection system 10 of the present embodiment can appropriately record (print) the defect information to be printed on the ink i ejected from the printing head 13a in the recording area of the double-sided bonding film F105.

The double-sided bonding film F105 is preferably wound around the outer peripheral surface of the seventh guide roller 153c in an angle range of 40° to 130° (hereinafter referred to as a surrounding angle θ). The surrounding angle in the present embodiment refers to an angular range in which the film is in contact with the outer peripheral surface of the guide roller in the circumferential direction by the central angle of the guide roller.

When the surrounding angle θ is less than 40°, the double-sided bonding film F105 easily slides on the outer peripheral surface of the seventh guide roller 153c. Therefore, in order to prevent scratches and the like due to the sliding of the double-sided bonding film F105, it is preferable that the surrounding angle θ be 40° or more. On the other hand, when the surrounding angle θ exceeds 130°, for example, air bubbles tend to be bitten between the second and third films F102 and F103 and the first film F101, which are surface protection films, for example. Therefore, in order to prevent the entrapment of such air bubbles, the surrounding angle θ is preferably 130° or less.

Moreover, when the tension|tensile_strength applied to the double-sided bonding film F105 is low, it is preferable to make surrounding angle (theta) more than 90 degrees, More preferably, it is 95 degrees or more. In this way, it is possible to suppress the popping that occurs in the double-sided bonding film F105. On the other hand, when the tension applied to the double-sided bonding film F105 is high, the surrounding angle θ is preferably less than 90°, more preferably 85° or less. In this way, the double-sided bonding film F105 can be prevented from adhering to the outer peripheral surface of the seventh guide roller 153c excessively.

The conveyance speed of the double-sided bonding film F105 is usually about 9 to 35 m/min. The tension applied to the double-sided adhesive film F105 is about 400 to 1500N inside the drying oven, and about 200 to 500N outside the drying oven. The smaller the tension applied to the double-sided lamination film F105, the easier it is to pop. The width of the double-sided lamination film F105 is in the range of 500 to 1500 mm. The larger the width of the double-sided lamination film F105 is, the more likely it is to pop. The thickness of the double-sided bonding film F105 is in the range of 13 to 300 μm. The thinner the thickness of the double-sided lamination film F105, the easier it is to pop.

In addition, the outer diameter of the seventh guide roller 153c is preferably in the range of 100 to 150 mm. As the outer diameter of the seventh guide roller 153c increases, the area of the double-sided bonding film F105 that is in contact with the outer peripheral surface of the seventh guide roller 153c with respect to the surrounding angle θ increases. Therefore, the popping which occurs in the double-sided bonding film F105 can be suppressed, and the recording area can be more stabilized. However, as the outer diameter of the seventh guide roller 153c increases, the above-mentioned scratches and entrapment of air bubbles are likely to occur, so it is preferable that the outer diameter be within the above-mentioned range.

Moreover, as the roundness of the seventh guide roller 153c is higher, the vibration of the double-sided bonding film F105 in contact with the seventh guide roller 153c can be suppressed, and the recording area can be more stabilized. Specifically, the roundness of the seventh guide roller 153c is preferably 1.0 mm or less, more preferably 0.5 mm or less.

In addition, the surface roughness (maximum roughness Ry) of the outer peripheral surface of the seventh guide roller 153c is preferably 100 s or less, more preferably 25 s or less. In this way, the occurrence of the above-mentioned scratches and entrapment of air bubbles can be suppressed.

In addition, in the defect inspection system 10 of the present embodiment, in order to suppress the snapping that occurs in the double-sided bonding film 105 also on the upstream side and the downstream side of the seventh guide roller 153c, a guide roller that is in contact with the double-sided bonding film F105 can be added. . In this case, the distance between the additional guide roller and the seventh guide roller 153c is preferably within 1000 mm. The double-sided bonding film F105 may have a surrounding angle with respect to an additional guide roll. It is preferable to have a surrounding angle with respect to the guide rolls added to the upstream side, and it is more preferable to have a surrounding angle with respect to the guide rolls added to both the upstream side and the downstream side.

As described above, the defect inspection system 10 of the present embodiment can reduce the influence caused by the popping of the double-sided bonding film F105 during conveyance, and can appropriately record (print) defect information on the double-sided bonding film F105 . Therefore, the film manufacturing apparatus 100 of the present embodiment can prevent the occurrence of reading errors of defect information due to printing errors, and can cut out the optical film F10X from the double-sided lamination film F105 with a good yield, and can manufacture high-quality The optical film F10X.

