WO2014061573A1 - Method for manufacturing illumination device - Google Patents

Abstract

A method for manufacturing a backlight device (13) comprises at least a frame forming process for forming a plurality of frames (27) parallel to a conveyance base material (33) by respectively pulling out in the same direction along the parallel direction a first frame-shaped sheet roll material (30R) constituted by winding in a roll a plurality of first frame-shaped sheet materials (30) linearly arranged parallel to each other, a second frame-shaped sheet roll material (31R) constituted by winding in a roll a plurality of second frame-shaped sheet materials (31) linearly arranged parallel to each other along the parallel direction to the first frame-shaped sheet materials (30), and a conveyance roll material (33R) constituted by winding in a roll a conveyance base material (33) linearly extending along the parallel direction; by laminating the first frame-shaped sheet material (30) on the conveyance base material (33); and by laminating the second frame-shaped sheet material (31) on the first frame-shaped sheet material (30) while joining the materials together by pressing from the front and rear.

Description

Manufacturing method of lighting device

The present invention relates to a method for manufacturing a lighting device.

In recent years, display devices in electronic devices such as portable information terminals (cell phones, smartphones, tablet notebook computers, etc.) have used liquid crystal panels as display panels for displaying images and supplied illumination light to the liquid crystal panels. A liquid crystal display device using a backlight device is employed. Backlight devices used in such liquid crystal display devices are roughly classified into direct type and edge light type according to the mechanism, and in order to realize further thinning of the liquid crystal display device, an edge light type backlight is used. A light device is preferably used, and as an example, Patent Document 1 below describes a method for manufacturing an edge light type backlight device.

JP 2008-226561 A

(Problems to be solved by the invention)
In the above-mentioned Patent Document 1, a frame-like frame surrounding a light guide plate for guiding light from a light source has a laminated structure of a plurality of frame sheets, thereby increasing production efficiency. . However, when laminating each frame sheet sequentially, each frame sheet is adsorbed by an adsorption device and assembled in a single wafer type, so there is a limit to shortening the tact time, and the manufacturing equipment is limited. The complexity and the manufacturing cost tend to be high, and there is still room for improvement.

The present invention has been completed based on the above circumstances, and aims to shorten the tact time and simplify the manufacturing equipment.

(Means for solving the problem)
The manufacturing method of the lighting device of the present invention is a frame-shaped member forming step of forming a frame-shaped member that forms a frame shape so as to surround a light guide plate for guiding light from a light source, A first frame-shaped sheet roll material obtained by winding a plurality of first frame-shaped sheet materials constituting the frame-shaped member in a linear form, and a second frame constituting the frame-shaped member A second frame-shaped sheet roll material obtained by winding a frame-shaped sheet material in a form of a plurality of lines arranged in a straight line along the parallel direction of the first frame-shaped sheet material; and in the parallel direction A transporting roll material formed by winding a transporting base material that extends linearly along the roll, and the transporting base material that is pulled out in the same direction along the parallel direction and transported along the parallel direction. The first frame-shaped sheet material is laminated on the first frame-shaped sheet material. On the other hand, by laminating the second frame-like sheet material from the front and back with a pressure roller and laminating them, a large number of the frame-like members are juxtaposed along the parallel direction with respect to the transport substrate. At least a frame-shaped member forming step.

In this manner, in the frame-shaped member forming step, the first frame-shaped sheet roll material, the second frame-shaped sheet roll material, and the transport roll material are each pulled out in the same direction along the parallel direction. Since the drawn conveyance base material is conveyed along the parallel direction of the first frame-shaped sheet material, the first frame-shaped sheet material is laminated on the conveyance base material, and the first frame-shaped sheet material is Two frame-shaped sheet materials are laminated. And when the conveyance base material, the 1st frame-shaped sheet material, and the 2nd frame-shaped sheet material which were mutually laminated | stacked are pressed and bonded from the front and back by the press roller, a frame-shaped member will be in a parallel direction with respect to a conveyance base material. Are formed in parallel with each other. As a result, a large number of frame-shaped members can be formed continuously while conveying the conveyance substrate, so that the tact time is shorter than when each frame-shaped sheet material is assembled in a single-wafer type by an adsorption device. The time can be shortened and the manufacturing equipment can be simplified and the cost can be reduced.

The following configuration is preferable as an embodiment of the present invention.
(1) In the frame-shaped member forming step, light is arranged as being in contact with a plate surface of the light guide plate opposite to the light emitting surface that emits light as the transport base material, and the light is emitted to the light emitting surface side. In this case, a plurality of reflecting members that are reflected in a straight line are arranged along the parallel direction. If it does in this way, since a reflective member will serve as a conveyance base material, it will become useful when aiming at reduction of a number of parts.

(2) In the frame-shaped member forming step, a frame-shaped member roll material is formed by winding a plurality of the frame-shaped members arranged in a parallel manner along the parallel direction with respect to the transport base material. A light guide plate roll material formed by winding the light guide plate in a shape of being arranged in a straight line along the parallel direction with respect to the transport substrate for the light guide plate; and The frame-shaped member roll material is pulled out in the same direction along the parallel direction, and pressed from the front and back by a pressing roller while placing the light guide plate on the transport base material transported along the parallel direction. After bonding, the light guide plate is attached to the transport substrate in a form surrounded by the frame member by winding the light guide plate transport substrate with a light guide plate transport substrate winding device. An attachment process is provided. If it does in this way, in a light guide plate attachment process, a light guide plate roll material and a frame-shaped member roll material will be pulled out in the same direction along a parallel direction, respectively. When the light guide plate is placed on the transport base material that is pulled out and transported along the parallel direction, the transport base material and the light guide plate are bonded together by being pressed from the front and back by the pressing roller. Then, the light guide plate is attached to the transport base material in a form surrounded by the frame-shaped member by winding the light guide plate transport base material with the light guide plate transport base material winding device. As a result, a large number of light guide plates can be attached continuously while transporting the transport base material, so compared to the case where the light guide plate is attached to the transport base material by a suction device by a suction device, The tact time can be shortened, and the manufacturing equipment can be simplified and the cost can be reduced.

(3) In the frame-shaped member forming step, the frame is formed such that at least one of the first frame-shaped sheet material and the second frame-shaped sheet material constituting the frame-shaped member has a light guide plate positioning portion. In the light guide plate mounting step, the light guide plate is placed on the frame by bringing the light guide plate positioning portion into contact with the light guide plate when the light guide plate is placed on the transport substrate. Positioning is performed in the plane of the transport base with respect to the shaped member. In this way, in the light guide plate mounting step, when the light guide plate is placed on the conveyance base material, at least one of the first frame shape sheet material and the second frame shape sheet material constituting the frame shape member is used. The existing light guide plate positioning portion is brought into contact with the light guide plate. Thereby, since the light guide plate is appropriately positioned in the plane of the transport base material with respect to the frame-shaped member, the generation of defective products having an inappropriate positional relationship is suppressed, and thus the yield is improved.

(4) In the light guide plate mounting step, a light guide plate is added by winding a plurality of the frame-shaped member and the light guide plate arranged in parallel along the parallel direction with respect to the transport base material in a roll shape. A roll material is formed, and a large number of optical members arranged in contact with a light emitting surface that emits light out of the light guide plate are linearly formed along the parallel direction with respect to the conveying base for optical members. The optical member roll material formed by winding the material arranged in parallel with each other in a roll shape and the light guide plate-added roll material are each pulled out in the same direction along the parallel direction, and conveyed along the parallel direction. After the optical member is laminated on the light guide plate attached to the transport base material, the optical member transport base material is bonded to the optical member transport base material by pressing from the front and back sides with a pressing roller. By take-up device By taking can comprises an optical member attaching step of attaching the optical element in the form of laminated to the light guide plate. If it does in this way, in an optical member attachment process, an optical member roll material and a light-guide plate addition roll material will each be pulled out in the same direction along a parallel direction. If an optical member is laminated | stacked with respect to the light guide plate attached to the conveyance base material pulled out and conveyed along a parallel direction, these light guide plates and an optical member will be pressed from the front and back by a press roller, and will be bonded together. Then, the optical member is attached in the form laminated | stacked on the light-guide plate by winding up the conveyance base material for optical members with the conveyance base material winding apparatus for optical members. As a result, a large number of optical members can be continuously attached to the light guide plate while transporting the transport base material, which is compared with a case where the optical member is attached to the light guide plate by a suction device in a single wafer manner. In addition, the tact time can be shortened, and the manufacturing equipment can be simplified and the cost can be reduced.

(5) In the frame-shaped member forming step, a frame-shaped member roll material is formed by winding a plurality of the frame-shaped members arranged in a parallel manner along the parallel direction with respect to the transport base material. A light source roll material formed by winding a light source having a plurality of light sources arranged in a straight line along the parallel direction with respect to the light source transport base; and the frame-shaped member The roll material is pulled out in the same direction along the parallel direction, and the light source is placed on the frame-shaped member attached to the transport base material transported along the parallel direction. After pressing and bonding together, at least a light source mounting step of attaching the light source to the frame-shaped member by winding the light source transport base material with a light source transport base material winding device. If it does in this way, in a light source attachment process, a light source roll material and a frame-shaped member roll material will be pulled out in the same direction along a parallel direction, respectively. When the light source is placed on the frame-shaped member attached to the transport base material that is pulled out and transported along the parallel direction, the frame-shaped member and the light source are pressed and bonded from the front and back by the pressing roller. Then, a light source is attached with respect to a frame-shaped member by winding up the conveyance base material for light sources with the conveyance base material winding device for light sources. As a result, a large number of light sources can be continuously attached to the frame-shaped member while conveying the conveyance base material, so that it is compared with the case where the light source is attached to the frame-shaped member by a suction device in a single wafer manner In addition, the tact time can be shortened, and the manufacturing equipment can be simplified and the cost can be reduced.

(6) In the frame-shaped member forming step, at least one of the first frame-shaped sheet material and the second frame-shaped sheet material constituting the frame-shaped member has a light source positioning portion, so that the frame shape is formed. A member is formed, and in the light source mounting step, the light source positioning unit is brought into contact with the light source when the light source is placed on the frame-shaped member, whereby the light source is placed on the frame-shaped member. Positioning is performed in the plane of the transport substrate. In this way, in the light source mounting step, when the light source is placed on the frame-shaped member, it is included in at least one of the first frame-shaped sheet material and the second frame-shaped sheet material constituting the frame-shaped member. The light source positioning unit is in contact with the light source. Thereby, since the light source is positioned with respect to the frame-shaped member in the plane of the transport base material, the occurrence of defective products having an inappropriate positional relationship is suppressed, thereby improving the yield.

(7) In the frame-shaped member forming step, as the first frame-shaped sheet roll material, a material obtained by winding the adjacent first frame-shaped sheet materials in a roll shape is used, and the second As the frame-shaped sheet roll material, a material obtained by winding the adjacent second frame-shaped sheet materials into a roll shape is used. If it does in this way, while separating a lot of 1st frame-like sheet roll materials and a lot of 2nd frame-like sheet roll materials individually, respectively, a 1st frame-like sheet roll material and a 2nd frame-like sheet roll material are changed. Compared to the case of transport using a dedicated transport base material, a dedicated transport base material is not required, so the number of parts can be reduced and there is no need to wind up the dedicated transport base material. This is suitable for simplifying the above.

(The invention's effect)
According to the present invention, the tact time can be shortened and the manufacturing equipment can be simplified.

