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WO2014156530A1 - Procédé de fabrication de corps stratifié - Google Patents

Procédé de fabrication de corps stratifié Download PDF

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Publication number
WO2014156530A1
WO2014156530A1 PCT/JP2014/055725 JP2014055725W WO2014156530A1 WO 2014156530 A1 WO2014156530 A1 WO 2014156530A1 JP 2014055725 W JP2014055725 W JP 2014055725W WO 2014156530 A1 WO2014156530 A1 WO 2014156530A1
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WO
WIPO (PCT)
Prior art keywords
film
liquid crystal
tension
fpr
sheet
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/JP2014/055725
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English (en)
Japanese (ja)
Inventor
孝浩 大場
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Fujifilm Corp
Original Assignee
Fujifilm Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from JP2013064667A external-priority patent/JP2014191075A/ja
Priority claimed from JP2013073587A external-priority patent/JP2014197156A/ja
Application filed by Fujifilm Corp filed Critical Fujifilm Corp
Publication of WO2014156530A1 publication Critical patent/WO2014156530A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/30—Polarising elements
    • G02B5/3016—Polarising elements involving passive liquid crystal elements
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B30/00—Optical systems or apparatus for producing three-dimensional [3D] effects, e.g. stereoscopic images
    • G02B30/20—Optical systems or apparatus for producing three-dimensional [3D] effects, e.g. stereoscopic images by providing first and second parallax images to an observer's left and right eyes
    • G02B30/22—Optical systems or apparatus for producing three-dimensional [3D] effects, e.g. stereoscopic images by providing first and second parallax images to an observer's left and right eyes of the stereoscopic type
    • G02B30/25—Optical systems or apparatus for producing three-dimensional [3D] effects, e.g. stereoscopic images by providing first and second parallax images to an observer's left and right eyes of the stereoscopic type using polarisation techniques

Definitions

  • the present invention relates to a method for producing a laminate including a patterned retardation film and a display panel.
  • a patterned retardation film (Film Pattern Retarder, hereinafter referred to as FPR) is used as an optical filter of a stereoscopic image display device that uses polarized glasses with different circularly polarized directions on the left and right sides.
  • the FPR has a stripe pattern in which first and second phase difference regions having a line width of 250 to 700 ⁇ m are alternately arranged horizontally.
  • a liquid crystal layer aligned so that the optical axes are orthogonal to each other is formed in the first retardation region and the second retardation region.
  • the lines of the first phase difference region and the second phase difference region are made to coincide with the pixel pitch constituting the horizontal line of the display screen of the stereoscopic image display device with high accuracy.
  • a stereoscopic image is observed by observing the display light whose polarization direction is modulated for each horizontal pixel line through the corresponding first and second phase difference regions and polarizing glasses.
  • a pretreatment sheet is formed by a mixture containing a polymer compound and a photoisomerization substance, and the pretreatment sheet is uniaxially stretched. Thereafter, the pretreatment sheet is irradiated with light having an irradiation intensity distribution to form a first region and a second region having different slow axis directions or fast axis directions.
  • the method of International Publication No. 2010/090429 A2 uses two types of mask plates in which slits and light-shielding portions are exchanged and arranged in the width direction of the support of the FPR when manufacturing FPR. Are arranged in the film transport direction. Further, in the method of International Publication No. 2010/090429 A2, ultraviolet rays having different polarization directions are sequentially irradiated to the support through each mask plate while the film is conveyed.
  • FPR is required to have extremely high accuracy with respect to the stripe pattern of the first phase difference region and the second phase difference region. This is because the accuracy of the stripe pattern affects the display accuracy of the display device. Therefore, when manufacturing FPR by the method of Japanese Patent Laid-Open No. 10-153707, a high irradiation technique is required to form regions having different irradiation intensities in the light irradiation step. In addition, when FPR is manufactured by the method of International Publication No. 2010/090429 A2, the positional relationship between the two types of mask plates and the support, the positional relationship between the two types of mask plates, and the like are set by trial and error. The
  • an object of the present invention is to propose a method for manufacturing a laminate that improves display accuracy in a display device.
  • the manufacturing method of the laminated body of this invention is equipped with a 1st cutting step (A step), a 1st tension
  • step A a long patterned retardation film is cut into a desired size to obtain a patterned retardation sheet.
  • first and second retardation regions having different retardation characteristics are alternately formed in the width direction.
  • the first and second retardation regions are formed by forming a liquid crystal layer on the reaction film after irradiating a specific light onto a support that is continuously transported with the reaction film formed on the surface.
  • the specific light is irradiated in an irradiation pattern in which linear irradiation regions and non-irradiation regions are alternately arranged in the width direction orthogonal to the conveyance direction of the support.
  • the reaction film is given different alignment characteristics with respect to the liquid crystal depending on the presence or absence of specific light irradiation.
  • step B the patterned phase difference sheet is pulled in a direction corresponding to the conveyance direction with a tension within a range of 20% to 180% of the tension in the conveyance direction of the support while being irradiated with specific light.
  • the patterned retardation sheet is bonded to the display panel in a state of being pulled by the B step to form a laminate.
  • the method for producing a laminate of the present invention includes a second cutting step (D step), a second tension step (E step), and a second bonding step (F step).
  • D step a multilayer film in which a long patterned retardation film and a long transparent polymer film overlap is cut into a target size to form a multilayer sheet.
  • the patterned retardation film first and second retardation regions having different retardation characteristics are alternately formed in the width direction. The first and second retardation regions are formed by forming a liquid crystal layer on the reaction film after irradiating a specific light onto a support that is continuously transported with the reaction film formed on the surface.
  • the specific light is irradiated in an irradiation pattern in which linear irradiation regions and non-irradiation regions are alternately arranged in the width direction orthogonal to the conveyance direction of the support.
  • the reaction film is given different alignment characteristics with respect to the liquid crystal depending on the presence or absence of specific light irradiation.
  • the polymer film is manufactured while being continuously conveyed.
  • the multilayer sheet is pulled in a direction corresponding to the conveyance direction of the support.
  • the patterned retardation sheet is bonded to the display panel in a state of being pulled by the E step to form a laminate.
  • the E step pulls the multilayer sheet with a tension based on the tension in the transport direction of the support while the specific light is irradiated.
  • the present invention is particularly effective when the support is formed by applying a tension in the width direction.
  • the present invention is particularly effective when the polymer film is formed by applying a tension in the width direction.
  • the manufacturing method of a laminated body is further provided with a multilayering step (G step).
  • G step the patterned retardation film and the polymer film are bonded together to form a multilayer film.
  • the manufacturing method of a laminated body is further provided with the alignment step (H step).
  • the display panel and the stretched patterned retardation sheet are aligned before bonding.
  • the display panel has a plurality of pixels arranged in the horizontal and vertical directions.
  • the patterned retardation sheet and the display panel are positioned in a state where the boundary between the specific first retardation area and the second retardation area of the patterned retardation sheet overlaps the edges of a plurality of pixels arranged in the horizontal or vertical direction. To be combined.
  • the laminate manufacturing method further includes an irradiation step (I step) and a liquid crystal layer forming step (J step).
  • I step the reaction film is irradiated with specific light emitted from the light source unit through the mask in the aforementioned irradiation pattern.
  • the mask slits extending in the transport direction of the support are formed at a constant pitch in the width direction of the support.
  • J step a liquid crystal layer is formed on the reaction film that has undergone the I step.
  • the display accuracy in the display device is improved.
  • Examples of the laminate manufactured according to the present invention include a display device (display), and examples of the display device include a liquid crystal display device and a plasma display device.
  • a liquid crystal display device is manufactured by attaching an FPR (Film Patterned Retarder) to a display panel.
  • FPR Fin Patterned Retarder
  • the liquid crystal display device 10 as an example is configured by bonding a sheet-like FPR 12 to a liquid crystal panel 11 as a display panel.
  • the liquid crystal panel 11 instead of the liquid crystal panel 11, other known liquid crystal panels may be used.
  • the liquid crystal panel 11 includes a liquid crystal cell 15 that changes the polarization state of transmitted light, and two polarizing plates 16 and 17.
  • the liquid crystal cell 15 includes a glass substrate 20 on the surface on the light source side and a glass substrate 21 on the surface on the viewing side.
  • a plurality of transparent X electrodes 22 are formed on the inner surface of the glass substrate 20, and an alignment film 23 is laminated so as to cover them.
  • a color filter layer 26 and a protective film 27 are formed on the inner surface of the glass substrate 21.