As shown in FIGS. 6(a) to (c), the recording device 13 in this embodiment is provided with a cover 30 to prevent the ink i from adhering to at least the inner side other than the recording area S of the double-sided lamination film F105 area. 6(a) is a plan view of the cover 30 seen from the upper side of the double-sided bonding film F105, and FIG. 6(b) is a side view of the cover 30 seen from the upstream side of the double-sided bonding film F105 in the conveying direction, Fig. 6(c) is a side view of the cover 30 viewed from the outside of the double-sided bonding film F105.

Specifically, the cover 30 includes: a first side plate part 30a that covers the inner side of the double-sided sticking film F105 in the space K where the double-sided sticking film F105 faces the print head 13a; The 2nd side board part 30b of the upstream side of the conveyance direction of the bonding film F105, and the 3rd side board part 30c which block the side facing the downstream side of the conveyance direction of the double-sided bonding film F105.

The cover 30 is detachably mounted relative to the print head 13a by means of screw locking or the like. The cover 30 opens the side facing the outer side of the double-sided lamination film F105 in the space K, so that the attachment and detachment with respect to the printing head 13a is facilitated.

It is preferable that the space|interval T between the surface which opposes the double-sided bonding film F105 of the cover 30 and the surface of the double-sided bonding film F105 is 1 mm or less. When the interval T is set to be 1 mm or less, when the ink i ejected from the print head 13a is scattered around, the scattering of the ink i can be prevented from being scattered to the outside of the cover 30 .

Among the ink i ejected from the printing head 13a, for example, the ink i is scattered around the information recording position, and the ink i is attached to the double-sided lamination film F105 and then scattered around.

The recording area S is located outside the area which overlaps with the display area P4 of the liquid crystal display panel P when the double-sided bonding film F105 is bonded to the liquid crystal display panel P described above. In addition, the recording area S is an area to be cut out before being attached to the liquid crystal display panel P described above.

Among the three side plate portions 30a, 30b, and 30c constituting the cover 30, the first side plate portion 30a prevents the scattering of the ink i from adhering to the area of the double-sided lamination film F105 overlapping the display area P4, and the second side plate portion 30b is a The third side plate portion 30c prevents the scattering of ink i from adhering to the upstream side in the conveyance direction of the double-sided bonding film F105, and the third side plate portion 30c prevents the scattering of ink i from adhering to the downstream side in the conveying direction of the double-sided bonding film F105.

The scattered matter of the ink i adheres to the inner surface of the cover 30 . Therefore, the cover 30 can be periodically removed from the print head 13a, washed, and then attached to the print head 13a for repeated use.

Moreover, it is preferable that the film manufacturing apparatus 100 is provided with the structure provided with the static electricity removal apparatus 40 which removes the static electricity on the surface of the double-sided bonding film F105. The static electricity removal apparatus 40 is what is called an ionizer, and is arrange|positioned at the upstream side rather than the recording apparatus 13 (printing head 13a) in the conveyance direction of the double-sided bonding film F105. This static electricity removal apparatus 40 removes the static electricity which generate|occur|produces on the surface of the double-sided bonding film F105 by spraying ionized gas over the width direction of the double-sided bonding film F105.

Thereby, the film manufacturing apparatus 100 prevents the scattering material of the ink i from being attracted to the surface of the double-sided bonding film F105 by electrostatic attraction. Therefore, the film manufacturing apparatus 100 can further suppress the attachment of the scattered matter of the ink i to the surface of the double-sided bonding film F105 by combining the above-mentioned cover 30 and the static electricity removing apparatus 40.

As described above, the defect inspection system 10 of the present embodiment can prevent contamination of the double-sided bonding film F105 due to scattering of the ink i when recording defect information on the double-sided bonding film F105.

The present invention is not necessarily limited to the above-described embodiment, and various modifications can be added without departing from the gist of the present invention.

Specifically, in the above-mentioned cover 30, at least the first side plate portion 30a may be arranged among the three side plate portions 30a, 30b, and 30c. Thereby, the spatter of the ink i can be prevented from adhering to the area|region which overlaps with the display area P4 of the double-sided bonding film F105.

Moreover, as shown in FIG. 7, about the said cover 30, in addition to the said three side board parts 30a, 30b, 30c, the 4th side board which covers the side which faces the outer side of the double-sided lamination film F105 may be arrange|positioned. The structure of the part 30d.

In addition, regarding the recording device 13, as shown in Figs. Thereby, the space|interval T with the double-sided bonding film F105 can be made into 1 mm or less.