1 is an exploded perspective view of a liquid crystal display device according to Embodiment 1 of the present invention. Sectional drawing which cut | disconnected the liquid crystal display device along the long side direction (Y-axis direction) A conveyance roll material, a 1st frame shape sheet roll material, a 2nd frame shape sheet roll material, a 3rd frame shape sheet roll material, a pressure roller, and a frame roll material used in a frame shape member formation process are shown roughly. Side view The perspective view which shows a conveyance base material, a 1st frame-shaped sheet | seat coupling body, a 2nd frame-shaped sheet | seat coupling body, and a 3rd frame-shaped sheet | seat coupling body assembled | attached at a frame-shaped member formation process. A frame coupled body that is manufactured through a frame-shaped member forming step and is laminated in the order of a first frame-shaped sheet coupled body, a second frame-shaped sheet coupled body, and a third frame-shaped sheet coupled body with respect to a conveyance base material. Perspective view Side view schematically showing a frame roll material, a reflective sheet roll material, a pressing roller, a transport substrate winding device, and a reflective sheet addition roll material used in the reflective sheet attaching step A perspective view showing a frame coupled body and a reflective sheet coupled body assembled in the reflective sheet mounting step. The perspective view which shows the reflection sheet addition coupling body manufactured through the reflection sheet attachment process, and a frame coupling body is attached to a reflection sheet coupling body Side view schematically showing a reflection sheet-added roll material, a light guide plate roll material, a pressure roller, a light guide plate conveyance base material winding device, and a light guide plate addition roll material used in the light guide plate mounting step The perspective view which shows the conveyance base material for light guide plates to which the light guide plate was attached, and a reflective sheet addition coupling body assembled | attached at the light guide plate attachment process. The perspective view which shows the light guide plate addition coupling body manufactured through the light guide plate attachment process, and a light guide plate being attached to a reflection sheet addition coupling body Side view schematically showing each optical sheet roll material, light guide plate-added roll material, each pressing roller, each optical sheet conveying base material winding device, and optical sheet-added roll material used in the optical sheet mounting step The perspective view which shows the conveyance base material for each optical sheet to which each optical sheet was attached, and a light-guide plate addition coupling body assembled | attached by an optical sheet attachment process. The perspective view which shows the optical sheet | seat addition coupling body manufactured through the optical sheet | seat attachment process and each optical sheet being attached to the light guide plate addition coupling body Optical sheet-added roll material, LED substrate roll material, panel adhesive tape roll material, casing adhesive tape roll material, each pressure roller, LED substrate transport base used in LED attachment process, adhesive tape attachment process, and cutting process Side view schematically showing a material winding device and a cutting device The perspective view which shows the conveyance base material for LED boards to which the LED board was attached, and an optical sheet addition coupling body assembled | attached by an LED attachment process The perspective view which shows the LED board addition coupling body manufactured through the LED attachment process, and an LED board is attached to the optical sheet addition coupling body A panel adhesive tape transport substrate to which a panel adhesive tape is attached, a casing adhesive tape transport substrate to which a casing adhesive tape is attached, and an LED substrate additional compound assembled in the adhesive tape mounting step. Perspective view The perspective view which shows the backlight apparatus coupling body manufactured through the adhesive tape attachment process, and the panel board adhesive tape and the casing adhesive tape are attached to the LED board addition coupling body Reflective sheet roll material, first frame-shaped sheet roll material, second frame-shaped sheet roll material, third frame-shaped sheet roll material, pressure roller, used in the frame-shaped member forming step according to Embodiment 2 of the present invention And side view schematically showing frame roll material The perspective view which shows the reflection sheet coupling body, the 1st frame-shaped sheet coupling body, the 2nd frame-shaped sheet coupling body, and the 3rd frame-shaped sheet coupling body assembled | attached at a frame-shaped member formation process. A frame coupled body manufactured through a frame-shaped member forming step and laminated in the order of a first frame-shaped sheet coupled body, a second frame-shaped sheet coupled body, and a third frame-shaped sheet coupled body with respect to a reflective sheet coupled body A perspective view showing The top view which shows the frame coupling body manufactured through the frame-shaped member formation process which concerns on Embodiment 3 of this invention. The top view which shows the light-guide plate addition coupling body manufactured through the light-guide plate attachment process The top view which shows the LED board additional coupling body manufactured through the LED attachment process Conveying roll material, each frame-shaped sheet roll material, each pressing roller, each frame-shaped sheet material conveying base material take-up device, and frame roll material used in the frame-shaped member forming step according to Embodiment 4 of the present invention Side view schematically showing The perspective view which shows the conveyance base material for 1st frame-shaped sheets to which the 1st frame-shaped sheet material was attached, and a conveyance base material assembled | attached at a frame-shaped member formation process. The perspective view which shows the conveyance base material for which the 2nd frame-shaped sheet material to which the 2nd frame-shaped sheet material was attached, and the conveyance base material to which the 1st frame-shaped sheet material was attached assembled in a frame-shaped member formation process. The third frame-shaped sheet conveyance base material to which the third frame-shaped sheet material is attached, and the first frame-shaped sheet material and the second frame-shaped sheet material are assembled, which are assembled in the frame-shaped member forming step. Perspective view showing substrate

<Embodiment 1>
A first embodiment of the present invention will be described with reference to FIGS. In this embodiment, the backlight device 13 included in the liquid crystal display device 10 including the cover panel 12 is illustrated. In addition, a part of each drawing shows an X axis, a Y axis, and a Z axis, and each axis direction is drawn to be a direction shown in each drawing. As for the vertical direction, FIG. 2 is used as a reference, and the upper side of the figure is the front side and the lower side of the figure is the back side.

As shown in FIG. 1, the liquid crystal display device 10 has a vertically long rectangular shape as a whole. The liquid crystal display device 10 has a front plate surface as a display surface for displaying an image and a back plate surface as an opposite surface. A panel (display panel) 11, a cover panel 12 arranged to face the display surface with respect to the liquid crystal panel 11, and a shape opposite to the opposite surface to the liquid crystal panel 11 (opposite to the cover panel 12 side) And a backlight device (illumination device) 13 that is an external light source that supplies light to the liquid crystal panel 11. Furthermore, the liquid crystal display device 10 includes a casing (housing member, exterior member) 14 that houses the cover panel 12, the liquid crystal panel 11, and the backlight device 13. Among the components of the liquid crystal display device 10, the cover panel 12 and the casing 14 constitute the appearance of the liquid crystal display device 10. The liquid crystal display device 10 according to the present embodiment includes a portable information terminal (such as a mobile phone, a smartphone, and a tablet notebook computer), an in-vehicle information terminal (such as a stationary car navigation system and a portable car navigation system), and a portable game. It is used for various electronic devices such as a machine. For this reason, the screen sizes of the liquid crystal panel 11 and the cover panel 12 constituting the liquid crystal display device 10 are in the range of several inches to several tens of inches, such as about 7 inches, and are generally classified as small or medium-sized. It is supposed to be a size.

The liquid crystal panel 11 will be described. As shown in FIG. 1, the liquid crystal panel 11 has a vertically long rectangular shape as a whole, and displays an image at a position slightly deviated on one end side (upper right side in FIG. 1) in the long side direction. And a driver (panel driving unit) 15 for driving the liquid crystal panel 11 at a position offset toward the other end side (lower left side shown in FIG. 1) in the long side direction. Is attached. In the liquid crystal panel 11, a substantially frame-like (frame-like) region surrounding the display unit is a non-display unit (non-active area) that does not display an image. Glass) is implemented. A non-display portion in the liquid crystal panel 11 is connected to a flexible substrate (not shown) for supplying various input signals to the driver 15. Further, the long side direction in the liquid crystal panel 11 coincides with the Y-axis direction, and the short side direction coincides with the X-axis direction.

As shown in FIG. 2, the liquid crystal panel 11 is interposed between a pair of transparent (translucent) glass substrates 11a and 11b, and both the substrates 11a and 11b, and has optical characteristics as the electric field is applied. And a liquid crystal layer (not shown) containing liquid crystal molecules, which are substances that change, and both substrates 11a and 11b are bonded together with a sealing agent (not shown) while maintaining a gap corresponding to the thickness of the liquid crystal layer. Among the pair of substrates 11a and 11b, the CF substrate 11a arranged on the front side has a short side dimension substantially equal to the array substrate 11b arranged on the back side as shown in FIG. The substrate is smaller than the substrate 11b, and is bonded to the array substrate 11b in a state where one end in the long side direction (upper right side in FIG. 1) is aligned. Therefore, the other end (lower left side shown in FIG. 1) of the array substrate 11b in the long side direction does not overlap the CF substrate 11a over a predetermined range, and both the front and back plate surfaces are exposed to the outside. The mounting area of the driver 15 is secured here. Further, polarizing plates 11c and 11d are attached to the outer surfaces of both the substrates 11a and 11b, respectively.

Among the substrates 11a and 11b, the front side (front side) is the CF substrate 11a, and the back side (back side) is the array substrate 11b. On the inner surface side (the liquid crystal layer side, the surface facing the CF substrate 11a) of the array substrate 11b, a number of TFTs (Thin Film Transistors) and pixel electrodes, which are switching elements, are provided side by side. A gate wiring and a source wiring having a lattice shape are disposed around the gate. A predetermined image signal is supplied to each wiring from a control circuit (not shown). The pixel electrode disposed in a rectangular region surrounded by the gate wiring and the source wiring is made of a transparent electrode such as ITO (Indium Tin Oxide) or ZnO (Zinc Oxide). On the other hand, a large number of color filters are arranged side by side on the CF substrate 11a at positions corresponding to the respective pixels. The color filter is arranged so that three colors of R, G, and B are alternately arranged. A light shielding layer (black matrix) for preventing color mixture is formed between the color filters. On the surface of the color filter and the light shielding layer, a counter electrode facing the pixel electrode on the array substrate 11b side is provided. The CF substrate 11a is slightly smaller than the array substrate 11b. An alignment film for aligning liquid crystal molecules contained in the liquid crystal layer is formed on the inner surfaces of both the substrates 11a and 11b.

As shown in FIGS. 1 and 2, the cover panel 12 is arranged so as to cover the liquid crystal panel 11 from the front side over the entire region, thereby protecting the liquid crystal panel 11. The back side of the center side portion of the cover panel 12 (specifically, the whole area of the display portion of the liquid crystal panel 11 and the portion of the non-display portion that overlaps the inner peripheral side portion adjacent to the display portion in plan view) The liquid crystal panel 11 is attached to the plate surface via an adhesive BL. The adhesive BL is applied to one or both of the liquid crystal panel 11 and the cover panel 12 in a liquid state, and is solidified after the panels 11 and 12 are bonded together. Are bonded in a bonded state. Therefore, since an air layer is avoided between the cover panel 12 and the liquid crystal panel 11, display quality is improved. As the adhesive BL, it is preferable to use, for example, an ultraviolet curable resin material that is cured by irradiation with ultraviolet rays. The cover panel 12 is made of, for example, a plate-like tempered glass having high transparency. As the tempered glass used for the cover panel 12, it is preferable to use chemically tempered glass having a chemically strengthened layer on the surface, for example, by subjecting the surface of a plate-like glass substrate to chemical tempering treatment. This chemical strengthening treatment refers to, for example, a treatment for strengthening a plate-like glass substrate by replacing alkali metal ions contained in a glass material by ion exchange with alkali metal ions having an ion radius larger than that, The resulting chemically strengthened layer is a compressive stress layer (ion exchange layer) in which compressive stress remains. Thereby, since the cover panel 12 is supposed to have high mechanical strength and impact resistance, the liquid crystal panel 11 arranged on the back side can be more reliably prevented from being damaged or damaged. .

Like the liquid crystal panel 11, the cover panel 12 has a vertically long rectangular shape when seen in a plane, and the size seen in the plane is slightly larger than the substrates 11a and 11b constituting the liquid crystal panel 11, and will be described later. It is approximately the same as the outer shape of 27. Therefore, the outer peripheral side portion of the cover panel 12 projects outward from the outer peripheral end of the liquid crystal panel 11 in a bowl shape. The cover panel 12 is formed with a light shielding portion 12a that surrounds the display portion of the liquid crystal panel 11 and is arranged so as to overlap with the non-display portion in a plan view so as to block light around the display portion. The light shielding portion 12a is made of a light shielding material such as a paint exhibiting black, for example, and the light shielding material is printed on the back surface of the cover panel 12, that is, the surface of the liquid crystal panel 11 side. It is provided integrally on the plate surface. In providing the light shielding portion 12a, for example, printing means such as screen printing and ink jet printing can be employed. In addition to the portion of the cover panel 12 that overlaps the entire area of the non-display portion of the liquid crystal panel 11, the light shielding portion 12 a is also formed on the outer peripheral side portion that protrudes outward from the outer peripheral end of the liquid crystal panel 11. It is formed in a vertically long substantially frame shape (substantially frame shape) when seen in a plan view, so that light from the backlight device 13 is in a stage before entering the plate surface on the back side of the cover panel 12 around the display unit. The light can be shielded by the light shielding part 12a. That is, the light shielding portion 12a is formed over almost the entire area of the cover panel 12 that is not superposed with the display portion of the liquid crystal panel 11 in a plan view. In FIG. 1, the light shielding portion 12a is shown in a shaded shape, and a white square region inside the light shielding portion 12a is a region that transmits light from the display portion.