  • a transparent Y electrode 28 is formed on the surface of the protective film 27, and an alignment film 31 is laminated so as to cover the Y electrode.
  • the liquid crystal is sealed between the pair of alignment films 23 and 31 to form a liquid crystal layer 32.
  • the liquid crystal panel 11 controls the transmission of light from the light source for each pixel arranged in a matrix by arranging a plurality in the horizontal and vertical directions.
  • the liquid crystal panel 11 is driven by a known simple matrix method. That is, a plurality of X electrodes 22 and Y electrodes 28 are provided in a state of being orthogonal to each other. By applying a voltage between any X electrode 22 and Y electrode 28, these X electrode 22 and Y electrode 28 The alignment state of the liquid crystal of the pixel at the position where the line 28 intersects is changed.
  • each filter 33 is a filter of any one color of an R filter that transmits red light, a G filter that transmits green light, and a B filter that transmits blue light.
  • the filter 33 is provided for each pixel. Therefore, each pixel is either a red pixel provided with an R filter, a green pixel provided with a G filter, or a blue pixel provided with a B filter.
  • the polarizing plate 16 is disposed on the outer surface of the glass substrate 20, and the polarizing plate 17 is disposed on the outer surface of the glass substrate 21.
  • the polarizing plates 16 and 17 are both of the linear polarization type, and have a crossed Nicols arrangement. Thereby, the light from the light source is incident on the liquid crystal cell 15 through the polarizing plate 16, and the polarization state is changed according to the alignment state of the liquid crystal cell 15, whereby the amount of light transmitted through the polarizing plate 17 is changed for each pixel. Control.
  • the FPR 12 has first and second phase difference regions R1 and R2 whose details will be described later.
  • each of the first phase difference region R1 and the second phase difference region R2 has a width of three pixels (the length in the vertical direction in FIG. 1) and extends in a line shape in the horizontal direction. Are lined up alternately.
  • the first phase difference region R1 and the second phase difference region R2 extend in the horizontal direction with widths of other pixels such as 2 pixels and 4 pixels, for example, instead of the width of 3 pixels. May be.
  • the FPR 12 is bonded to the polarizing plate 17 in a state where the boundaries between the first and second retardation regions R1 and R2 coincide with the pixel boundaries of the liquid crystal panel 11.
  • the optical axes for example, (in-plane) slow axes are orthogonal to each other as indicated by arrows A1 and A2.
  • the direction in which the first phase difference region R1 and the second phase difference region R2 are alternately arranged coincides with the width direction of the support 40 that is orthogonal to the transport direction of the support 40 when the FPR 12 is manufactured.
  • the support 40 include films composed of cellulose acylate such as cellulose triacetate (TAC), norbornene polymer, cycloolefin polymer, and acrylic polymer such as polymethyl methacrylate.
  • the FPR 12 has a structure in which an alignment film 41, a liquid crystal layer 42, and an adhesive layer 45 are laminated on one surface of the support 40.
  • the adhesive layer 45 is provided to adhere the FPR 12 and the liquid crystal panel 11. Note that the adhesive layer 45 may be disposed on the surface of the support 40 opposite to the surface on which the alignment film 41 is formed, instead of on the liquid crystal layer 42.
  • the first and second retardation regions R1 and R2 have their slow axes orthogonal to each other by changing the alignment direction of the liquid crystal in the liquid crystal layer.
  • Reference numeral 38 denotes a boundary between the first retardation region R1 and the second retardation region R2 which are non-oriented regions.
  • the FPR 12 is manufactured by, for example, the FPR manufacturing facility 50 shown in FIG.
  • the FPR manufacturing equipment 50 includes a transport mechanism 51, a reaction film forming unit 52, an exposure device 53, a tension adjusting unit 54, a rubbing processing unit 55, a liquid crystal layer forming unit 56, an adhesive layer forming unit 57, a cutting unit 58, and the like. Is done.
  • the FPR manufacturing equipment 50 manufactures the sheet-like FPR 12 by performing various processes on the supplied long support 40.
  • the sheet-like FPR 12 manufactured by the FPR manufacturing facility 50 is guided to a bonding device 59 described later and bonded to the liquid crystal panel 11 (see FIG. 1).
  • a winding unit may be provided between the reaction film forming unit 52 and the exposure device 53 and between the liquid crystal layer forming unit 56 and the adhesive layer forming unit 57.
  • the FPR manufacturing facility 50 includes a cutting unit 58, but the cutting unit 58 may be provided outside the FPR manufacturing facility 50.
  • the FPR manufacturing facility 50 is for manufacturing a long FPR 12 and includes a winding unit (not shown) that winds the long FPR 12 downstream of the adhesive layer forming unit 57.
  • the support 40 is transparent and flexible.
  • the support 40 is drawn from a support roll (not shown) wound in a roll shape and supplied to the FPR manufacturing facility 50.
  • the support 40 is continuously transported at a constant speed by the transport mechanism 51.
  • the reaction film forming unit 52 is for forming a reaction film on one surface of the support 40.
  • the reaction film contains a photoacid generator that reacts with light irradiated in a subsequent process.
  • a coating solution containing a photoacid generator is applied to the surface of the support 40, and further a drying process is performed to form a reaction film having a certain thickness on the support 40.
  • the reaction film forming unit 52 may saponify the support surface to be applied before applying the coating solution.
  • the photoacid generator decomposes by irradiation with ultraviolet rays to generate an acid.
  • a pyridinium salt, an iodonium salt, a sulfonium salt, or the like can be used.
  • the photoacid generator may react with light having a specific wavelength other than ultraviolet rays.
  • a technique such as spraying other than coating may be used.
  • the support 40 on which the alignment film is formed is sent from the reaction film forming unit 52 to the exposure device 53.
  • the exposure device 53 includes a light source 61, a mask 62, a backup roller 63, and the like.
  • the light source unit 61 outputs ultraviolet light that decomposes the photoacid generator contained in the reaction film to generate an acid.
  • a light source unit that outputs the reacting light is used. Ultraviolet rays from the light source unit 61 are applied through the mask 62 to the reaction film of the support 40 that is being continuously conveyed and is wound around the peripheral surface 63a of the backup roller 63 and supported on the back surface side.
  • stripe pattern irradiation is performed in which the portion that becomes the first retardation region R1 is a linear irradiation region and the other portion is a linear non-irradiation region. Details of pattern irradiation will be described later with reference to another drawing.
  • the backup roller 63 is rotatable and may be rotated following the conveyance of the support 40, or may be rotated by a motor or the like in synchronization with the conveyance of the support 40.
  • the tension adjusting unit 54 is composed of, for example, a dancer roller 66 and a spring 67. The position of the dancer roller 66 in the lateral direction in FIG. Thereby, the tension adjusting unit 54 holds the tension in the transport direction of the support 40 being transported, in particular, the tension in the transport direction of the support 40 while the exposure device 53 is radiating ultraviolet rays at a preset value. To do.
  • various known tension adjustment units that can adjust the tension in the conveyance direction of the support 40 that is continuously conveyed may be used.
  • the rubbing processing unit 55 includes a rubbing roller (not shown) and its driving mechanism (not shown), and performs a rubbing process on the reaction film irradiated with ultraviolet rays by the exposure device 53 to give the reaction film an orientation.
  • the alignment film 41 (see FIG. 2) is used.
  • the rubbing processing unit 55 performs a rubbing process on the reaction film on the support 40 in a rubbing direction of 45 ° with respect to the transport direction of the support 40 by a rubbing roller.
  • the support 40 that has undergone the rubbing treatment is sent to the liquid crystal layer forming section 56.
  • the rubbing processing unit 55 is provided downstream of the exposure apparatus 53, but instead of this aspect, it may be provided between the reaction film forming unit 52 and the exposure apparatus 53. In this case, the reaction film is subjected to a rubbing process by the rubbing processing unit 55, and becomes an alignment film 41 (FIG. 2) by irradiation of ultraviolet light from the exposure device 53.
  • the liquid crystal layer forming unit 56 forms a liquid crystal layer 42 (see FIG. 2) that exhibits retardation characteristics on the alignment film 41 according to the first and second retardation regions R1 and R2.
  • a coating liquid containing a vertical alignment agent, a discotic liquid crystal, etc. is applied to the surface of the alignment film 41, further subjected to treatment such as heat aging and cooling, and further curing the coating film by irradiation with ultraviolet rays.
  • the liquid crystal layer 42 is obtained.
  • the adhesive layer forming portion 57 is for forming the adhesive layer 45 on the liquid crystal layer 42 of the support 40 sent from the liquid crystal layer forming portion 56.