Moreover, as another embodiment of this invention, the cover 32 as shown in FIG. 9 (a), (b), for example can also be employ|adopted. The cover 32 is formed of a parallel flat plate, and is arranged to face the double-sided bonding film F105 in a state close to the double-sided bonding film F105. Further, a window portion (opening portion) 32a is provided at a position facing the recording area S on the cover 32 . In the case of this configuration, the cover 32 covers the area other than the recording area S, thereby preventing contamination of the double-sided bonding film F105 caused by scattering of the ink i when the double-sided bonding film F105 records defect information. In addition, the cover 32 may be provided with the above-mentioned side plate portions 30a, 30b, 30c, and 30d. That is, the cover 32 can constitute a bottom portion covering the bottom surface of the cover 30 .

In addition, although the said recording apparatus 13 is formed in the structure arrange|positioned on the downstream side of the 2nd defect inspection apparatus 12, you may arrange|position it on the downstream side of the 1st defect inspection apparatus 11. In this case, after the defect inspection by the first defect inspection device 11 is performed, the recording of defect information by the recording device 13 may be performed.

In addition, the recording device 13 described above is not limited to recording defect information after the above-described defect inspection. Also, for example, a plurality of recording devices are arranged on a long-distance conveying line, distance information is recorded at each predetermined distance, and distance correction is performed based on the recorded distance information. The recording apparatus which records such distance information is arrange|positioned at the upstream of the 1st defect inspection apparatus 11, etc., for example.

In addition, the film suitable for use in the present invention is not necessarily limited to the above-mentioned optical films such as the polarizing film, retardation film, brightness enhancement film, etc., and the present invention can also be extended to the recording device 13 for recording thereon. film.

In addition to the above-described ink jet method, the present invention can also be widely applied to a non-contact printing apparatus and a printing method such as a laser method. In particular, the ink jet method tends to generate ink mist, so if the optical film bounces, it is easy to be affected by it and cause printing errors. The same is true for defect information. In the case of printing complex information such as the above-mentioned two-dimensional barcode by inkjet, it is more likely to be affected by the popping of the optical film.

10‧‧‧Defect Inspection System

13‧‧‧Recording device

13a‧‧‧Print head

153c‧‧‧Seventh guide roller

F105‧‧‧Double-sided lamination film

Claims (9)

A defect inspection system comprising: a conveying line for conveying a long strip-shaped film; a defect inspection device for inspecting defects of the film conveyed on the conveying line; and a recording device for obtaining a result of the defect inspection The defect information is recorded on the film conveyed on the conveying line; wherein, the recording device is provided with a printing head, and the printing head prints the defect information on the recording area along the edge of the film, and the printing head is connected with the The guide rollers in contact with the film are arranged opposite to each other, and printing is performed from the side opposite to the side where the film and the guide rollers are in contact; there are additional guide rollers in contact with the film on the upstream side and the downstream side of the guide rollers; The distance between the guide roller and the additional guide roller is within 1000 mm. The defect inspection system according to claim 1, wherein the film system is wound around the outer peripheral surface of the guide roller at an angle ranging from 40° to 130°. The defect inspection system according to claim 1 or 2, wherein the printing head prints the defect information by ejecting ink to the recording area of the film. The defect inspection system according to claim 3, wherein the recording device has a cover for preventing the ink from adhering to at least the inner side of the recording area of the film. area. The defect inspection system according to claim 1 or 2, further comprising: a static electricity removing device located at a position upstream of the recording device in the conveying direction of the film, for inspecting the film The surface is de-staticized. A film manufacturing apparatus including the defect inspection system described in any one of claims 1 to 5 of the scope of application. A film manufacturing method, comprising: a process of performing defect inspection using the defect inspection system described in any one of claims 1 to 5 of the patent application. A printing device comprising: a printing head for printing information on a recording area along an edge portion of the film during conveyance of a long strip-shaped film, the printing head facing a guide roller in contact with the film are arranged, and the printing is performed from the side opposite to the side where the film and the guide roller are in contact; the upstream side and the downstream side of the guide roller have additional guide rollers that are in contact with the film; the guide roller and the additional guide roller The distance is within 1000mm. A printing method comprising: a process of using a printing head to print information on a recording area along an edge portion of the film during conveyance of a long strip-shaped film, wherein the printing head is brought into contact with a guide roller in contact with the film match opposite set, and print from the opposite side of the position where the film and the guide roller are in contact; there are additional guide rollers in contact with the film on the upstream and downstream sides of the guide roller; the distance between the guide roller and the additional guide roller Department within 1000mm.

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