As shown in FIGS. 1 and 2, the backlight device 13 has a vertically long and substantially block shape as in the liquid crystal panel 11 as a whole. The backlight device 13 includes an LED (Light Emitting Diode) 22 that is a light source, an LED substrate (light source mounting substrate) 23 on which the LED 22 is mounted, a light guide plate 24 that guides light from the LED 22, and a light guide. An optical sheet (optical member) 25 stacked on the light plate 24, a reflective sheet (reflective member) 26 stacked on the light guide plate 24, and surrounds the light guide plate 24 and the optical sheet 25 and the liquid crystal panel 11 on the back side. And a frame (frame-like member) 27 supported from the side opposite to the cover panel 12 side. The backlight device 13 is an edge light type (side light type) of a one-side incident light type in which the LEDs 22 are unevenly distributed at one end portion on the short side of the outer peripheral portion. Each component of the backlight device 13 is in the form of a sheet, which enables manufacture in a roll-to-roll system, which will be described later. Hereinafter, the components of the backlight device 13 will be described sequentially.

As shown in FIG. 2, the LED 22 has a configuration in which an LED chip is sealed with a resin material on a substrate portion fixed to the plate surface of the LED substrate 23. The LED chip mounted on the substrate unit has one main emission wavelength, and specifically, one that emits blue light in a single color is used. On the other hand, the resin material that seals the LED chip is dispersed and blended with a phosphor that emits a predetermined color when excited by the blue light emitted from the LED chip, and generally emits white light as a whole. It is said. The LED 22 is a so-called side-emitting type in which a side surface adjacent to the mounting surface with respect to the LED substrate 23 is a light emitting surface. The LED 22 has a protruding height from the LED substrate 23 of, for example, about 0.4 mm to 0.8 mm.

As shown in FIGS. 1 and 2, the LED substrate 23 has a flexible sheet-like (film-like) base material made of an insulating material, and the LED 22 described above is surface-mounted on the base material. In addition, a wiring pattern for supplying power to the LED 22 is patterned. The LED substrate 23 is disposed only at one end portion on the short side of the backlight device 13 and extends along the short side direction (Y-axis direction) of the backlight device 13. A plurality of LEDs 22 are mounted on the LED substrate 23 in an intermittent manner along the extending direction. The LED substrate 23 is arranged in the form of being sandwiched between the liquid crystal panel 11 and a frame 27 described later in the thickness direction (Z-axis direction) of the backlight device 13. Therefore, the mounting surface of the LED 22 on the LED substrate 23 is a surface facing the back side (the side opposite to the liquid crystal panel 11 side). The LED substrate 23 has a thickness dimension of, for example, about 200 μm to 600 μm.

As shown in FIGS. 1 and 2, the light guide plate 24 has a vertically long sheet shape (film shape) having a plate surface parallel to the plate surface of the liquid crystal panel 11, and is flexible. Of the outer peripheral end surfaces, the end surface on the short side on the left side (lower left side in FIG. 1) shown in FIG. 2 is opposed to the LED 22 and serves as a light incident surface 24a on which light from the LED 22 is incident. Of the light guide plate 24, a plate surface facing the front side (the liquid crystal panel 11 side) is a light emitting surface 24 b that emits light toward the liquid crystal panel 11. In addition, three end surfaces (specifically, the right side short end surface and the pair of long side end surfaces shown in FIG. 2) of the outer peripheral end surface of the light guide plate 24 excluding the light incident surface 24 a are respectively connected to the LED 22. Is an LED non-opposing end face (light source non-opposing end face) that does not face each other. Note that the alignment direction of the light guide plate 24 and the LEDs 22 coincides with the long side direction (Y-axis direction) of the light guide plate 24. The light guide plate 24 has a thickness dimension of, for example, about 50 μm to 800 μm. The thickness dimension of the light guide plate 24 is preferably approximately the same as the protruding height of the LED 22 described above.

As shown in FIGS. 1 and 2, the optical sheet 25 has a flexible sheet shape (film shape) and is placed on the light emitting surface 24 b of the light guide plate 24, so that the liquid crystal panel 11 and the light guide plate are provided. 24, the light emitted from the light guide plate 24 is transmitted and emitted toward the liquid crystal panel 11 while applying a predetermined optical action to the transmitted light. A plurality of optical sheets 25 (three in this embodiment) are stacked on each other, and the first optical sheet 25a, the second optical sheet 25b, and the third optical sheet 25c are sequentially formed from the back side (light guide plate 24 side). The Each of the optical sheets 25a to 25c has a vertically long rectangular shape like the light guide plate 24, and has a size (long side dimension and short side dimension) viewed from the plane larger than that of the light guide plate 24. 11 array substrate 11b. Specific types of the optical sheet 25 include, for example, a diffusion sheet, a lens sheet, a reflective polarizing sheet, and the like, which can be appropriately selected and used. The total thickness dimension of the three optical sheet 25 groups is, for example, about 120 μm to 700 μm. If the optical sheet 25 group includes a diffusion sheet, the thickness dimension is, for example, about 40 μm to 100 μm. When a lens sheet is included, the thickness dimension is, for example, about 40 μm to 200 μm. When a reflective polarizing sheet is included, the thickness dimension is, for example, about 280 μm to 400 μm.

As shown in FIGS. 1 and 2, the reflection sheet 26 is disposed so as to cover a plate surface 24 c on the back side (opposite to the light emitting surface 24 b) of the light guide plate 24. The reflection sheet 26 is made of a synthetic resin sheet (film) that has flexibility and has a light-reflecting white surface, so that the light propagating in the light guide plate 24 can be transmitted. It is possible to efficiently start up toward the front side (light emitting surface 24b). The reflection sheet 26 has a vertically long rectangular shape, similar to the light guide plate 24, and has a size (long side dimension and short side dimension) viewed from the plane larger than the light guide plate 24, and the array substrate of the liquid crystal panel 11. It should be the same as or larger than 11b. The reflection sheet 26 is superimposed on almost the entire area of the liquid crystal panel 11 (display unit and non-display unit) in plan view, and is also superimposed on the inner peripheral side portion of the frame 27 described below in plan view. Note that at least one of the light exit surface 24b and the opposite surface 24c of the light guide plate 24 is patterned so that a scattering portion (not shown) that scatters internal light has a predetermined in-plane distribution. Thus, the light that is raised by the reflection sheet 26 and emitted from the light emitting surface 24b is controlled to have a uniform distribution in the surface. The thickness dimension of the reflection sheet 26 is, for example, about 30 μm to 200 μm.

As shown in FIG. 1, the frame 27 has a substantially vertically long frame shape whose outer shape is substantially the same as that of the cover panel 12, and the liquid crystal panel 11, the light guide plate 24, and the optical sheet 25 are accommodated inside the frame 27. ing. The frame 27 includes a pair of short side portions extending along the X-axis direction and a pair of long side portions extending along the Y-axis direction. The frame 27 is opposed to the plate surface on the back side of the outer peripheral end portion of the cover panel 12 where the light shielding portion 12a is formed and the outer peripheral end portion (part) of the non-display portion of the liquid crystal panel 11, and the same plate surface from the back side. It can be supported over the entire circumference. The frame 27 supports most of the outer peripheral end portion of the optical sheet 15 from the back side.

As shown in FIG. 2, the frame 27 has a substantially stepped shape with three steps in cross section, and the highest first step portion 27 a supports the outer peripheral end of the cover panel 12 from the back side, and is the second highest. The second step portion 27b supports the outer peripheral end portion of the non-display portion of the liquid crystal panel 11 from the back side, and the lowest third step portion 27c supports a part of the outer peripheral end portion of the optical sheet 25 and the LED substrate 23 from the back side. is doing. Among these, between the 2nd step part 27b of the flame | frame 27 and the liquid crystal panel 11, it has distribute | arranged in the form which the adhesive tape 28 for panels (adhesive member for panels) adhering to both interposes, and this adhesive for panels The liquid crystal panel 11 and the frame 27 are kept in the attached state by the tape 28. The panel adhesive tape 28 has a tape-like base material having flexibility, and an adhesive is applied to both the front and back surfaces of the base material, and is adapted to the shape of the frame 27 to be adhered. As a whole, it is formed in a vertically long substantially frame shape (FIG. 1). With this panel adhesive tape 28, the liquid crystal panel 11 and the frame 27 are fixed substantially over the entire circumference. The width dimension of the panel adhesive tape 28 having a substantially frame shape is substantially the same as or slightly narrower than the width dimension of the second step portion 27 b of the frame 27. Although the first step portion 27a and the third step portion 27c are provided on the short side portion on the LED 22 side of the frame 27, the second step portion 27b is not provided, and the LED substrate is provided on the third step portion 27c. 23 is placed. Part of the LED substrate 23 is sandwiched between the third step portion 27 c of the frame 27 and the panel adhesive tape 28. The optical sheet 25 has three other sides excluding the short side portion on the LED 22 side, specifically, the short side portion on the opposite side to the LED 22 side and the pair of long side portions on the third step portion 27 c of the frame 27. It is on. The thickness dimension of the panel adhesive tape 28 is approximately the same as the thickness dimension of the polarizing plate 11d on the back side of the liquid crystal panel 11, and specifically, for example, approximately 100 μm to 200 μm.

The frame 27 is formed by laminating three flexible frame-like sheet materials 30 to 32 as shown in FIG. Specifically, the frame 27 has a first frame-shaped sheet material 30 having a first step portion 27a, a second frame-shaped sheet material 31 having a second step portion 27b, and a third step portion 27c in order from the front side. The three-frame sheet material 32 has a laminated structure in which the frame-like sheet materials 30 to 32 are laminated in the Z-axis direction in the above order. The three frame-shaped sheet materials 30 to 32 have the same outer dimensions, but have different inner dimensions. Specifically, the first frame-shaped sheet material 30 has the largest inner dimensions in the long-side direction and the short-side direction among all the frame-shaped sheet materials 30 to 32, in other words, the long side Each width dimension of the portion and the short side portion is the smallest among all the frame-shaped sheet materials 30 to 32. On the other hand, the third frame-shaped sheet material 32 has the smallest inner dimensions in the long-side direction and the short-side direction among all the frame-shaped sheet materials 30 to 32, in other words, the long-side portion. In addition, each width dimension of the short side portion is the largest among all the frame-shaped sheet materials 30 to 32. In addition, the second frame-shaped sheet material 31 is larger than the third frame-shaped sheet material 32, although the inner dimensions in the long side direction and the short side direction are both smaller than the first frame-shaped sheet material 30. In other words, the width dimensions of the long side portion and the short side portion are both larger than the first frame-shaped sheet material 30 but smaller than the third frame-shaped sheet material 32. That is, each of the frame-like sheet materials 30 to 32 is formed such that the inner dimension is smaller on the back side than on the front side, and the width dimension is larger on the back side than on the front side. In addition, about the short side part by the side of LED22 among the 2nd frame-shaped sheet material 31 and the 3rd frame-shaped sheet material 32, the width dimension is made substantially the same, The arrangement | positioning which the inner edge part overlaps seeing in a plane It is said. In addition, the LED substrate 23 is mounted on and attached to the third step portion 27 c of the third frame-shaped sheet material 32. The first frame-like sheet material 30 has a thickness that is slightly larger than the thickness of the liquid crystal panel 11, specifically, for example, about 300 μm to 1400 μm. The second frame-shaped sheet material 31 has a thickness dimension that is substantially the same as the total thickness dimension of the three optical sheets 25, specifically, for example, approximately 120 μm to 700 μm. The thickness of the third frame-shaped sheet material 32 is approximately the same as that of the light guide plate 24. Specifically, for example, the thickness is approximately 50 μm to 800 μm. The thickness of the frame 27 as a whole is, for example, about 300 μm to 1500 μm.