  • the long pressure-sensitive adhesive film 68 forming the pressure-sensitive adhesive layer 45 is rolled.
  • the adhesive layer forming unit 57 includes a delivery device (not shown) that pulls out and sends out the adhesive film 68 from the adhesive film roll, a roller pair 69, and the like.
  • the roller pair 69 nips the adhesive film 68 and the support 40 supplied from the delivery machine and continuously bonds them together to form a long FPR 12.
  • the cutting unit 58 cuts the long FPR 12 into a target size, for example, a rectangular sheet.
  • the alignment state of the liquid crystal of the liquid crystal layer 42 in the FPR 12 is governed by the interaction of the material of the alignment film 41, the liquid crystal, and an alignment controller added as desired.
  • the photoacid generator contained in the reaction film 72 on the support 40 remains undecomposed in the unirradiated region of ultraviolet rays, and decomposes to generate an acidic compound in the irradiated region.
  • the above interaction is no longer dominant, the rubbing direction of the alignment film 41 dominates the alignment state, and the liquid crystal is aligned with the slow axis in the rubbing direction, that is, parallel alignment.
  • the alignment control agent there is a vertical alignment agent as the alignment control agent, and a discotic liquid crystal as the liquid crystal.
  • the vertical alignment agent has an action of raising the discotic liquid crystal vertically with respect to the surface of the alignment film 41 and an action of aligning the discotic liquid crystal in a direction orthogonal to the rubbing direction.
  • the mask 62 of the exposure apparatus 53 has a mask pattern in which a plurality of slits 62a whose longitudinal direction is aligned with the transport direction of the support 40 are arranged at a constant pitch in the width direction orthogonal to the transport direction. Have.
  • the light from the light source unit 61 is irradiated to the reaction film 72 through the mask 62.
  • the surface of the support 40 during continuous conveyance is irradiated with specific light in an irradiation pattern in which irradiation and non-irradiation are alternately arranged in the width direction, and irradiation regions RE and non-irradiation extending in a stripe shape in the conveyance direction.
  • the regions RN are formed so as to be alternately arranged in the width direction.
  • the irradiation region RE in which the acidic compound is generated has the function of vertically raising the discotic liquid crystal, but the function of aligning in the direction perpendicular to the rubbing direction is lost. For this reason, in the liquid crystal layer 42 disposed on the irradiation region RE, the discotic liquid crystal stands up and is oriented in the rubbing direction.
  • the action by the vertical alignment agent is still preserved in the non-irradiated region RN.
  • the discotic liquid crystal stands vertically and has an orientation posture orthogonal to the rubbing direction.
  • the FPR 12 (see FIG. 3) obtained through this irradiation pattern has a fixed-width line of discotic liquid crystal in a posture that is erected and oriented in the rubbing direction, and a discotic that is erected and orthogonal to the rubbing direction.
  • a line having a certain width of liquid crystal is alternately arranged, and has a stripe pattern of a first retardation region R1 and a second retardation region R2 whose slow axes are orthogonal to each other.
  • the long FPR 12 is cut into a sheet shape as shown in FIG.
  • the broken line in (A) of FIG. 5 is a cutting line which shows a cutting position.
  • two rectangular sheets are taken in the width direction from the long FPR 12, but the number of sheets cut out in the width direction depends on the width of the long FPR 12 and the size of the target sheet. Different.
  • each sheet has the length of the first edge E1 of the sheet corresponding to the cutting line C1 in the center in the width direction, and the width direction.
  • the lengths of the second edges E2 corresponding to the outer cutting lines C2 are different from each other.
  • the second edge E2 is slightly longer than the first edge E1.
  • two sheets are taken with a cutting line forming a rectangle of 400 mm ⁇ 700 mm having a short side matching the width direction as shown in FIG.
  • the length of the first edge E1 of each sheet is approximately 700.0 mm, and the length of the second edge E2 is approximately 700.3 mm.
  • the first phase difference region R1 and the second phase difference region R2 that extend linearly in the conveyance direction in the long FPR 12 are the second edge side in the sheet as shown in FIG. It becomes a very slightly convex curve.
  • FIG. 5A the illustration of the first phase difference region R1 and the second phase difference region R2 is omitted to avoid complication of the illustration.
  • FIG. 5B the degree of deformation of the sheet is greatly exaggerated.
  • the sheet-like FPR 12 is pulled in a direction corresponding to the conveying direction when the sheet is long.
  • the first retardation region R1 and the second retardation region R2 that are deformed slightly in the sheet are linearized as shown in FIG. 5C.
  • the sheet-like FPR 12 is liquid crystal by the laminating device 59 (see FIG. 3) in a state where the first retardation region R1 and the second retardation region R2 are held in a straight line, that is, in a state where tension is applied. It is bonded to the panel 11 (see FIG. 1).
  • the bonding device 59 is in a state where the boundary 38 between the first phase difference region R1 and the second phase difference region R2 of the FPR 12 is overlapped with the edges (edges) of a plurality of pixels arranged in a certain direction of the liquid crystal panel 11, and the FPR 12 This is for attaching the liquid crystal panel 11 together.
  • the bonding device 59 includes a tension part 81, a bonding part 82, and the like, and bonds the liquid crystal panel 11 to the sheet-like FPR 12 held at a predetermined tension.
  • the tension portion 81 includes first and second clips 83 and 84, a tension measuring device 87, a tension mechanism 88, a camera 91, a moving mechanism 92, an elevating mechanism 93, a controller 96, and the like.
  • the first clip 83 and the second clip 84 are for gripping the supplied FPR 12, and control the clamping members 83a and 84a that sandwich the FPR 12, and the clamping and release of the clamping members 83a and 84a.
  • the first and second clips 83 and 84 have a direction in which the distance between them is changed (referred to as A direction), a vertical direction (B direction) in FIG.
  • first and second clips 83 and 84 are displaced while maintaining their mutual posture and relative position in the AC plane determined by the A direction and the C direction.
  • the first clip 83 sandwiches one end of the sheet-like FPR 12 in the direction corresponding to the above-described transport direction, and the second clip 84 sandwiches the other end. Therefore, when the FPR 12 is sandwiched, the first clip 83 and the second clip 84 make the A direction coincide with the transport direction described above.
  • the coincidence does not necessarily have to be a strict coincidence, and there may be a deviation as long as it is a slight deviation within 0.0001 °. Since the first and second clips 83 and 84 are for holding the FPR 12, other holding means, for example, a suction plate (not shown) for holding the FPR 12 by suction on the film surface of the FPR 12, You may replace with the pin (not shown) etc. which penetrate and hold
  • the clip body 83 b of the first clip 83 is connected to the tension measuring device 87, and the tension measuring device 87 is connected to the controller 96.
  • the tension measuring device 87 detects the tension applied to the FPR 12 by the first and second clips 83 and 84 and outputs the detection signal to the controller 96.
  • Examples of the tension measuring device 87 include a load cell and a spring measurement.
  • the clip main body 84 b of the second clip 84 is connected to the pulling mechanism 88.
  • the pulling mechanism 88 includes, for example, a ball screw and a motor that displace the clip main body 84b of the second clip 84, and displaces the clip main body 84b in the A direction with the FPR 12 being held.
  • the controller 96 is also connected to the pulling mechanism 88, and when the detection signal from the tension measuring device 87 is input, the position of the clip body 84b in the A direction is controlled via the pulling mechanism 88. Thereby, the target tension in the A direction is applied to the FPR 12 held between the holding members 83a and 84a.
  • the pulling mechanism 88 may be composed of an air cylinder or the like.
  • the target tension is in the range of 20% or more and 180% or less of the tension in the transport direction of the support 40 while the exposure device 53 is irradiated with ultraviolet rays.
  • the tension in this specification is a tension per 1 m width. That is, when the tension per 1 m width in the conveying direction of the support body 40 during irradiation with ultraviolet rays is T1 (N / m), the A direction is applied in the A direction by the first clip 83 and the second clip 84.
  • the tension per 1 m in the direction perpendicular to is in the range of T1 ⁇ 0.20 or more and T1 ⁇ 1.80 or less.
  • This tension is applied to change the first phase difference region R1, the second phase difference region R2, and the boundary 38 from a curved line to a straight line having a constant width, which is less than 20% and exceeds 180%.
  • the tension is not a straight line with a sufficient width.
  • the more preferable tension (N / m) applied in the A direction is in the range of 90% to 110% of the tension in the conveying direction of the support 40 while being irradiated with ultraviolet rays, and the difference from T1 is Smaller is better.