The casing 14 that accommodates the backlight device 13 or the like having the above-described configuration is made of a synthetic resin material or a metal material, and has a substantially bowl shape (substantially open) toward the front side, as shown in FIGS. 1 and 2. (Bowl type). The cover panel 12, the liquid crystal panel 11, and the backlight device 13 are completely accommodated in the accommodation space held inside the casing 14. Therefore, the casing 14 covers the backlight device 13 from the back side, and covers the backlight device 13 and the cover panel 12 from the side over the entire circumference, thereby constituting the appearance of the back side and the side surface side of the liquid crystal display device 10. ing. Between the portion of the casing 14 facing the frame 27 constituting the backlight device 13 and the back surface of the frame 27, a casing adhesive tape (adhesive member for casing) 29 that adheres to both is provided. The casing 14 and the frame 27 are kept in an attached state by the casing adhesive tape 29. Since the casing adhesive tape 29 is formed in a substantially vertically long frame shape as a whole in accordance with the shape of the frame 27 to be adhered, the casing 14 and the frame 27 are fixed substantially over the entire circumference. A part of the casing adhesive tape 29 is also attached to the outer peripheral end of the reflection sheet 26. Moreover, the adhesive tape 29 for casings has a tape-shaped base material which has flexibility, an adhesive is apply | coated to both the front and back in the base material, and is the same as the above-mentioned adhesive tape 28 for panels. It is a member. In addition, in the housing space of the casing 14, the space remaining on the back side of the backlight device 13 includes a control board for controlling the driving of the liquid crystal panel 11 and an LED driving board for supplying driving power to the LEDs 22. Contains non-performing boards. The thickness of the casing adhesive tape 29 is, for example, about 60 μm to 600 μm.

The liquid crystal display device 10 according to the present embodiment has the above-described structure, and a manufacturing method thereof will be described next. The liquid crystal display device 10 is manufactured by separately assembling each component (liquid crystal panel 11, cover panel 12, backlight device 13, and casing 14) manufactured separately. Here, in particular, a method for manufacturing the backlight device 13 will be described in detail.

The backlight device 13 is manufactured by a so-called roll-to-roll method because all the components are formed into a sheet as described above. Specifically, the backlight device 13 includes a frame forming process (frame-shaped member forming process) in which the frame-shaped sheet materials 30 to 32 are stacked to form the frame 27, and a reflective sheet for attaching the reflective sheet 26 to the frame 27. A mounting step (reflection member mounting step), a light guide plate mounting step for mounting the light guide plate 24 on the reflection sheet 26, an optical sheet mounting step for mounting each optical sheet 25 on the light guide plate 24, and an LED substrate on which the LEDs 22 are mounted on the frame 27 LED attaching process (light source attaching process) for attaching 23, adhesive tape attaching process (adhesive member attaching process) for attaching the adhesive tapes 28 and 29 to the reflection sheet 26 and the frame 27, and a large number of coupled backlight devices 13 Is manufactured through a dividing step of individually dividing. Hereinafter, each step will be described in detail.

As shown in FIGS. 3 and 4, the frame forming process (frame-shaped member forming process) is such that a large number of first frame-shaped sheet materials 30 are arranged in a straight line along the short side direction (X-axis direction). A first frame-shaped sheet roll material 30R formed by winding the first frame-shaped sheet coupled bodies 30C that are connected to each other in a roll shape, and a plurality of second frame-shaped sheet materials 31 are linearly formed along the short side direction. The second frame-shaped sheet roll material 31R formed by winding the second frame-shaped sheet coupled body 31C that are connected to each other in parallel to each other, and the third frame-shaped sheet material 32 in the short side direction. A third frame-shaped sheet roll material 32R formed by winding a third frame-shaped sheet continuous body 32C that is connected in a line along a large number of lines along the roll, and each of the frame-shaped sheet materials 30 to 32. And extend in a straight line along the parallel direction (X-axis direction) A transport roll material 33R formed by winding a transport base material 33 for transporting the film 27 in a roll shape, and a pressing roller 34 for pressing the stacked transport base material 33 and each of the frame-shaped sheet continuous bodies 30C to 32C. And using. In each of the frame-like sheet coupling bodies 30C to 32C, a large number of each of the frame-like sheet materials 30 to 32 are arranged at substantially equal intervals along the X-axis direction. When performing the frame forming step, the transport roll material 33R, the first frame-shaped sheet roll material 30R, the second frame-shaped sheet roll material 31R, and the third frame-shaped sheet roll material 32R are arranged in this order from the front side. The roll members 30R to 33R are pulled out in the same direction (the right side shown in FIG. 3) along the parallel direction of the frame-like sheet materials 30 to 32, respectively. Then, the frame-like sheet continuous bodies 30C to 32C are laminated on the conveying base material 33 conveyed along the parallel direction by being pressed from the front and back by the pressing roller 34 while being laminated. In addition, in order to bond the conveyance base material 33 and each frame-shaped sheet coupled body 30C to 32C, an adhesive or the like is applied to each bonding surface (each opposing surface) in the conveyance base material 33 and each frame-shaped sheet coupling body 30C to 32C. It is preferable to apply it. Then, as shown in FIG. 5, the first frame-shaped sheet material 30, the second frame-shaped sheet material 31, and the third frame-shaped sheet material 32 are laminated in order from the front side with respect to the back side plate surface of the transport base material 33. A plurality of frames 27 are formed in parallel with each other along the parallel direction. When a frame coupled body (frame-shaped member coupled body) 27C in which a large number of parallel frames 27 are connected to each other and attached to the conveyance base material 33 is manufactured in this way, the frame coupled body 27C is wound in a roll shape. Thus, as shown in FIG. 3, a frame roll material (frame-shaped member roll material) 27R is formed.

As shown in FIGS. 6 and 7, the reflective sheet attaching step (reflecting member attaching step) includes the frame roll material 27 </ b> R manufactured through the frame forming step described above and the reflective sheet 26 in the short side direction (X-axis direction). ), A reflective sheet roll material (reflective member roll material) 26R formed by winding a reflective sheet continuous body (reflective member continuous body) 26C, which are connected to each other in a linearly parallel manner, This is performed using a pressing roller 35 for pressing the laminated frame coupled body 27 </ b> C and reflecting sheet coupled body 26 </ b> C, and a transport base material winding device 36 for winding the transport base material 33. A large number of reflection sheets 26 are arranged at substantially equal intervals along the X-axis direction in the reflection sheet coupling body 26C. When performing the reflection sheet attaching step, the frame roll material 27R and the reflection sheet roll material 26R are arranged in this order from the front side, and the roll materials 26R and 27R are respectively arranged along the parallel direction of the frame 27 (X-axis direction). Pull out in the same direction (right side shown in FIG. 6). Then, the reflection sheet coupling body 26 </ b> C is laminated on the frame coupling body 27 </ b> C transported along the parallel direction by being pressed from the front and back by the pressing roller 35. In addition, in order to bond the reflection sheet coupling body 26C and the frame coupling body 27C, it is preferable to apply an adhesive or the like to the bonding surfaces (opposing surfaces) of the reflection sheet coupling body 26C and the frame coupling body 27C. After that, as shown in FIG. 6, the transport base material 33 of the reflection sheet coupling body 26 </ b> C and the frame coupling body 27 </ b> C bonded together is wound by the transport base material winding device 36. Then, as shown in FIG. 8, a large number of reflection sheet addition materials 37 formed by laminating the frames 27 on the front plate surface of the reflection sheet 26 are formed in parallel along the parallel direction. In this state, the space in the frame 27, that is, the accommodation space for the light guide plate 24 and the optical sheet 25 is opened only on the front side, so that the light guide plate 24 and the optical sheet 25 can be attached. When the reflection sheet addition coupled body (reflection member addition coupled body) 37C formed by connecting a large number of the reflection sheet addition materials (reflection member addition materials) 37 arranged in parallel as described above is manufactured, the reflection sheet addition coupled body 37C is manufactured. As shown in FIG. 6, a reflection sheet-added roll material (reflective member-added roll material) 37 </ b> R is formed. In the following steps, the reflection sheet coupled body 26 </ b> C bears the transport function that the transport base material 33 described above bears. That is, the reflection sheet coupling body 26 </ b> C functions as a “conveyance substrate”.

As shown in FIGS. 9 and 10, the light guide plate mounting step extends the reflective sheet additional roll material 37R manufactured through the above-described reflective sheet mounting step and the light guide plate 24 linearly along the parallel direction described above. Light guide plate roll material 24R formed by winding a plurality of linearly parallel shapes on the existing light guide plate transport substrate 38 in a roll shape, laminated reflection sheet additional coupled body 37C and light guide plate transport It is performed using a pressure roller 39 for pressing the base material 38 and a light guide plate transport base material winding device 40 for winding the light guide plate transport base material 38. In the reflection sheet additional coupled body 37C, a large number of light guide plates 24 are arranged at substantially equal intervals along the X-axis direction. When performing the light guide plate mounting step, the light guide plate roll material 24R and the reflection sheet-added roll material 37R are arranged in this order from the front side, and the roll materials 24R and 37R are arranged in the parallel direction of the frame 27 (X-axis direction). Along the same direction (right side shown in FIG. 9). Then, the light guide plate 24 and the light guide plate transport base material 38 are stacked on the reflection sheet additional coupled body 37 </ b> C transported along the parallel direction by being pressed from the front and back by the pressing roller 39. In addition, in order to bond the reflection sheet additional coupled body 37 </ b> C and the light guide plate 24, it is preferable to apply an adhesive or the like to the bonding surfaces (opposing surfaces) of the reflective sheet additional coupled body 37 </ b> C and the light guide plate 24. After that, as shown in FIG. 9, the light guide plate transport base material 38 is wound up by the light guide plate transport base material winding device 40 from the light guide plate 24 bonded to the reflective sheet additional coupled body 37 </ b> C. Then, as shown in FIG. 11, a large number of light guide plate additional materials 41 in which the light guide plate 24 is laminated on the front plate surface of the reflection sheet 26 are formed in a parallel manner along the parallel direction. After producing the light guide plate additional coupled body 41C in which a large number of light guide plate additional materials 41 arranged in parallel as described above are connected to each other, the light guide plate additional coupled body 41C is wound into a roll shape, thereby forming the structure shown in FIG. As shown, a light guide plate-added roll material 41R is formed.

In the optical sheet attaching step (optical member attaching step), as shown in FIG. 12, the three optical sheets 25a to 25c are successively attached to the light guide plate additional coupled body 41C in succession. A first optical sheet attaching step (first optical member attaching step) for attaching the sheet 25a, a second optical sheet attaching step (second optical member attaching step) for attaching the second optical sheet 25b, and a third optical sheet 25c are attached. A third optical sheet attaching step (third optical member attaching step). As shown in FIGS. 12 and 13, the first optical sheet attachment process is performed along the parallel direction of the light guide plate additional roll material 41 </ b> R manufactured through the light guide plate attachment process and the first optical sheet 25 a described above. A first optical sheet transport base (first optical member transport base) 42 that extends in a straight line is formed by winding a large number of straight bases arranged in parallel at approximately equal intervals. 1 optical sheet roll material 25aR, a pressure roller 43 for pressing the laminated light guide plate additional coupled body 41C and the first optical sheet transport substrate 42, and the first optical sheet transport substrate 42 The first optical sheet carrying substrate take-up device (first optical member carrying substrate take-up device) 44 is used. When performing the first optical sheet attaching step, the first optical sheet roll material 25aR and the light guide plate-added roll material 41R are arranged in this order from the front side, and the roll materials 25aR and 41R are arranged in the parallel direction of the frame 27 (X (Axial direction) along the same direction (right side shown in FIG. 12). Then, the first optical sheet 25a and the first optical sheet transport base material 42 are stacked on the light guide plate additional coupled body 41C transported along the parallel direction, and are pressed and bonded from the front and back by the pressing roller 43. . In addition, in order to bond the light guide plate additional coupled body 41C and the first optical sheet 25a, an adhesive or the like is applied to the bonding surfaces (opposing surfaces) of the light guide plate additional coupled body 41C and the first optical sheet 25a. preferable. Thereafter, as shown in FIG. 12, the first optical sheet transport substrate 42 is transferred from the first optical sheet 25 a bonded to the light guide plate additional coupled body 41 </ b> C by the first optical sheet transport substrate winding device 44. Take it up. Then, as shown in FIG. 14, the first optical sheet additional material 45 formed by laminating the first optical sheet 25 a on the light emitting surface 24 b of the light guide plate 24 is formed in a form in which a large number are arranged in parallel along the parallel direction. Is done. As described above, a first optical sheet addition coupled body 45C in which a large number of first optical sheet addition materials 45 arranged in parallel is connected to each other is manufactured. 13 and 14, the second optical sheet transport base 46, the second optical sheet addition material 49, and the second optical sheet used in the second optical sheet attaching step and the third optical sheet attaching step described below. The additional coupled body 49C, the third optical sheet conveyance base material 50, the third optical sheet additional material 53, and the third optical sheet additional coupled body 53C are also illustrated.

As shown in FIGS. 12 and 13, in the second optical sheet attaching step, the first optical sheet additional coupled body 45C manufactured through the first optical sheet attaching step and the second optical sheet 25b are arranged in parallel as described above. A large number of linearly-parallelly-arranged parallel rolls are wound on a second optical sheet conveyance base material (second optical member conveyance base material) 46 extending linearly along the direction. Rotating second optical sheet roll material 25bR, a pressing roller 47 for pressing the laminated first optical sheet additional coupled body 45C and the second optical sheet transport base 46, and a second optical sheet transport base The second optical sheet carrying substrate winding device (second optical member carrying substrate winding device) 48 for winding the material 46 is used. When performing the second optical sheet attaching step, the second optical sheet roll material 25bR is disposed on the front side with respect to the first optical sheet addition coupled body 45C, and the second optical sheet roll material 25bR is disposed on the first optical sheet addition continuous body. The adult 45C is pulled out along the conveyance direction (the right side shown in FIG. 12). Then, the second optical sheet 25b and the second optical sheet transport base material 46 are stacked on the first optical sheet additional coupled body 45C to be transported, and are pressed and bonded from the front and back by the pressing roller 47. In order to bond the first optical sheet additional coupled body 45C and the second optical sheet 25b, an adhesive or the like is applied to the bonding surfaces (opposing surfaces) of the first optical sheet additional coupled body 45C and the second optical sheet 25b. It is preferable to keep it. Thereafter, as shown in FIG. 12, the second optical sheet transport base material 46 is transferred from the second optical sheet 25b bonded to the first optical sheet additional coupled body 45C to the second optical sheet transport base material winding device. Take up by 48. Then, as shown in FIG. 14, a plurality of second optical sheet addition materials 49 formed by laminating the second optical sheet 25b on the front plate surface of the first optical sheet 25a are arranged in parallel along the parallel direction. Formed with. As described above, a second optical sheet addition coupled body 49 </ b> C in which a large number of second optical sheet addition materials 49 arranged in parallel are connected to each other is manufactured.

As shown in FIGS. 12 and 13, in the third optical sheet attaching step, the second optical sheet additional coupled body 49C manufactured through the above-described second optical sheet attaching step and the third optical sheet 25c are arranged in parallel. A large number of linearly-parallelly-arranged parallel rolls are wound on a third optical sheet conveyance base material (third optical member conveyance base material) 50 extending linearly along the direction. Rotating third optical sheet roll material 25cR, pressing roller 51 for pressing the laminated second optical sheet additional coupled body 49C and the third optical sheet transport base material 50, and a third optical sheet transport base And a third optical sheet transport substrate winding device (third optical member transport substrate winding device) 52 for winding the material 50. When performing the third optical sheet attaching step, the third optical sheet roll member 25cR is arranged on the front side with respect to the second optical sheet addition continuous body 49C, and the third optical sheet roll member 25cR is attached to the second optical sheet addition continuous member. The adult 49C is pulled out along the conveyance direction (right side shown in FIG. 12). Then, the third optical sheet 25c and the third optical sheet transport base material 50 are stacked on the second optical sheet additional coupled body 49C to be transported, and are pressed and bonded from the front and back by the pressing roller 51. In order to bond the second optical sheet additional coupled body 49C and the third optical sheet 25c together, an adhesive or the like is applied to the bonding surfaces (opposing surfaces) of the second optical sheet additional coupled body 49C and the third optical sheet 25c. It is preferable to keep it. Thereafter, as shown in FIG. 12, the third optical sheet transport base material 50 is transferred from the third optical sheet 25c bonded to the second optical sheet additional coupled body 49C to the third optical sheet transport base material winding device. It winds up by 52. Then, as shown in FIG. 14, a large number of third optical sheet additional materials 53 formed by laminating the third optical sheet 25c on the front surface of the second optical sheet 25b are arranged in parallel along the parallel direction. Formed with. After manufacturing the third optical sheet addition compound 53C in which a large number of the third optical sheet addition materials 53 arranged in parallel are connected to each other as described above, the third optical sheet addition compound 53C is wound in a roll shape. Thereby, as shown in FIG. 12, the third optical sheet addition roll material (optical member addition roll material) 53R is formed.

As shown in FIGS. 15 and 16, the LED attachment process (light source attachment process) is arranged in the parallel direction in which the third optical sheet addition roll material 53R manufactured through the optical sheet attachment process described above and the LED substrate 23 are arranged in the parallel direction. LED substrate roll material formed by winding a plurality of linearly arranged parallel lines at almost equal intervals on a LED substrate transport base material (light source transport base material) 54 extending linearly along (Light source roll material) 23R, a pressing roller 55 for pressing the laminated third optical sheet additive 53C and the LED substrate transport substrate 54, and an LED for winding the LED substrate transport substrate 54 And a substrate conveyance base material take-up device (light source conveyance base material take-up device) 56. When performing the LED mounting step, the LED substrate roll material 23R and the third optical sheet addition roll material 53R are arranged in this order from the front side, and the roll materials 23R and 53R are arranged in parallel with each other in the frame 27 (X-axis direction). Are pulled out in the same direction (right side shown in FIG. 15). Then, the LED substrate 23 and the LED substrate transport base material 54 are stacked on the third optical sheet additional coupled body 53 </ b> C transported along the parallel direction, and are pressed and bonded from the front and back by the pressing roller 55. In addition, in order to bond the third optical sheet additional coupled body 53C and the LED substrate 23, an adhesive or the like is applied to the bonding surfaces (opposing surfaces) of the third optical sheet additional coupled body 53C and the LED substrate 23. preferable. Thereafter, as shown in FIG. 15, the LED substrate transport base material 54 is wound up by the LED substrate transport base material winding device 56 from the LED substrate 23 bonded to the third optical sheet additional coupled body 53 </ b> C. To do. Then, as shown in FIG. 17, the LED substrate additional material (light source additional material) 57 in which the LED substrate 23 is laminated on the third step portion 27 c in the third frame-shaped sheet material 32 constituting the frame 27 is the above-mentioned. It is formed in the form of a large number of parallels along the parallel direction. As described above, an LED substrate additional coupled body 57C in which a large number of LED substrate additional materials 57 arranged in parallel is connected to each other is manufactured.

As shown in FIGS. 15 and 18, the adhesive tape attaching step (adhesive member attaching step) includes the LED substrate additional coupled body 57 </ b> C manufactured through the LED attaching step and the panel adhesive tape 28 in the parallel direction described above. A plurality of linearly parallel strips are wound in a roll shape on a protective film for panel adhesive tape (first adhesive member transport substrate) 58 extending linearly along The panel adhesive tape roll material (first adhesive member roll material) 28R and the casing adhesive tape 29 linearly extend along the parallel direction as described above. An adhesive tape roll material for casing (second adhesive member roll material) 29R, which is formed by winding a plurality of linearly arranged parallel lines on the transport substrate 59 in a substantially straight line, in a roll shape; A pressing roller 60 for pressing the layers have been LED substrate added communication adult 57C, panel adhesive tape protective film 58, and a casing for adhesive tape protective film 59 is performed using. When performing the adhesive tape attaching step, the panel adhesive tape roll material 28R is disposed on the front side and the casing adhesive tape roll material 29R is disposed on the back side with respect to the LED substrate additional coupled body 57C. 29R is pulled out along the conveyance direction (right side shown in FIG. 15) of the LED substrate additional coupled body 57C. And the protective film 58 for panel adhesive tapes and the protective film 59 for casing adhesive tapes are laminated | stacked on the LED board addition coupling body 57C conveyed, and it sticks together from the front and back by the pressing roller 60. In addition, in order to paste together the LED board additional coupling body 57C, the panel adhesive tape 28, and the casing adhesive tape 29, the bonding surface (opposite surface) in the LED board additional coupling body 57C, the panel adhesive tape 28, and the casing adhesive tape 29 is used. ) Is preferably coated with an adhesive or the like. Then, as shown in FIG. 19, the panel adhesive tape 28 and the panel adhesive tape protective film 58 are laminated on the third step portion 27 c and the LED substrate 23 in the third frame-shaped sheet material 32 constituting the frame 27. In addition, a large number of backlight devices 13 in which a casing adhesive tape 29 and a casing adhesive tape protective film 59 are laminated on the rear surface of the reflection sheet 26 are formed in a parallel manner along the parallel direction. Is done. As described above, a backlight assembly 13C is manufactured in which a large number of backlight devices 13 arranged in parallel are connected to each other.

As shown in FIG. 15, the dividing step is performed using the backlight complex 13C manufactured through the above-described adhesive tape attaching step and a dividing device CA for dividing the backlight complex 13C. The dividing device CA has a cutter capable of dividing the backlight coupled body 13C along a direction (Y-axis direction) orthogonal to the conveying direction. When performing the dividing step, the dividing device CA is intermittently operated with respect to the backlight coupled body 13C transported along the transport direction, so that each backlight device 13 is separated from the backlight coupled body 13C. It has become. When the backlight device 13 thus manufactured is attached to the casing 14, the casing adhesive tape 29 is exposed by peeling off the casing adhesive tape protective film 59, and the backlight is placed in the casing 14. The apparatus 13 is accommodated so that the casing adhesive tape 29 is fixed to the casing 14. When attaching the liquid crystal panel 11 to the backlight device 13, the panel adhesive tape 28 is exposed by peeling the panel adhesive tape protective film 58, and the liquid crystal panel 11 is mounted on the front side of the backlight device 13. The panel adhesive tape 28 is fixed to the liquid crystal panel 11.

As described above, all the components of the backlight device 13 (the LED substrate 23, the light guide plate 24, the optical sheet 25, the reflection sheet 26, the frame 27, the panel adhesive tape 28, and the casing adhesive tape 29) are all rolled. Since the backlight device 13 is manufactured by assembling in a roll system, the tact time is greatly shortened as compared with the case where each component is assembled with a single wafer using a suction device. In addition, the manufacturing equipment can be simplified and the cost can be reduced.

As described above, the manufacturing method of the backlight device (illumination device) 13 according to the present embodiment has a frame shape so that the light guide plate 24 for guiding the light from the LED (light source) 22 can be surrounded. A frame forming process (frame-shaped member forming process) for forming a frame (frame-shaped member) 27 formed by arranging a large number of first frame-shaped sheet materials 30 constituting the frame 27 in a straight line. A shape in which a first frame-shaped sheet roll material 30R wound in a roll shape and a second frame-shaped sheet material 31 constituting the frame 27 are juxtaposed in a straight line along the parallel direction of the first frame-shaped sheet material 30. The second frame-shaped sheet roll material 31R formed by winding the roll arranged in the form of a roll, and the transport roll material 33R formed by winding the conveyance base material 33 extending linearly along the parallel direction into a roll shape , Each in parallel direction Thus, the first frame-shaped sheet material 30 is stacked on the conveyance base material 33 that is pulled out in the same direction and conveyed along the parallel direction, and the second frame-shaped sheet material 31 is stacked on the first frame-shaped sheet material 30. At least a frame forming step of forming a plurality of frames 27 in parallel with the conveying base material 33 along the parallel direction by pressing and adhering them together from the front and back with the pressing roller 34 while laminating the layers.

In this manner, in the frame forming step, the first frame-shaped sheet roll material 30R, the second frame-shaped sheet roll material 31R, and the transport roll material 33R are each pulled out in the same direction along the parallel direction. Since the drawn conveyance base material 33 is conveyed along the parallel direction of the first frame-shaped sheet material 30, the first frame-shaped sheet material 30 is laminated on the conveyance base material 33, and the first frame shape is further formed. A second frame-shaped sheet material 31 is laminated on the sheet material 30. When the transport base material 33, the first frame-shaped sheet material 30, and the second frame-shaped sheet material 31 stacked on each other are pressed and bonded from the front and back by the pressing roller 34, the frame 27 is attached to the transport base material 33. On the other hand, it is formed in the form where many are arranged along the parallel direction. As a result, a large number of frames 27 can be continuously formed while transporting the transport base material 33, so that the tact time is shorter than when each frame-like sheet material is assembled in a single-wafer type by a suction device. The time can be shortened and the manufacturing equipment can be simplified and the cost can be reduced.