  • Each clip body 83b, 84b is connected to a moving mechanism 92, and the moving mechanism 92 displaces each clip body 83b, 84b in the B direction and the C direction. Thereby, the FPR 12 clamped by the clamping members 83a and 84a is displaced in the B direction and the C direction.
  • the moving mechanism 92 changes the position of the clip main bodies 83b and 84b in the AC plane while maintaining the posture and the positional relationship between the first clip 83 and the second clip 84. As described above, when the clip bodies 83b and 84b are integrally displaced in the AC plane, the FPR 12 rotates in the AC plane.
  • the pasting unit 82 includes a mounting table 97, a pressing member 98, a shaft 99, and the like.
  • the bonding part 82 is provided with a mounting table 97 on its upper surface 82a.
  • the liquid crystal panel 11 is placed on the placement surface 97 a of the placement table 97.
  • the liquid crystal panel 11 is placed with the light source side of the liquid crystal display device 10 (see FIG. 1) facing the mounting surface 97a. That is, in this example, the polarizing plate 16 (see FIG. 1) is directed downward to face the mounting surface 97a, and the polarizing plate 17 (see FIG. 1) is directed upward.
  • the mounting surface 97a is made of transparent glass 102, for example, and the mounted liquid crystal panel 11 is illuminated from one panel surface by a lamp 103 disposed inside the mounting table 97.
  • the pressing member 98 is for pressing the FPR 12 supplied and stacked on the liquid crystal panel 11 and sticking it to the liquid crystal panel 11.
  • the pressing member 98 is a plate-like member whose one end is fixed to a rotating shaft 99 provided on the upper surface 82 a of the bonding portion 82.
  • the pressing member 98 moves integrally with the shaft 99 between a pressing position for pressing the FPR 12 and a retracted position retracted from the pressing position, and is in an upright posture as shown in FIG.
  • the camera 91 is for detecting the boundary 38 (see FIG. 2) between the first phase difference region R1 and the second phase difference region R2 in the FPR 12 and the relative position of the FPR 12 with respect to the liquid crystal panel 11.
  • the camera 91 is provided with the mounting surface 97a of the mounting table 97 and the lens 91a facing each other.
  • a polarizing plate 104 is provided between the supplied FPR 12 and the lens 91a in a crossed Nicol arrangement with the polarizing plate 17 disposed on the viewing side in the liquid crystal display device 10, and the camera 91 displaces the polarizing plate 104.
  • the polarizing plate 104 is displaced in the B direction by an elevating mechanism 93 constituted by a motor or the like.
  • the light from the lamp 103 transmitted through the boundary 38 between the phase difference regions R1 and R2 that are non-oriented regions maintains the linearly polarized light emitted from the liquid crystal panel 11, and the vibration direction of the polarizing plate 104 Orthogonal to the transmission axis. For this reason, since the light from the boundary 38 does not pass through the polarizing plate 104, it is photographed as a black line by the camera 91.
  • the transport mechanism 51 causes the reaction film forming unit 52, the exposure device 53, the tension adjusting unit 54, the rubbing processing unit 55, the liquid crystal layer forming unit 56, Guided sequentially to the cutting section 58.
  • the reaction film forming unit 52 continuously applies a coating solution containing a photoacid generator on one surface of the support 40. Thereafter, the reaction film forming unit 52 dries the coating film formed by coating, whereby a reaction film 72 having a certain thickness is formed on the support 40.
  • the support 40 on which the reaction film 72 is formed is guided to the exposure device 53, and in a state of being wound around a backup roller, a stripe pattern irradiation in which an ultraviolet irradiation region and a non-irradiation region alternate in the width direction. Is performed continuously.
  • the support 40 during pattern irradiation is held at a preset value of the tension in the transport direction.
  • the support 40 is guided to the rubbing treatment part 55 and the reaction film 72 is subjected to rubbing treatment, and the reaction film 72 is changed to the alignment film 41 by this rubbing treatment. Thereafter, the support 40 is guided to the liquid crystal layer forming unit 56, and the liquid crystal layer 42 is formed on the alignment film 41.
  • the adhesive layer 45 is formed on the liquid crystal layer 42 by the adhesive layer forming unit 57, and a long FPR 12 is obtained.
  • the FPR 12 is cut into a sheet having a target size by the cutting unit 58.
  • the sheet-like FPR 12 is guided from the FPR manufacturing facility 50 to the bonding device 59 and bonded to the liquid crystal panel 11 as follows. First, the first clip 83 and the second clip 84 are arranged in a state in which the clamping members 83a and 84a face each other in the A direction that is coincident with the transport direction of the support body 40 while the exposure device 53 is irradiated with ultraviolet rays. Is done.
  • the FPR 12 is sandwiched between the one end and the other end in the A direction by the sandwiching members 83a and 84a. Note that, after the FPR 12 is sandwiched, the A direction and the transport direction at the time of manufacturing the FPR 12 may be matched.
  • the tension measuring device 87 measures the tension in the A direction of the FPR 12 held between the first and second clips 83 and 84, and outputs the detection result to the controller 96.
  • the controller 96 displaces the second clip 84 in the A direction via the pulling mechanism 88, and changes the position of the second clip 84 until the detection result by the tension measuring device 87 reaches the target tension described above.
  • the above-described target tension is applied to the FPR 12 in the A direction.
  • the first phase difference region R1 and the second phase difference region R2 in the FPR 12 are linear with a constant width, and the boundary. 38 is also linear. Note that it is not necessary to perform photographing with the camera 91 during the displacement of the second clip 84.
  • the liquid crystal panel 11 is supplied in advance to the mounting table 97, and the FPR 12 is placed on the liquid crystal panel 11 by the moving mechanism 92 in a state where a predetermined tension is applied in the A direction by the first and second clips 83 and 84. As shown in FIG. 7, the liquid crystal panel 11 is slightly separated. Above the FPR 12, a polarizing plate 104 is disposed in a state slightly separated from the FPR 12.
  • the FPR 12 being irradiated with light by the lamp 103 is photographed by the camera 91
  • the FPR 12 and the liquid crystal panel 11 in a state where a target tension is applied are aligned.
  • the boundary 38 is shifted in any arrangement direction of the plurality of pixels 106 arranged in the horizontal direction and the vertical direction in the color filter layer 26 of the liquid crystal panel 11. Therefore, in the camera 91, as shown in FIG. 8, the boundary 38 photographed as a black line intersects with the edges of the plurality of pixels 106 arranged in the horizontal direction and also intersects with the edges of the plurality of pixels 106 arranged in the vertical direction.
  • the moving mechanism 92 integrates the first and second clips 83 and 84 while maintaining the posture and positional relationship.
  • the FPR 12 is rotated in the AC plane by being displaced in the AC plane.
  • the edges of a plurality of pixels arranged in one direction intersecting the boundary 38 are adjusted to be in a parallel state.
  • the moving mechanism 92 integrally displaces the FPR 12 in at least one of the A direction and the C direction while maintaining the posture and the positional relationship of the first and second clips 83 and 84, and thereby the FPR 12 is connected to the AC. Move in the plane.
  • the boundary 38 is overlapped on the edges of a plurality of pixels arranged in one direction.
  • the “edge” refers to a plurality of pixels arranged in one direction (referred to as a first pixel group), a plurality of pixels arranged in the same direction as the first pixel group, and adjacent to the first pixel group (second pixel group). If there is a boundary region having a constant width between the two, this boundary region is also included.
  • the boundary 38 may be placed in the boundary region between the first pixel group and the second pixel group.
  • the FPR 12 is rotated and then moved in the AC plane.
  • the FPR 12 may be moved in the AC plane and then rotated in the AC plane. Through the above steps, the FPR 12 is aligned with the liquid crystal panel 11.
  • the FPR 12 is aligned with the liquid crystal panel 11 in a state where a target tension is applied, but the present invention is not limited to this mode.
  • a target tension is applied to the FPR 12, and then the boundary You may perform the 2nd position alignment which overlaps with the edge of the some pixel in which 38 aligns in one direction.
  • the FPR 12 aligned with the liquid crystal panel 11 is lowered to a state in which the FPR 12 is in contact with the liquid crystal panel 11 by the moving mechanism 92 while the target tension is applied.
  • the pressing member 98 moves from the retracted position to the pressing position, the FPR 12 is pressed from the sheet surface opposite to the film surface facing the liquid crystal panel 11.
  • the FPR 12 is bonded to the liquid crystal panel 11 with the boundary 38 overlapping the edges of the plurality of pixels 106 (see FIGS. 8 to 10) arranged horizontally or vertically on the liquid crystal panel 11.
  • the liquid crystal display device 10 whose display accuracy is improved as compared with the conventional product is obtained.
  • the FPR 12 when the FPR 12 and the liquid crystal panel 11 are aligned, the FPR 12 is moved by moving the FPR 12 with respect to the liquid crystal panel 11 placed on the mounting table 97, but this is not a limitation.
  • the mounting table 97 with a displacement mechanism in the A direction and the C direction and a rotation mechanism in the AC plane, in addition to or instead of the movement and rotation of the FPR 12, the movement and rotation of the liquid crystal panel 11 can be performed. You may align by performing.
  • the above method has a particularly remarkable effect when the support body 40 that has been subjected to the step of applying tension in the width direction is provided to the FPR manufacturing facility 50.
  • the support 40 obtained by applying tension in the width direction in the manufacturing process has a larger residual stress in the end portion in the width direction than in the center portion in the width direction, and is cut into a sheet shape by the cut portion 58.
  • the degree of contraction is different between the part corresponding to the end part and the part corresponding to the center part. Therefore, the irradiation region RE, the non-irradiation region RN, and the boundary 38 formed in a line shape with a constant width by the exposure device 53 are curved as described above by cutting into a sheet shape.
  • the first phase difference region R1 and the first phase difference region R1 are attached to the first retardation region R1 by attaching the FPR 12 in a state where a tension close to the tension T1 is applied with reference to the tension T1 in the transport direction while the exposure device 53 is irradiated with ultraviolet rays.
  • the two phase difference regions R1 and the boundaries 38 thereof are linear, and the resulting liquid crystal display device 10 exhibits good display performance.
  • the stretching device 120 in FIG. 11 is for applying tension in the width direction in the process of manufacturing the support 40.
  • the stretching device 120 may be connected to, for example, a film forming unit provided on the upstream side, or may be connected to a sending machine.
  • a film forming part a melt film forming part that melts the raw material polymer and extrudes it into a film shape, or a raw material polymer dissolved in a solvent and cast on a casting support to form a casting film, this casting film There is a solution film forming part that peels off after developing self-supporting property.
  • As a sending machine there is a machine in which a film roll manufactured in these film forming sections and wound in a roll shape is set, and the film 122 is unwound from the film roll and sent to the stretching apparatus 120.
  • a plurality of clips 121 are attached to a pair of chains (not shown) arranged on a pair of rails (not shown) extending in the transport direction.
  • the pair of rails are provided to be separated from each other in the width direction of the film 122, and the clip 121 sandwiches the side end portion of the long film 122 that is continuously supplied.
  • Each chain moves on the rails, whereby the individual clips 121 move, whereby the film 122 is conveyed.
  • the width of the film 122 is expanded (widened), narrowed (reduced), or kept constant.
  • the stretching apparatus 120 in FIG. 11 includes a preheating unit 120a that raises the temperature of the film 122 while keeping the width constant, a widening unit 120b that widens the width provided downstream of the preheating unit, and a relaxation unit that is provided downstream of the widening unit. 120c.
  • the widened portion 120b widens the width of the film 122 by setting the temperature of the film 122 to a high temperature such as near the glass transition point.
  • the preheating unit 120a prevents the film 122 from being deformed or broken in the widened portion 120b by raising the temperature of the film 122 toward the widened portion 120b.
  • the relaxation part 120c performs stress relaxation of the film generated in the widened part 120b.
  • the support 40 is obtained through the treatment by the preheating part 120a, the widening part 120b, and the relaxation part 120c, residual stress remains in the obtained support 40 even after the stress relaxation in the relaxation part 120c. In many cases, the deformation of the FPR 12 accompanying the sheet formation as described above occurs.
  • the support body 40 is manufactured with a stretching pattern of holding a constant width, widening, and holding a constant width after widening, but the stretching pattern is not limited thereto.
  • a liquid crystal display device is manufactured by attaching a multilayer film to a display panel.
  • the liquid crystal display device 130 of this example is configured by laminating a sheet-like multilayer film 14 to a liquid crystal panel 11 as a display panel.
  • the multilayer film 14 is attached to the liquid crystal panel 11 instead of the FPR 12.
  • symbol is attached
  • the multilayer film 14 includes an FPR 12 and a protective film 13.
  • the protective film 13 is for protecting the surface of the FPR 12.
  • other known liquid crystal panels may be used.
  • various optical function films may be used in place of the protective film 13.
  • the optical function film may be, for example, a polarizing film that transmits only specific polarized light, or a viewing angle expansion film that expands the viewing angle in the display device.
  • the protective film 13 is provided on the surface of the FPR 12 on the viewing side.
  • the protective film 13 has elasticity and is transparent in the present embodiment.
  • cellulose acylate such as cellulose triacetate (TAC), polyethylene terephthalate (PET), polypropylene (PP), norbornene-based polymer, cycloolefin-based
  • TAC cellulose triacetate
  • PET polyethylene terephthalate
  • PP polypropylene
  • norbornene-based polymer norbornene-based polymer
  • cycloolefin-based cycloolefin-based
  • the film is formed of a polymer and a film composed of a polymer such as an acrylic polymer such as polymethyl methacrylate.
  • the adhesive layer 45 is provided to adhere the FPR 12 of the multilayer film 14 and the liquid crystal panel 11 as described above.
  • the protective film 13 is disposed on the surface of the support 40 opposite to the surface on which the alignment film 41 is provided.
  • the adhesive layer 45 is provided on the liquid crystal layer 42 as in the first embodiment. However, it may be arranged on the surface of the protective film 13 instead of this embodiment.
  • the sheet-like multilayer film 14 is manufactured by, for example, a multilayer sheet manufacturing facility 132 shown in FIG.
  • the multilayer sheet manufacturing facility 132 includes a transport mechanism 51, a reaction film forming unit 52, an exposure device 53, a tension adjusting unit 54, a rubbing processing unit 55, a liquid crystal layer forming unit 56, a multilayered unit 133, a cutting unit 58, and the like. Consists of. That is, the multilayer sheet manufacturing facility 132 is configured to include a multilayered portion 133 instead of the adhesive layer forming portion 57 of the FPR manufacturing facility.
  • the multilayer sheet manufacturing facility 132 performs various processes on the supplied long support 40 to manufacture the sheet-shaped multilayer film 14.
  • the sheet-like multilayer film 14 manufactured by the multilayer sheet manufacturing facility 132 is guided to a laminating device 59 described later and bonded to the liquid crystal panel 11 (see FIG. 12).
  • a winding unit may be provided between the liquid crystal layer forming unit 56 and the multi-layered unit 133.
  • the multilayer sheet manufacturing facility 132 includes the cutting unit 58, but the cutting unit 58 may be provided outside the multilayer sheet manufacturing facility 132.
  • the multilayer sheet manufacturing facility 132 is for manufacturing a long multilayer film 14 in which the FPR 12 and the protective film 13 overlap, and a long multilayer film is formed downstream of the multilayering section 133.
  • a winding unit (not shown) for winding the film 14 is provided.
  • the support 40 is drawn out from a support roll (not shown) wound in a roll shape and supplied to the multilayer sheet manufacturing facility 132, for example.
  • the multilayered portion 133 is for forming the adhesive layer 45 and the protective film 13.
  • the multi-layered portion 133 forms an adhesive layer 45 on the liquid crystal layer 42 and is opposite to the surface on which the alignment film 41 and the liquid crystal layer 42 of the support 40 sent from the liquid crystal layer forming portion 56 are layered.
  • a protective film 13 is applied to the surface.
  • the long adhesive film 68 that forms the adhesive layer 45 and the long protective film 134 that becomes the protective film 13 are each formed into a roll.
  • the multi-layer unit 133 includes a feeding machine (not shown) that pulls out and sends out the adhesive film 68 from the adhesive film roll, a feeding machine (not shown) that pulls out and sends the protective film 134 from the protective film roll, and a roller pair 69 and the like Prepare.
  • the roller pair 69 sandwiches the support 40 sent from the liquid crystal layer forming unit 56 between the adhesive film 68 and the protective film 134 supplied from each delivery machine, and nips them.
  • the cutting part 58 cuts the long multilayer film 14 into a desired size, for example, a rectangular sheet.
  • the long multilayer film 14 is cut into a sheet shape as shown in FIG. Note that a broken line in FIG. 15A is a cutting line indicating a cutting position. In this example, two rectangular sheets are taken in the width direction from the long multilayer film 14, but the number of sheets cut out in the width direction is the width and purpose of the long multilayer film 14. Depending on the size of the sheet.