Also, in the frame forming step, a frame roll material (frame-shaped member roll material) 27R is formed by winding a plurality of frames 27 arranged in parallel along the parallel direction with respect to the transport base material 33 into a roll shape. A reflecting sheet roll material obtained by winding a reflecting sheet coupling body (reflecting member coupling body) 26C in which a large number of reflecting sheets (reflection members) 26 are arranged in a straight line along the parallel direction into a roll shape. (Reflection member) 26R and frame roll material 27R are each pulled out in the same direction, and pressed and pasted from the front and back by the pressing roller 35 while the frame 27 is placed on the reflection sheet coupled body 26C conveyed along the parallel direction. After the alignment, the conveyance base material 33 is wound up by the conveyance base material take-up device 36, whereby the frame 27 is attached to the reflection sheet coupled body 26C, A reflecting sheet attaching step (reflecting member attaching step) for forming a reflecting sheet adding roll material (reflecting member adding roll material) 37R by winding the reflecting sheet continuous body 26C to which the screen 27 is attached in a roll shape; and the light guide plate 24 A light guide plate roll material 24R formed by winding a roll of a plurality of linearly arranged in a parallel direction with respect to the light guide plate conveyance base material 38, and a reflection sheet addition roll material 37R; Are pulled out in the same direction along the parallel direction, and pressed from the front and back by the pressing roller 39 while placing the light guide plate 24 on the reflection sheet coupled body 26C functioning as the transport base material 33 transported along the parallel direction. After bonding, the light guide plate transport base material 38 is wound up by the light guide plate transport base material winding device 40 so that the light guide plate 24 is surrounded by the frame 27. A reflective sheet attached to the communicating adult 26C light guide plate mounting step. In this way, in the light guide plate mounting step, the light guide plate roll material 24R and the reflection sheet addition roll material 37R are each pulled out in the same direction along the parallel direction. When the light guide plate 24 is placed on the reflection sheet coupling body 26C that functions as the transport base material 33 that is pulled out and transported along the parallel direction, the reflection sheet coupling body 26C and the light guide plate 24 are pressed from the front and back by the pressing roller 39. Are pasted together. Then, the light guide plate transport base material 38 is wound up by the light guide plate transport base material winding device 40, so that the light guide plate 24 is attached to the reflection sheet coupled body 26 </ b> C in a form surrounded by the frame 27. As a result, a large number of light guide plates 24 can be continuously attached while transporting the reflecting sheet coupling body 26C functioning as the transport base material 33, so that the light guide plate is temporarily attached to the transport base material by a suction device. Compared with the case where it is made to attach, the tact time can be shortened and the manufacturing equipment can be simplified and the cost can be reduced.

In the light guide plate mounting step, a plurality of frames 27 and light guide plates 24 arranged in parallel with the transport base material 33 along the parallel direction are wound in a roll shape to form a light guide plate additional roll material 41R. The optical sheet (optical member) 25 arranged in contact with the light emitting surface 24b that emits light of the light guide plate 24 is transferred to the optical sheet transport base (optical member transport base) 42, Optical sheet roll materials (optical member roll materials) 25aR, 25bR, and 25cR, which are formed by rolling a large number of linearly arranged along the parallel direction with respect to 46 and 50, and addition of a light guide plate The roll material 41R is pulled out in the same direction along the parallel direction, and the optical sheet 25 is stacked on the light guide plate 24 attached to the transport base material 33 transported along the parallel direction. After laminating by pressing from the front and back surfaces by the rollers 43, 47, 51, the optical sheet transport base materials 42, 46, 50 are wound up by the optical sheet transport base material winding devices 44, 48, 52, so that the optical An optical sheet attaching step (optical member attaching step) for attaching the sheet 25 in the form of being laminated on the light guide plate 24 is provided. If it does in this way, in an optical sheet attachment process, optical sheet roll material 25aR, 25bR, 25cR and light guide plate addition roll material 41R will be pulled out in the same direction along a parallel direction, respectively. When the optical sheet 25 is laminated on the light guide plate 24 attached to the transport base material 33 that is pulled out and transported along the parallel direction, the light guide plate 24 and the optical sheet 25 are pressed by the pressing rollers 43, 47, 51. It is pressed from the front and back and bonded. After that, the optical sheet 25 is attached to the light guide plate 24 by winding the optical sheet transport base materials 42, 46, 50 by the optical sheet transport base material winding devices 44, 48, 52. As a result, a large number of optical sheets 25 can be continuously attached to the light guide plate 24 while transporting the transport base material 33, so that the optical sheet is temporarily attached to the light guide plate 24 by the suction device. Compared to the case, the tact time can be shortened, and the manufacturing equipment can be simplified and the cost can be reduced.

Further, in the optical sheet attaching step, a plurality of optical sheets 25a to 25c attached in a stacked form with respect to the light guide plate 24 are wound in a roll shape and arranged in a parallel manner along the parallel direction. A third optical sheet-added roll material (optical member-added roll material) 53R is formed, and a large number of LEDs 22 are arranged in a straight line along the parallel direction with respect to the LED substrate transport base material (light source transport base material) 54. The LED substrate roll material (light source roll material) 23R formed by winding the product arranged in the shape of a roll and the third optical sheet addition roll material 53R are pulled out in the same direction along the parallel direction, and the parallel direction The LED 22 is mounted on the frame 27 attached to the reflection sheet coupling body 26C functioning as the transport base material 33 transported along the front and back by the pressing roller 55. After bonding by applying the LED board conveying substrate 54 by winding the LED board conveying substrate take-up device 56 comprises at least a LED mounting step of mounting the LED22 to the frame 27. In this way, in the LED mounting step, the LED substrate roll material 23R and the third optical sheet addition roll material 53R are each pulled out in the same direction along the parallel direction. When the LED 22 is placed on the frame 27 attached to the reflection sheet coupling body 26C that functions as the transport base material 33 that is pulled out and transported along the parallel direction, the frame 27 and the LED 22 are pressed from the front and back by the pressing roller 55. Pressed and pasted together. Thereafter, the LED substrate 22 is attached to the frame 27 by winding the LED substrate carrier 54 with the LED substrate carrier 56. Thereby, since many LED22 can be continuously attached to the flame | frame 27, conveying the reflective sheet | seat coupling body 26C which functions as the conveyance base material 33, temporarily LED is single-wafer | sheet-fed with respect to the flame | frame 27 with an adsorption device. Compared with the case where it attaches, while shortening tact time, simplification of manufacturing equipment and cost reduction are achieved.

Further, in the frame forming step, the first frame-shaped sheet roll material 30R is formed by winding the adjacent first frame-shaped sheet materials 30 in a roll shape, and the second frame-shaped sheet roll material. As the 31R, the one obtained by winding the adjacent second frame-shaped sheet materials 31 in a roll shape is used. If it does in this way, while separating a lot of 1st frame-like sheet roll materials and a lot of 2nd frame-like sheet roll materials individually, respectively, a 1st frame-like sheet roll material and a 2nd frame-like sheet roll material are changed. Compared to the case of transport using a dedicated transport base material, a dedicated transport base material is not required, so the number of parts can be reduced and there is no need to wind up the dedicated transport base material. This is suitable for simplifying the above.

<Embodiment 2>
A second embodiment of the present invention will be described with reference to FIGS. In the second embodiment, a case where a reflective sheet coupling body 126C is used in place of the conveyance base material 33 described in the first embodiment is shown. In addition, the overlapping description about the same structure, an effect | action, and effect as above-mentioned Embodiment 1 is abbreviate | omitted.

In the present embodiment, in the frame forming step, as shown in FIGS. 20 and 21, the frame-like sheet body 127C is formed by attaching the respective frame-like sheet-like bodies 130C to 132C to the reflecting sheet-like body 126C. ing. Specifically, in the frame forming step, each of the frame-shaped sheet rolls 130C to 132C wound in the form of a roll and each of the frame-shaped sheet rolls 130R to 132R and the reflection sheet-boundary structure 126C in a roll shape are reflected. This is performed using the sheet roll material 126R and the pressing roller 134. When performing the frame forming step, the reflective sheet roll material 126R, the first frame-shaped sheet roll material 130R, the second frame-shaped sheet roll material 131R, and the third frame-shaped sheet roll material 132R are arranged in this order from the front side. The respective roll materials 126R, 130R to 132R are pulled out in the same direction (the right side shown in FIG. 20) along the parallel direction of the respective frame-shaped sheet materials 130 to 132. Then, the frame-like sheet coupling bodies 130C to 132C are laminated on the reflection sheet coupling body 126C conveyed along the parallel direction by being pressed from the front and back by the pressing roller 134. Then, as shown in FIG. 22, the third frame-shaped sheet combination 132 </ b> C, the second frame-shaped sheet combination 131 </ b> C, and the first frame-shaped sheet combination in order from the back side with respect to the front side plate surface of the reflection sheet combination 126 </ b> C. A frame coupled body 127C formed by stacking 130C is formed. As shown in FIG. 20, the frame roll material 127 </ b> R is formed by winding the frame coupled body 127 </ b> C thus manufactured in a roll shape. As described above, in the frame forming process, the frame coupled body 127C is assumed to have the same transport function as that of the transport base material 33 described in the first embodiment, and the same applies to each process after the frame forming process. It is assumed to carry the transport function. Thereby, since the conveyance base material 33 described in Embodiment 1 can be omitted, the conveyance base material winding device 36 (see FIG. 6) used in the reflection sheet attaching step in Embodiment 1 described above is unnecessary. It becomes. Thus, the manufacturing facility can be further simplified.

As described above, according to the present embodiment, in the frame forming process, light is transmitted by being arranged in contact with the surface of the light guide plate opposite to the light emitting surface that emits light, as the transport base material. A structure is used in which a plurality of reflection sheets (reflection members) 126 for reflection on the emission surface side are connected in a line in a straight line along the parallel direction. In this way, the reflection sheet 126 serves also as the transport base material, which is useful for reducing the number of parts.

<Embodiment 3>
A third embodiment of the present invention will be described with reference to FIGS. In the third embodiment, the case where the light guide plate 224 and the LED substrate 223 are positioned in the light guide plate attaching step and the LED substrate attaching step is shown. In addition, the overlapping description about the same structure, an effect | action, and effect as above-mentioned Embodiment 1 is abbreviate | omitted.

As shown in FIG. 23, the third frame-shaped sheet material 232 included in the frame coupling body 227C formed through the frame forming process has a light guide plate positioning recess (light guide plate positioning portion) 61 for positioning the light guide plate 224. And LED positioning recesses (light source positioning portions) 62 for positioning the LEDs 222 included in the LED substrate 223 are formed. The light guide plate positioning recess 61 is formed in a concave shape by partially cutting out one long side portion (the long side portion on the right side shown in FIG. 23) of the third frame-shaped sheet material 232. The side portion is arranged in the vicinity of the end opposite to the LED 222 side, and the shape viewed in a plane is a vertically long rectangular shape. On the other hand, an end face on one long side of the light guide plate 224 is provided with a positioned convex portion 63 that can be engaged with the light guide plate positioning concave portion 61 so as to protrude sideways (FIG. 24). ). The LED positioning recess 62 is formed in a concave shape by partially notching a short side portion to which the LED substrate 223 is attached in the third frame-shaped sheet material 232, and in detail, excluding both end portions of the short side portion. Most of the shape is cut out, and the shape in a plan view is a horizontally long rectangular shape. In the LED positioning recess 62, an LED group composed of a plurality of LEDs 222 arranged side by side along the X-axis direction on the LED substrate 223 can be accommodated (FIG. 25).

In the light guide plate mounting step, as shown in FIG. 24, the light guide plate 224 transported by the light guide plate transport base material (not shown) is housed in the frame 227 forming the frame composite body 227C, and the frame composite body. A light guide plate 224 is attached to a reflection sheet coupling body (not shown) forming 227C. At this time, the light-guide plate 224 has an X-axis with respect to the frame 227 by fitting the positioned convex portion 63 of the light-guide plate 224 to the light-guide plate positioning recess 61 of the third frame-shaped sheet material 232. Positioning is performed in the direction and the Y-axis direction. Thus, a light guide plate additional coupled body 241C is formed in which each light guide plate 224 is attached to an appropriate position. Thereafter, when the optical sheet (not shown) is attached through the optical sheet attaching step, the LED attaching step is subsequently performed. In the LED mounting step, as shown in FIG. 25, the LED substrate 223 conveyed by the LED substrate conveyance base material (not shown) to the third frame-shaped sheet material 232 of the frame 227 forming the optical sheet additional coupled body. Is attached. At this time, the plurality of LEDs 222 included in the LED substrate 223 are collectively concavo-convexly fitted to the LED positioning recesses 62 included in the third frame-shaped sheet material 232, so that the LED substrate 223 is X-axis with respect to the frame 227. Positioning is performed in the direction and the Y-axis direction. Thereby, LED board additional coupled body 257C formed by attaching each LED board 223 to an appropriate position is formed.

As described above, according to the present embodiment, in the frame forming step, the third frame-shaped sheet material 232 constituting the frame 227 (at least one of the first frame-shaped sheet material and the second frame-shaped sheet material). Has a light guide plate positioning concave portion (light guide plate positioning portion) 61, and in the light guide plate mounting step, when the light guide plate 224 is placed on the reflection sheet coupled body that functions as a conveyance base material. The light guide plate positioning recess 61 is brought into contact with the light guide plate 224 so that the light guide plate 224 is positioned with respect to the frame 227 in the plane of the reflection sheet coupled body that functions as a transport base material. In this way, in the light guide plate mounting step, the light guide plate included in the third frame-shaped sheet material 232 constituting the frame 227 when the light guide plate 224 is placed on the reflection sheet coupled body that functions as a transport base. The positioning recess 61 is brought into contact with the light guide plate 224. As a result, the light guide plate 224 is appropriately positioned in the plane of the reflection sheet coupled body that functions as a transport base material with respect to the frame 227, so that the occurrence of defective products having an inappropriate positional relationship is suppressed, and the yield is thus improved. Improvement is achieved.

In the frame forming step, the third frame-shaped sheet material 232 (at least one of the first frame-shaped sheet material and the second frame-shaped sheet material) constituting the frame 227 is replaced with the LED positioning recess (light source positioning portion) 62. In the LED mounting process, when the LED 222 is mounted on the frame 227, the LED positioning recess 62 is brought into contact with the LED 222, whereby the LED 222 is used as a transport base material with respect to the frame 227. Positioning is performed in the plane of the functioning reflecting sheet composite. In this way, in the LED mounting step, when the LED 222 is placed on the frame 227, the LED positioning recess 62 included in the third frame-shaped sheet material 232 constituting the frame 227 is brought into contact with the LED 222. Thereby, since LED222 is positioned in the surface of the reflective sheet | seat coupling body which functions as a conveyance base material with respect to the flame | frame 227, generation | occurrence | production of inferior goods with inappropriate positional relationship is suppressed, and the improvement of a yield is aimed at. .

<Embodiment 4>
A fourth embodiment of the present invention will be described with reference to FIGS. In the fourth embodiment, a case where the frame-shaped sheet materials 330 to 332 attached to the frame-shaped sheet conveyance base materials 64 to 66 are used in the frame forming process is shown. In addition, the overlapping description about the same structure, an effect | action, and effect as above-mentioned Embodiment 1 is abbreviate | omitted.

In the frame forming process according to the present embodiment, as shown in FIG. 26, the frame 327 is formed by sequentially attaching the three frame-like sheet materials 330 to 332 to the transport base material 333 sequentially. The first frame-shaped sheet attaching step for attaching the first frame-shaped sheet material 330 to the transport base material 333, and the second frame-shaped sheet for attaching the second frame-shaped sheet material 331 to the first frame-shaped sheet material 330 An attachment process and the 3rd frame-shaped sheet attachment process of attaching the 3rd frame-shaped sheet material 332 with respect to the 2nd frame-shaped sheet material 331 are included. As shown in FIGS. 26 and 27, the first frame-shaped sheet attaching step is a process in which the transport roll material 333 </ b> R and the first frame-shaped sheet material 330 are linearly extended along the transport direction of the transport base material 333. A first frame-shaped sheet roll material 330R formed by winding a plurality of linearly arranged parallel lines at substantially equal intervals on a single-frame-shaped sheet conveyance base material 64, a pressing roller 65, a first This is performed by using the conveyance base material take-up device 66 for the frame-shaped sheet. When performing the first frame-shaped sheet attaching step, the transport roll material 333R and the first frame-shaped sheet roll material 330R are arranged in this order from the front side, and these roll materials 333R and 330R are respectively the same along the X-axis direction. Pull out in the direction (right side shown in FIG. 26). Then, the first frame-like sheet material 330 and the first frame-like sheet conveyance base material 64 are laminated on the conveyance base material 333 conveyed along the X-axis direction by pressing from the front and back sides with the pressing roller 65. Match. Thereafter, as shown in FIG. 26, the first frame-shaped sheet conveyance base material 64 is transferred from the first frame-shaped sheet material 330 bonded to the conveyance base material 333, and the first frame-shaped sheet conveyance base material winding device. 66 to take up. Then, as shown in FIG. 28, a large number of first frame-like sheet materials 330 are attached to the back surface of the transport base material 333 in a parallel manner along the X-axis direction.

In the second frame-shaped sheet attaching step, as shown in FIGS. 26 and 28, the conveyance base material 333 to which a large number of first frame-shaped sheet materials 330 are attached and the second frame-shaped sheet material 331 are conveyed to the conveyance base material 333. A second frame shape in which a large number of linearly arranged in parallel at substantially equal intervals on a second frame-shaped sheet conveying base 67 extending linearly along the conveying direction are wound in a roll shape. This is performed using the sheet roll material 331R, the pressing roller 68, and the second frame-shaped sheet conveyance base material winding device 69. When performing the second frame-shaped sheet attaching step, the second frame-shaped sheet roll material 331R is disposed on the back side with respect to the transport base material 333, and the second frame-shaped sheet roll material 331R is transported in the transport direction of the transport base material 333. Pull out along (right side shown in FIG. 26). The pressure roller while laminating the second frame-shaped sheet material 331 and the second frame-shaped sheet conveyance base material 67 on the first frame-shaped sheet material 330 of the conveyance base material 333 conveyed along the X-axis direction. Attached by pressing from the front and back by 68. Thereafter, as shown in FIG. 26, the second frame-shaped sheet conveyance base material 67 is wound around the second frame-shaped sheet conveyance base material 67 from the second frame-shaped sheet material 331 attached to the first frame-shaped sheet material 330. A take-up device 69 is used for winding. Then, as shown in FIG. 29, each 2nd frame-shaped sheet material 331 is attached with respect to the surface of the back side in each 1st frame-shaped sheet material 330, respectively.

As shown in FIGS. 26 and 29, the third frame-shaped sheet attaching step includes a conveying base material 333 to which a large number of first frame-shaped sheet materials 330 and second frame-shaped sheet materials 331 are attached, and a third frame shape. On the third frame-shaped sheet transport base material 70 that extends linearly along the transport direction of the transport base material 333, the sheet material 332 is formed into a roll shape in which a large number of straight lines are arranged in parallel at substantially equal intervals. The third frame-shaped sheet roll material 332R that is wound, the pressing roller 71, and the third frame-shaped sheet conveyance base material winding device 72 are used. In performing the third frame-shaped sheet attaching step, the third frame-shaped sheet roll material 332R is disposed on the back side with respect to the conveyance base material 333, and the third frame-shaped sheet roll material 332R is conveyed in the conveyance direction of the conveyance base material 333. Pull out along (right side shown in FIG. 26). The pressure roller while laminating the third frame-shaped sheet material 332 and the third frame-shaped sheet conveyance base material 70 on the second frame-shaped sheet material 331 of the conveyance base material 333 conveyed along the X-axis direction. 71 is pressed and bonded from the front and back. Thereafter, as shown in FIG. 26, the third frame-shaped sheet conveyance base material 70 is wound from the third frame-shaped sheet material 332 attached to the second frame-shaped sheet material 331, and the third frame-shaped sheet conveyance base material is wound. The take-up device 72 is used for winding. Then, a frame coupled body (see FIG. 5) is formed by attaching each third frame-shaped sheet material 332 to the back side surface of each second frame-shaped sheet material 331. Therefore, the frame coupled body is formed. Is rolled into a roll shape to form a frame roll material 327R shown in FIG.

As described above, according to the present embodiment, in the frame forming step, the first frame-shaped sheet material 330 is arranged in a parallel direction with respect to the first frame-shaped sheet conveyance base material 64 as the first frame-shaped sheet roll material 330R. In addition to using a roll of a plurality of linearly arranged along the roll, the second frame-shaped sheet material 331 is conveyed for the second frame-shaped sheet as the second frame-shaped sheet roll material 331R. The first frame-shaped sheet roll material 330 </ b> R and the conveyance roller are used after being wound in a roll shape in which a large number of lines arranged in parallel along the parallel direction with respect to the base material 67 are used. After the material 333R is pulled out in the same direction along the parallel direction, and the first frame-like sheet material 330 is stacked on the transport base material 333 while being pressed from the front and back by the pressing roller 65 and bonded together. The first frame-shaped sheet conveyance substrate 64 is wound up by the first frame-shaped sheet conveyance substrate winding device 66, and the second frame-shaped sheet roll material 331R is the same as the conveyance substrate 333 along the parallel direction. The second frame-shaped sheet material 331 is pressed and bonded from the front and back by the pressing roller 68 while being stacked on the first frame-shaped sheet material 330 while the second frame-shaped sheet material 331 is laminated. The second frame-shaped sheet conveyance base material take-up device 69 is adapted to take up.

<Other embodiments>
The present invention is not limited to the embodiments described with reference to the above description and drawings. For example, the following embodiments are also included in the technical scope of the present invention.
(1) In each of the above-described embodiments, the frame attachment process for forming the frame by attaching each frame-like sheet material to the transport base material (reflection sheet) is performed first, and then the reflection sheet attachment process and the light guide plate attachment process ( In the case where the reflection sheet is used as the conveyance base material, the manufacturing method in which the light guide plate attaching step) is sequentially performed is exemplified, but other than that, for example, for the conveyance base material or the reflection sheet (reflection sheet composite) first It is also possible to perform a frame attachment step of forming a frame by attaching each frame-like sheet material to the conveyance base material or the reflection sheet after performing the light guide plate attachment step of attaching the light guide plate. Here, when a conveyance base material is used separately from the reflection sheet in the light guide plate attachment step and the frame attachment step, the reflection sheet attachment step may be performed after the frame attachment step.

(2) In each of the above-described embodiments, the manufacturing method in which the manufacturing is performed in the order of the frame mounting process, the reflection sheet mounting process, and the light guide plate mounting process has been exemplified. It is also possible to perform the light guide plate attaching step by attaching the light guide plate to the transport substrate or the reflective sheet (reflective sheet composite). Here, when a conveyance base material is used separately from the reflection sheet in the frame attachment step and the light guide plate attachment step, the reflection sheet attachment step may be performed after the light guide plate attachment step.

(3) In each of the above-described embodiments, a manufacturing method in which manufacturing is performed in the order of the light guide plate mounting step, the optical sheet mounting step, and the LED mounting step is exemplified, but other than that, for example, the above-described Embodiment 2 is described. As described above, after forming the frame by attaching each frame-shaped sheet material to the reflective sheet (reflective sheet composite) in the frame attaching process, the LED attaching process for attaching the LED substrate to the frame is performed, and then the light guide plate is attached. It is also possible to sequentially perform the process and the optical sheet attaching process.

(4) In Embodiment 1 described above, the manufacturing method in which the frame-shaped sheet coupled bodies drawn from the frame-shaped sheet roll materials in the frame mounting step are simultaneously laminated on the conveyance base material is exemplified. In addition, for example, the manufacturing method described in the fourth embodiment can be applied to sequentially stack the frame-shaped sheet composites on the conveyance base material. Specifically, first, a first frame-shaped sheet attachment process is performed for attaching the first frame-shaped sheet coupled body drawn from the first frame-shaped sheet roll material to the conveyance base material, and then the first frame-shaped sheet coupled body is formed. On the other hand, a second frame-shaped sheet attachment step for attaching the second frame-shaped sheet coupling body drawn from the second frame-shaped sheet roll material is performed, and then the third frame-shaped sheet roll material is applied to the second frame-shaped sheet coupling body. What is necessary is just to make it perform the 3rd frame-shaped sheet | seat attachment process which attaches the 3rd frame-shaped sheet | seat coupling body pulled out from.

(5) It is of course possible to combine the manufacturing method described in the above (4) with the manufacturing method described in the above-described embodiment 2 and replace the transport substrate with a reflective sheet.