  • each sheet is the sheet corresponding to the cutting line C1 in the center in the width direction, as in the first embodiment.
  • the length of the first edge E1 and the length of the second edge E2 corresponding to the cutting line C2 on the outer side in the width direction are different from each other.
  • the second edge E2 is slightly longer than the first edge E1.
  • a sheet is cut with a cutting line that forms a 400 mm ⁇ 700 mm rectangle having a short side that coincides with the width direction as shown in FIG.
  • the length of the first edge E1 of each sheet is approximately 700.0 mm, and the length of the second edge E2 is approximately 700.3 mm.
  • the first retardation region R1 and the second retardation region R2 that respectively extend linearly in the transport direction in the FPR 12 of the long multilayer film 14 are different from each other in the sheet-shaped multilayer film 14 shown in FIG.
  • a slightly convex curve is formed on the second edge E2 side.
  • illustration of the first phase difference region R1 and the second phase difference region R2 is omitted in order to avoid complication of the illustration.
  • the degree of deformation of the sheet is greatly exaggerated.
  • the sheet-like multilayer film 14 is pulled in a direction corresponding to the conveying direction when it is long. Since the transport direction of the multilayer film 14 coincides with the transport direction of the support 40 in the manufacturing process of the FPR 12, the pulling direction coincides with the direction corresponding to the transport direction of the FPR 12.
  • the first retardation region R1 and the second retardation region R2 that are deformed slightly in the sheet are linearized as shown in FIG.
  • the sheet-like multilayer film 14 is in a state where the first retardation region R1 and the second retardation region R2 are held in a straight line, that is, in a state where tension is applied, and a bonding device 59 (see FIG. 16). ) And the liquid crystal panel 11 (see FIG. 12).
  • the laminating of the sheet-like multilayer film 14 and the liquid crystal panel 11 is performed by the laminating apparatus 59 described above.
  • the boundary 38 between the first retardation region R1 and the second retardation region R2 of the FPR 12 in the multilayer film 14 is overlapped with the edges of the plurality of pixels arranged in a certain direction of the liquid crystal panel 11.
  • the bonding apparatus 59 bonds the liquid crystal panel 11 and the sheet-like multilayer film 14 held at a predetermined tension. That is, this 2nd Embodiment is an aspect which affixes the multilayer film 14 on the liquid crystal panel 11 instead of FPR12 in 1st Embodiment.
  • the first clip 83 sandwiches one end portion of the sheet-like multilayer film 14 in the direction corresponding to the aforementioned transport direction with the sandwiching member 83a, and the second clip 84 sandwiches the other end portion with the sandwiching member 84a. Therefore, when the multilayer film 14 is sandwiched, the first clip 83 and the second clip 84 make the A direction coincide with the transport direction described above. Similar to the first embodiment, the coincidence may not necessarily be a strict coincidence, and there may be a deviation as long as the deviation is within 0.0001 °.
  • the tension measuring device 87 detects the tension applied to the multilayer film 14 by the first and second clips 83 and 84, and outputs the detection signal to the controller 96.
  • the pulling mechanism 88 displaces the clip main body 84b in the A direction while sandwiching the multilayer film 14.
  • the controller 96 controls the position of the clip body 84 b via the pulling mechanism 88.
  • tensile_strength TD is provided in the A direction to the multilayer film 14 currently clamped by the clamping members 83a and 84a.
  • the application of tension in the A direction by the first clip 83 and the second clip 84 is for changing the first phase difference region R1, the second phase difference region R2, and the boundary 38 from a curved line to a straight line having a certain width. It is.
  • the target tension TD is set based on the tension Ts in the transport direction of the support 40 to which the reaction film 72 (see FIG. 4) is applied while the exposure apparatus 53 is irradiated with ultraviolet rays. For example, the target tension TD is set larger as the tension Ts is larger.
  • the tension in the present specification is a tension per 1 m width (unit: N / m).
  • the multilayer film 14 is displaced in the B direction and the C direction by the displacement of the clip bodies 83b and 84b in the B direction and the C direction by the moving mechanism 92.
  • the moving mechanism 92 changes the position of the clip main bodies 83b and 84b in the AC plane while maintaining the posture and the positional relationship between the first clip 83 and the second clip 84.
  • the multilayer film 14 rotates in the AC plane.
  • the liquid crystal panel 11 is mounted on the mounting surface 97a of the mounting table 97 provided in the bonding unit 82 with the light source side of the liquid crystal display device 130 facing the mounting surface 97a.
  • the lamp 103 illuminates the placed liquid crystal panel 11 from one panel surface.
  • the pressing member 98 is for pressing the multi-layer film 14 supplied and stacked on the liquid crystal panel 11 and sticking it to the liquid crystal panel 11.
  • the pressing member 98 moves integrally with the shaft 99 between a pressing position for pressing the multilayer film 14 and a retracted position retracted from the pressed position, and is in an upright posture as shown in FIG.
  • the camera 91 detects the boundary 38 (see FIG. 13) between the first retardation region R1 and the second retardation region R2 of the FPR 12 in the multilayer film 14 and the relative position of the multilayer film 14 with respect to the liquid crystal panel 11. Is for.
  • a polarizing plate 104 is provided between the supplied multilayer film 14 and the lens 91a.
  • the polarizing plate 104 is arranged in a crossed Nicols arrangement with the polarizing plate 17 of the liquid crystal display device 130, and the camera 91 takes an image through the polarizing plate 104.
  • the light from the lamp 103 that has passed through the boundary 38 that is a non-oriented region maintains the linearly polarized light emitted from the liquid crystal panel 11, and its vibration direction is orthogonal to the transmission axis of the polarizing plate 104. To do. For this reason, since the light from the boundary 38 does not pass through the polarizing plate 104, it is photographed as a black line by the camera 91.
  • a reaction film forming unit 52 When the long support 40 is supplied to the multilayer sheet manufacturing apparatus 50, a reaction film forming unit 52, an exposure device 53, a tension adjusting unit 54, a rubbing processing unit 55, and a liquid crystal layer forming unit are provided by a transport mechanism unit 51. 56, the multi-layered unit 133, and the cutting unit 58 are sequentially guided. After a reaction film 72 having a certain thickness is formed on one surface of the support 40 by the reaction film forming unit 52, the exposure device 53 stripes the irradiation regions and non-irradiation regions alternately in the width direction. The pattern irradiation is continuously performed. The support 40 during pattern irradiation is held at a preset value of the tension in the transport direction.
  • the liquid crystal layer forming part 56 forms the liquid crystal layer 42 on the alignment film 41.
  • the support 40 on which the liquid crystal layer 42 is formed is a surface opposite to the surface on which the adhesive layer 45 is formed on the liquid crystal layer 42 by the multi-layered portion 133 and the alignment film 41 and the liquid crystal layer 42 are layered. Is provided with a protective film 13, whereby a long multilayer film 14 is obtained.
  • the multilayer film 14 is cut into a sheet having a desired size by the cutting portion 58.
  • the sheet-like multilayer film 14 is guided from the multilayer sheet manufacturing facility 132 to the laminating apparatus 59 and bonded to the liquid crystal panel 11 as follows. First, the first clip 83 and the second clip 84 are arranged in a state in which the clamping members 83a and 84a face each other in the A direction that is coincident with the transport direction of the support body 40 while the exposure device 53 is irradiated with ultraviolet rays. Is done. The multilayer film 14 is sandwiched between one end portion and the other end portion in the A direction by the sandwiching members 83a and 84a in a state where the adhesive layer 45 is directed downward in FIG. 16, that is, toward the liquid crystal panel 11 side. In addition, after the multilayer film 14 is clamped, the A direction and the transport direction during the production of the multilayer film 14 may be matched.
  • the tension measuring device 87 measures the tension in the A direction of the multilayer film 14 and outputs the detection result to the controller 96.
  • the controller 96 displaces the second clip 84 in the A direction via the pulling mechanism 88, and changes the position of the second clip 84 until the detection result by the tension measuring device 87 reaches the target tension described above.
  • the above-described target tension is applied to the multilayer film 14 in the A direction, and as a result, the first retardation region R1 and the second retardation region R2 in the FPR 12 are each linear with a constant width. At the same time, the boundary 38 is also linear.
  • the liquid crystal panel 11 is supplied in advance to the mounting table 97, and the multilayer film 14 is liquid crystal by the moving mechanism 92 in a state where a predetermined tension is applied in the A direction by the first and second clips 83 and 84. It moves onto the panel 11 and is slightly separated from the liquid crystal panel 11 as shown in FIG.