(6) In the third embodiment described above, the case where the positioning convex portion is formed on the light guide plate side and the light guide plate positioning concave portion is formed on the frame side is shown, but the concave and convex relation is reversed and the positioning target portion is positioned on the light guide plate side. Of course, it is also possible to form a concave portion and to form a light guide plate positioning convex portion on the frame side that fits with the concave portion to be positioned. Similarly, it is also possible to form an LED positioning protrusion for positioning the LED by contacting the LED on the frame.

(7) The planar shape, arrangement, number of installations, and the like of the light guide plate positioning recesses (positioned protrusions) and LED positioning recesses described in the third embodiment can be changed as appropriate.

(8) It is of course possible to combine the manufacturing method described in the above-described embodiment 4 with the manufacturing method described in the above-described embodiment 2 and replace the transport base material with a reflective sheet.

(9) In each of the above-described embodiments, the frame is composed of three frame-shaped sheet materials. However, the number of frame-shaped sheet materials constituting the frame can be changed as appropriate, for example, 2 Or four or more.

(10) Besides the above-described embodiments, the thickness and planar shape of each frame-shaped sheet material constituting the frame can be appropriately changed.

(11) In each of the above-described embodiments, the case where an adhesive is used in bonding the components constituting the backlight device in each step has been described. However, by the welding method such as thermal welding or ultrasonic welding. It is also possible to take means such as welding. Further, a double-sided tape or the like can be used instead of the adhesive.

(12) In each of the above-described embodiments, the case where the components (excluding the LED substrate) constituting the backlight device in each step are transported along the short side direction is shown, but the backlight device is configured. Of course, it is also possible for the components to be transported along their long sides. Moreover, in at least any one of the reflection sheet attachment step, the light guide plate attachment step, the optical sheet attachment step, the LED attachment step, etc., at least one of the reflection sheet, the light guide plate, the optical sheet, the LED substrate, etc. It is also possible to attach one by a single wafer type (without using a roll-to-roll method) using an adsorption device.

(13) In each of the above-described embodiments, the color portion of the color filter included in the liquid crystal panel is exemplified as three colors of R, G, and B. However, the color portion may be four or more colors.

(14) In each of the embodiments described above, an LED is used as a light source, but other light sources such as an organic EL can be used.

(15) In the above-described embodiments, the panel support frame is made of a synthetic resin. However, the panel support frame may be made of metal.

(16) In each of the above-described embodiments, the case where the tempered glass subjected to the chemical tempering treatment is used as the cover panel is shown. It is.

(17) In each of the above-described embodiments, the cover panel using tempered glass is shown. However, it is of course possible to use a normal glass material (non-tempered glass) or a synthetic resin material that is not tempered glass.

(18) In each of the above-described embodiments, a liquid crystal display device having a vertically long display screen is exemplified, but a liquid crystal display device having a horizontally long display screen is also included in the present invention. A liquid crystal display device having a square display screen is also included in the present invention.

(19) In each of the embodiments described above, a TFT is used as a switching element of a liquid crystal display device. However, the present invention can also be applied to a liquid crystal display device using a switching element other than TFT (for example, a thin film diode (TFD)). In addition to the liquid crystal display device for display, the present invention can also be applied to a liquid crystal display device for monochrome display.

(20) In addition to the above-described embodiments, for example, a configuration in which an LED is directly mounted on a flexible board that is attached to an end of a liquid crystal panel and supplies various input signals to a driver, that is, the flexible board is an LED. It is also possible to adopt a configuration having both functions as a substrate. In that case, the thickness of the flexible substrate is preferably about 100 μm to 300 μm, for example.

(21) In each of the embodiments described above, an example in which three optical sheets are stacked and arranged has been exemplified, but the number of optical sheets used can be changed to two or less or four or more. In particular, when only one optical sheet is used, it is preferable to use one having a thickness dimension of, for example, about 40 μm to 700 μm.

(22) In each of the above embodiments, the light guide plate has the same thickness as the LED projection height from the LED substrate. However, the light guide plate thickness dimension is the LED projection height from the LED substrate. The setting may be smaller than that. In that case, if the light guide plate has a wedge shape in cross section so that the end portion having the light incident surface facing the LED of the light guide plate is locally thickened to have the same height as the protruding height of the LED, It is preferable because the light incident efficiency can be kept high. Moreover, the thickness dimension of the light guide plate may be set to be larger than the protruding height of the LED from the LED substrate.

(23) In each of the embodiments described above, the light guide plate has a sheet shape (film shape) and has a flexible configuration, but the light guide plate has a rigid configuration with little flexibility. It is also possible to use.

(24) As a specific manufacturing method of the light guide plate, for example, a long sheet-shaped (film-shaped) base material is manufactured, and the base material is punched (cut) to obtain a large number of sheet-shaped (film-shaped) base materials. It is possible to obtain the light guide plate continuously. In addition, it is also possible to obtain the light guide plate by resin molding individually by injection molding or the like.

(25) In each of the above-described embodiments, the one-side light incident type backlight device in which the LEDs are arranged opposite to the end surface on one short side of the outer peripheral end surfaces of the light guide plate is illustrated. The present invention can also be applied to a one-side light incident type backlight device in which LEDs are arranged so as to face one of the outer peripheral end surfaces of the light plate. In addition, a two-surface light incident type backlight device in which LEDs are arranged so as to be opposed to one short side end surface and one long side end surface of the outer peripheral end surfaces of the light guide plate. The present invention is also applicable. In addition, the present invention is also applied to a double-sided light input type backlight device in which LEDs are arranged opposite to each of a pair of short-side end faces or a pair of long-side end faces among the outer peripheral end faces of the light guide plate. Is possible.

DESCRIPTION OF SYMBOLS 13 ... Backlight apparatus (illuminating device) 22, 222 ... LED (light source), 23R ... LED board roll material (light source roll material), 24, 224 ... Light guide plate, 24b ... Light emission surface, 24c ... Plate surface, 24R Light guide plate roll material, 25 Optical sheet (optical member), 25aR First optical sheet roll material (optical member roll material), 25bR Second optical sheet roll material (optical member roll material), 25cR Third optical Sheet roll material (optical member roll material), 26, 126 ... Reflective sheet (reflective member), 27, 127, 227 ... Frame (frame-like member), 27R, 127R, 327R ... Frame roll material (frame-like member roll material) , 30, 130, 330 ... first frame-shaped sheet material, 30R, 130R, 330R ... first frame-shaped sheet roll material, 31, 131, 331 ... second frame-shaped sheet material, 31 , 131R, 331R ... second frame-shaped sheet roll material, 32, 132, 232, 332 ... third frame-shaped sheet material, 32R, 132R, 332R ... third frame-shaped sheet roll material, 33, 333 ... conveying substrate, 33R, 333R: transport roll material, 34, 39, 43, 47, 51, 55, 65, 68, 71, 134 ... pressure roller, 38: transport base material for light guide plate, 40: transport base material for light guide plate Device: 41R: Light guide plate-added roll material, 42: First optical sheet conveyance substrate (optical member conveyance substrate), 44: First optical sheet conveyance substrate winding device (optical member conveyance substrate winding) Take-up device), 46 ... second optical sheet carrying substrate (optical member carrying substrate), 48 ... second optical sheet carrying substrate take-up device (optical member carrying substrate take-up device), 50 ... Third optical sheet transport substrate (optical Material transport substrate), 52... Third optical sheet transport substrate winding device (optical member transport substrate winding device), 54. LED substrate transport substrate (light source transport substrate), 56. LED substrate transport substrate winding device (light source transport substrate winding device), 61... Light guide plate positioning recess (light guide plate positioning portion), 62... LED positioning recess (light source positioning portion)

Claims (8)

A frame-shaped member forming step of forming a frame-shaped member that forms a frame shape so as to surround a light guide plate for guiding light from a light source, the first frame shape forming the frame-shaped member A first frame-shaped sheet roll material obtained by winding a plurality of sheet materials arranged in a straight line into a roll shape, and a second frame-shaped sheet material constituting the frame-shaped member is the first frame shape. A second frame-shaped sheet roll material obtained by winding a plurality of sheets arranged in a straight line along the parallel direction of the sheet material into a roll, and a conveyance base extending linearly along the parallel direction A first roll-shaped sheet material with respect to the conveying base material that is drawn out in the same direction along the parallel direction and is conveyed along the parallel direction. And the second frame-shaped sheet material with respect to the first frame-shaped sheet material Lighting including at least a frame-shaped member forming step of forming a plurality of the frame-shaped members in parallel with each other along the parallel direction with respect to the transport base material by pressing and laminating from the front and back with a pressing roller while laminating. Device manufacturing method. In the frame-shaped member forming step, as the transport base material, the light guide plate is arranged in contact with a plate surface opposite to the light emitting surface that emits light, and reflects light to the light emitting surface side. The manufacturing method of the illuminating device of Claim 1 in which the reflection member for this was connected in the form where many linearly arranged in parallel along the said parallel direction. In the frame-shaped member forming step, a frame-shaped member roll material is formed by winding a plurality of the frame-shaped members arranged in parallel along the parallel direction with respect to the transport base material in a roll shape. And
A light guide plate roll material obtained by winding the light guide plate into a roll shape in which the light guide plate is arranged in a straight line along the parallel direction with respect to the light guide plate conveyance base material, and the frame-shaped member roll material And after pulling out in the same direction along the parallel direction, and pressing and sticking together from the front and back by a pressure roller while placing the light guide plate on the transport base material transported along the parallel direction, A light guide plate mounting step of attaching the light guide plate to the transport base material in a form surrounded by the frame-shaped member by winding the light guide plate transport base material with a light guide plate transport base material winding device. The manufacturing method of the illuminating device of Claim 1 or Claim 2. In the frame-shaped member forming step, the frame-shaped member is formed such that at least one of the first frame-shaped sheet material and the second frame-shaped sheet material constituting the frame-shaped member has a light guide plate positioning portion. Formed,
In the light guide plate mounting step, when the light guide plate is placed on the transport substrate, the light guide plate positioning unit is brought into contact with the light guide plate to place the light guide plate with respect to the frame-shaped member. The method for manufacturing an illumination device according to claim 3, wherein positioning is performed in a plane of the material. In the light guide plate mounting step, the frame-shaped member and the light guide plate arranged in a parallel manner along the parallel direction with respect to the transport base material are wound into a roll shape, and a light guide plate additional roll material is obtained. To form,
A roll in which a plurality of optical members arranged in contact with a light emitting surface that emits light out of the light guide plate are arranged in a line in a straight line along the parallel direction with respect to the conveyance base for optical members. The optical member roll material wound in a shape and the light guide plate additional roll material are each pulled out in the same direction along the parallel direction and attached to the transport base material transported along the parallel direction. After laminating the optical member to the light guide plate by pressing from the front and back with a pressing roller, the optical member transport base material is wound up by the optical member transport base material winding device, The manufacturing method of the illuminating device of Claim 3 or Claim 4 provided with the optical member attachment process attached in the form which laminated | stacked the optical member on the said light-guide plate. In the frame-shaped member forming step, a frame-shaped member roll material is formed by winding a plurality of the frame-shaped members arranged in parallel along the parallel direction with respect to the transport base material in a roll shape. And
A light source roll material obtained by winding a light source with a plurality of linearly arranged in parallel along the parallel direction with respect to the light source transport base material, and the frame-shaped member roll material. Each is pulled out in the same direction along the parallel direction, and pasted by pressing the light source from the front and back with a pressure roller onto the frame-like member attached to the transport base material transported along the parallel direction. The light source attachment process which attaches the said light source with respect to the said frame-shaped member by winding up the said conveyance base material for light sources with the conveyance base material winding device for light sources after match | combining at least. 6. A method for manufacturing a lighting device according to any one of items 5 to 6. In the frame-shaped member forming step, the frame-shaped member is formed such that at least one of the first frame-shaped sheet material and the second frame-shaped sheet material constituting the frame-shaped member has a light source positioning portion. And
In the light source mounting step, when the light source is placed on the frame-shaped member, the light source positioning portion is brought into contact with the light source, whereby the light source is brought into contact with the frame-shaped member in the plane of the transport base material. The manufacturing method of the illuminating device of Claim 6 made to position. In the frame-shaped member forming step, as the first frame-shaped sheet roll material, a material obtained by winding the adjacent first frame-shaped sheet materials in a roll shape and using the second frame-shaped sheet is used. The manufacturing method of the illuminating device of any one of Claim 1 to 7 which uses what rolls what connected the said 2nd frame-shaped sheet material adjacent as a roll material. .

Images