  • a polarizing plate 104 is disposed above the multilayer film 14 in a state of being slightly separated from the multilayer film 14.
  • the multilayer film 14 irradiated with light by the lamp 103 is photographed by the camera 91, the multilayer film 14 and the liquid crystal panel 11 in a state where a target tension is applied are aligned.
  • the boundary 38 is deviated in any arrangement direction of the plurality of pixels 106 arranged in the horizontal direction and the vertical direction in the color filter layer 26 of the liquid crystal panel 11. Accordingly, in the camera 91, as shown in FIG. 18, the boundary 38 photographed as a black line intersects with the edges of the plurality of pixels 106 arranged in the horizontal direction and also intersects with the edges of the plurality of pixels 106 arranged in the vertical direction.
  • the boundary 38 intersects the edges of the plurality of pixels 106 arranged in one direction in this way, the first and second clips 83 and 84 are displaced by the moving mechanism 92 so that the multilayer film 14 is placed in the AC plane. Rotate with. As a result, as shown in FIG. 19, the edges of a plurality of pixels arranged in one direction intersecting the boundary 38 are adjusted to be in a parallel state.
  • the moving mechanism 92 integrally displaces the first and second clips 83 and 84 while maintaining the posture and positional relationship thereof, and moves the multilayer film 14 in the AC plane.
  • the boundary 38 is overlapped on the edges of a plurality of pixels arranged in one direction.
  • the multilayer film 14 is aligned with the liquid crystal panel 11.
  • Second alignment may be performed in which the boundary 38 overlaps the edges of a plurality of pixels arranged in one direction.
  • the multilayer film 14 aligned with the liquid crystal panel 11 is lowered to a state in which it is in contact with the liquid crystal panel 11 by the moving mechanism 92 with a target tension applied, and the pressing member 98 causes the multilayer film 14 to be liquid crystal.
  • the film is pressed from the film surface opposite to the film surface facing the panel 11.
  • the multilayer film 14 is bonded to the liquid crystal panel 11 with the boundary 38 overlapping the edges of the plurality of pixels 106 (see FIGS. 18 to 20) aligned horizontally or vertically on the liquid crystal panel 11.
  • the liquid crystal display device 130 with improved display accuracy over the conventional product can be obtained.
  • the movement of the liquid crystal panel 11 is provided by providing the mounting table 97 with a displacement mechanism in the A direction and the C direction and a rotation mechanism in the AC plane. And may be aligned by performing rotation.
  • the display accuracy in the liquid crystal display device 130 is particularly remarkably improved.
  • the tension applying process in the width direction in the manufacturing process of the support 40 is performed by, for example, the stretching device 120 as described above. Even after stress relaxation at the relaxation portion 120c (see FIG. 11), residual stress often remains on the support 40, and the multilayer film 14 is deformed due to sheeting as described above. Therefore, in the present embodiment, the target tension TD is set as described above based on the tension T40 in the transport direction while the exposure apparatus 53 is irradiated with ultraviolet rays, and the set tension is applied to the multilayer film 14. In this state, the multilayer film 14 is pasted. As a result, the first retardation region R1 and the second retardation region R2 and the boundary 38 thereof are linear, and the obtained liquid crystal display device 130 exhibits good display performance.
  • the above method has a particularly remarkable effect when the protective film 134 that has undergone the step of applying tension in the width direction is provided to the multilayer sheet manufacturing facility 132.
  • the protective film 134 obtained by applying tension in the width direction in the manufacturing process has a larger residual stress in the end portion in the width direction than in the center portion in the width direction.
  • the degree of contraction is different between the portion corresponding to the end portion and the portion corresponding to the center portion. Therefore, the irradiation region RE, the non-irradiation region RN, and the boundary 38 formed in a line shape with a constant width by the exposure device 53 are curved as described above by cutting into a sheet shape.
  • the target tension TD as described above based on the thickness h70 and Young's modulus ⁇ 70 of the protective film 134 in addition to the tension T40.
  • the protective film 134 is also manufactured from a long film for forming the protective film 134 using the stretching device 120. In this case as well, as in the case of manufacturing the support body 40, residual stress often remains in the protective film 134 obtained even after stress relaxation at the relaxation portion, and the above-described sheeting due to sheet formation is often accompanied. Deformation of the layer film 14 occurs.
  • the third embodiment also forms a liquid crystal display device by attaching a multilayer film to a display panel.
  • a multilayer film 140 shown in FIG. 21 is attached to the liquid crystal panel 11 instead of the multilayer film 14 in the second embodiment.
  • 2nd Embodiment The same code
  • the multilayer film 140 includes an FPR 142, protective films 13 and 144, and an adhesive layer 45.
  • the FPR 142 includes a support body 40, an alignment film 41, and a liquid crystal layer 42, and has first and second retardation regions R1 and R2 similarly to the FPR12.
  • the protective film 13 is disposed on the liquid crystal layer 42, and the protective film 144 is disposed on the support 40.
  • the adhesive layer 45 is formed on the protective film 144, and the multilayer film 140 is bonded to the liquid crystal panel 11 by the adhesive layer 45.
  • the protective film 144 is for protecting the surface of the FPR 142 similarly to the protective film 13, and more specifically, protects the surface of the FPR 142 before being bonded to the liquid crystal panel 11.
  • the multilayer film 140 may include the above-described optical function film instead of the protective films 13 and 144.
  • the multilayer film 140 is manufactured by a multilayer sheet manufacturing facility (not shown) in which the multilayer section 133 of the multilayer sheet manufacturing facility 132 is replaced with the multilayer section 157 of FIG. Similarly to the multilayer unit 133, the multilayer unit 157 is provided between the liquid crystal layer forming unit 56 and the cutting unit 58, and applies a protective film 134 and a protective film 158 to be a protective film to the FPR 142.
  • the adhesive layer 45 is formed.
  • the protective film 158 is rolled in the same manner as the protective film 134.
  • the multi-layered portion 157 includes a feeder (not shown) that pulls out and sends out the protective film 134 from the protective film roll, a feeder (not shown) that pulls out and sends the protective film 158 from the protective film roll, and an adhesive film roll.
  • a feeding machine (not shown) that pulls out and feeds the adhesive film 68, a roller pair 69, and the like are provided.
  • the roller pair 69 sandwiches the FPR 142 sent from the liquid crystal layer forming unit 56 between the protective film 134 and the protective film 158 supplied from each feeder, and nips them together with the adhesive film 68.
  • the cutting unit 58 cuts the long multilayer film 140 into a target size, for example, a rectangular sheet.
  • the sheet-like multilayer film 140 is sent to the laminating device 59 in the same manner as the multilayer film 14, and is thereby bonded to the liquid crystal panel 11. Similar to the tension TD in the case of the multilayer film 14, the tension TD when the multilayer film 140 is bonded to the liquid crystal panel 11 is a reaction film 72 while being irradiated with ultraviolet rays by the exposure device 53 (see FIG. 4). Is set based on the tension T40 in the transport direction of the support 40 to which is provided.
  • the target tension TD is more effective in the range of 20% or more and 180% or less of the tension Tt from the viewpoint of display accuracy in the liquid crystal display device, and in the range of 90% or more and 110% or less of the tension Tt. If there is, it is more effective.
  • the tension Tt includes the tension Ts (N / m), the thickness hf (unit is m) of the FPR 142, the Young's modulus ⁇ f (unit is GPa) of the FPR 142, the thickness T1 (unit is m) of the protective film 134, and the protection.
  • Tt Ts ⁇ ⁇ (hf ⁇ ⁇ f) + (h1 ⁇ ⁇ 1) + (h2 ⁇ ⁇ 2) ⁇ / (hf ⁇ ⁇ f) (2)
  • This embodiment is a case where two layers excluding the adhesive layer 45, that is, the protective film 13 and the protective film 144 are applied to the FPR 142, but the number of layers applied to the FPR is not limited to two.
  • the target tension TD when the number of layers is 2 or more may be obtained as follows.
  • the number of layers does not include the number of adhesive layers.
  • each layer may be disposed on any surface side of the FPR 142.
  • each multilayer film is bonded to the liquid crystal panel 11 in a state where the TD thus determined is applied to each multilayer film.
  • the multilayer films 14 and 140 are bonded to the liquid crystal panel 11, but the present invention is not limited to these embodiments.
  • one of the multilayer film 14 and the multilayer film 140 and the polarizing plate 17 may be bonded in advance to form a multilayer member (not shown).
  • the number of layers in the formula (I) may be set to n, including the number of layers constituting the polarizing plate 17.
  • the polarizing plate 17 includes a polarizing film and a pair of protective films sandwiching the polarizing film
  • the number of layers of the polarizing plate 17 is 3, and the number of layers is set to the number n of the layers described above. Count.
  • the liquid crystal display device 10 was manufactured using the FPR manufacturing equipment 50 and the bonding device 59.
  • the thickness of the support 40 used is 100 ⁇ m.
  • the tension T1 of the support 40 on which the reaction film 72 is formed while the exposure apparatus 53 is irradiated with ultraviolet rays is changed to “T1” (unit: N / m) in Table 1 by the tension adjusting unit 54. Adjusted to the value shown.
  • the tension shown in “T2” (unit: N / m) in Table 1 was applied to the sheet-like FPR 12 in the A direction by the tension portion 81.
  • T1 and T2 in Table 1 are tension per 1 m width
  • T1 is a tension in the transport direction
  • T2 is a tension in the A direction that is matched with the transport direction.
  • Each of the supports 40 of each example is obtained through a widening step in the width direction by the stretching device 120.
  • region R2 of FPR12 and the edge of the several pixel 106 located in a line with the horizontal direction of the liquid crystal panel 11 The degree of the height was evaluated using the lamp 103, the polarizing plate 104, and the camera 91. In each evaluation, first, a plurality of sites as evaluation candidates are arbitrarily extracted at nine locations, and preliminary evaluation is performed to evaluate the degree of deviation between the boundary 38 and the edge of the pixel 106 for each extracted location. did.
  • the degree of deviation at the place where the magnitude of the deviation between the boundary 38 and the edge of the pixel 106 is the largest is taken as the evaluation result in the liquid crystal display device 10.
  • This evaluation result is described in the “deviation” column of Table 1.
  • the evaluation criteria are as follows. Small and medium are acceptable levels, and large are unacceptable levels. Small: Less than 10 ⁇ m Medium: 10 ⁇ m or more and less than 100 ⁇ m Large: 100 ⁇ m or more
  • the image display accuracy was evaluated according to the following criteria.
  • the evaluation result is described in the “display accuracy” column of Table 1.
  • a and B are acceptable levels, and C is an unacceptable level.
  • “there is light leakage” means that light from a line corresponding to the other adjacent one is observed through one of the first and second phase difference regions R1 and R2, for example. Means.
  • B There was light leakage, but it could be observed as a stereoscopic image
  • C There was light leakage, and it could not be observed as a stereoscopic image
  • the liquid crystal display devices obtained in Comparative Examples 1 to 5 were evaluated in the same manner as in Examples 1 to 7. That is, the degree of deviation between the boundary between the first phase difference region R1 and the second phase difference region R2 of the FPR, and the edges of a plurality of pixels arranged in the horizontal direction of the liquid crystal panel, and the display accuracy of the image. Each was evaluated.
  • Example 8 which manufactures the liquid crystal display device 130 was implemented using the multilayer sheet manufacturing equipment 132 and the bonding apparatus 59.
  • FIG. In addition, in place of the multi-layer unit 133 of the multi-layer sheet manufacturing facility 132 in place of the multi-layer unit 157 shown in FIG. Carried out.
  • the used support 40 has a thickness of 100 ⁇ m and a Young's modulus of 4.0 GPa.
  • the support body 40 and the protective films 134 and 158 are all obtained through a widening step in the width direction by the stretching device 120.
  • Table 2 shows the thickness T1 and Young's modulus G1 of the protective film 134 and the thickness T2 and Young's modulus G2 of the protective film 158 in each example.
  • Example 8 Since the protective film 158 is not used in Example 8, “N2” is described in “T2” of Table 1, and “ ⁇ ” is described in the “G2” column.
  • the tension Tt was obtained from the equation (1), the tension TD was set based on this Tt, and the tension was adjusted by the tension adjusting unit 54 in order to apply this tension TD to the multilayer film 14.
  • the tension Tt is obtained from the equation (2), the tension TD is set based on this Tt, and the tension is adjusted to apply the tension TD to the multilayer film 140 in the A direction. The tension was adjusted by the portion 54.
  • the measuring method of the Young's modulus of the support body 40 and the protective films 134 and 158 is based on ASTM D882.
  • region R2 of FPR12, and the edge of the several pixel 106 located in a line with the horizontal direction of the liquid crystal panel 11 is large.
  • the degree of thickness was evaluated by the same method and evaluation criteria as in Examples 1-7. Further, for each of the obtained liquid crystal display devices 130 and the like, the image display accuracy was evaluated based on the same criteria as in Examples 1 to 7.
  • Comparative Example 6 As a comparative example for the present invention, Comparative Example 6 in which a liquid crystal display device was manufactured using the multilayer sheet manufacturing facility 132 and the bonding apparatus 59 was performed. Further, the multilayer unit 133 of the multilayer sheet manufacturing facility 132 is replaced with the multilayer unit 157 shown in FIG. 22 to produce a multilayer film, and a liquid crystal display device (not shown) including the multilayer film is manufactured. Comparative examples 7 to 9 were carried out. In Comparative Examples 6 to 9, this multilayer film was bonded to the liquid crystal panel 11 in a state where the tension TD in the A direction with respect to the multilayer film was 0 N / m.
  • the liquid crystal display devices obtained in Comparative Examples 6 to 9 were evaluated in the same manner as in Examples 1 to 7. That is, the degree of deviation between the boundary between the first phase difference region R1 and the second phase difference region R2 of the FPR, and the edges of a plurality of pixels arranged in the horizontal direction of the liquid crystal panel, and the display accuracy of the image. Each was evaluated.

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  • Physics & Mathematics (AREA)
  • Chemical & Material Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • General Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Polarising Elements (AREA)
  • Liquid Crystal (AREA)

Abstract

L'invention porte sur un procédé pour fabriquer un corps stratifié qui améliore la précision d'affichage d'un appareil d'affichage. Un élément de retardement à motif à film (FPR) est obtenu par rayonnement continu d'ultraviolets à l'aide d'un appareil d'exposition sur un film réactif d'un corps de support qui est transféré. L'élément de retardement à motif à film est coupé sous la forme d'une feuille, et est lié à un panneau à cristaux liquides. L'élément de retardement à motif à film est tiré dans la direction A correspondant à la direction de transfert du corps de support avec une tension à l'intérieur d'une plage de 20 à 180 % de la tension appliquée dans la direction de transfert du corps de support pendant un temps pendant lequel les ultraviolets sont rayonnés à l'aide de l'appareil d'exposition. Dans l'état tiré produit à l'aide de l'étape de tension, l'élément de retardement à motif à film est lié au panneau à cristaux liquides.
PCT/JP2014/055725 2013-03-26 2014-03-06 Procédé de fabrication de corps stratifié Ceased WO2014156530A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
JP2013-064667 2013-03-26
JP2013064667A JP2014191075A (ja) 2013-03-26 2013-03-26 積層体の製造方法
JP2013-073587 2013-03-29
JP2013073587A JP2014197156A (ja) 2013-03-29 2013-03-29 積層体の製造方法

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WO2014156530A1 true WO2014156530A1 (fr) 2014-10-02

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2012111464A1 (fr) * 2011-02-16 2012-08-23 日本ゼオン株式会社 Procédé de fabrication d'un dispositif d'affichage à cristaux liquides
JP2013029827A (ja) * 2011-06-22 2013-02-07 Nippon Zeon Co Ltd パターン位相差板及びその製造方法、並びに液晶表示装置
JP2013033083A (ja) * 2011-08-01 2013-02-14 Fujifilm Corp 光学異方性素子、偏光板、画像表示装置、及び立体画像表示システム
WO2013031467A1 (fr) * 2011-08-31 2013-03-07 大日本印刷株式会社 Procédé de fabrication d'un film de déphasage à motif

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2012111464A1 (fr) * 2011-02-16 2012-08-23 日本ゼオン株式会社 Procédé de fabrication d'un dispositif d'affichage à cristaux liquides
JP2013029827A (ja) * 2011-06-22 2013-02-07 Nippon Zeon Co Ltd パターン位相差板及びその製造方法、並びに液晶表示装置
JP2013033083A (ja) * 2011-08-01 2013-02-14 Fujifilm Corp 光学異方性素子、偏光板、画像表示装置、及び立体画像表示システム
WO2013031467A1 (fr) * 2011-08-31 2013-03-07 大日本印刷株式会社 Procédé de fabrication d'un film de déphasage à motif

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