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CN112924457A - Measurement method, management method, and method for manufacturing optical component - Google Patents

Measurement method, management method, and method for manufacturing optical component Download PDF

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Publication number
CN112924457A
CN112924457A CN202011367256.8A CN202011367256A CN112924457A CN 112924457 A CN112924457 A CN 112924457A CN 202011367256 A CN202011367256 A CN 202011367256A CN 112924457 A CN112924457 A CN 112924457A
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China
Prior art keywords
layer
laminate
member layer
distance
pattern
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CN202011367256.8A
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Chinese (zh)
Inventor
川上武志
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Sumitomo Chemical Co Ltd
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Sumitomo Chemical Co Ltd
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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B11/00—Measuring arrangements characterised by the use of optical techniques
    • G01B11/02—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness
    • G01B11/06—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness for measuring thickness ; e.g. of sheet material
    • G01B11/0616—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness for measuring thickness ; e.g. of sheet material of coating
    • G01B11/0625—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness for measuring thickness ; e.g. of sheet material of coating with measurement of absorption or reflection
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/84—Systems specially adapted for particular applications
    • G01N21/88—Investigating the presence of flaws or contamination
    • G01N21/8806—Specially adapted optical and illumination features
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B11/00—Measuring arrangements characterised by the use of optical techniques
    • G01B11/02—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness
    • G01B11/028—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness by measuring lateral position of a boundary of the object
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B11/00—Measuring arrangements characterised by the use of optical techniques
    • G01B11/02—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness
    • G01B11/06—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness for measuring thickness ; e.g. of sheet material
    • G01B11/0616—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness for measuring thickness ; e.g. of sheet material of coating
    • G01B11/0675—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness for measuring thickness ; e.g. of sheet material of coating using interferometry
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/84—Systems specially adapted for particular applications
    • G01N21/8422—Investigating thin films, e.g. matrix isolation method
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/84—Systems specially adapted for particular applications
    • G01N2021/8411—Application to online plant, process monitoring
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/84—Systems specially adapted for particular applications
    • G01N21/8422—Investigating thin films, e.g. matrix isolation method
    • G01N2021/8427—Coatings
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/84—Systems specially adapted for particular applications
    • G01N21/8422—Investigating thin films, e.g. matrix isolation method
    • G01N2021/8438—Mutilayers
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/84—Systems specially adapted for particular applications
    • G01N21/88—Investigating the presence of flaws or contamination
    • G01N21/8806—Specially adapted optical and illumination features
    • G01N2021/8809—Adjustment for highlighting flaws
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/84—Systems specially adapted for particular applications
    • G01N21/88—Investigating the presence of flaws or contamination
    • G01N21/8806—Specially adapted optical and illumination features
    • G01N2021/8822—Dark field detection
    • G01N2021/8825—Separate detection of dark field and bright field

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Immunology (AREA)
  • Pathology (AREA)
  • Analytical Chemistry (AREA)
  • Biochemistry (AREA)
  • General Health & Medical Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Mathematical Physics (AREA)
  • Coating Apparatus (AREA)
  • Polarising Elements (AREA)
  • Length Measuring Devices By Optical Means (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
  • Laminated Bodies (AREA)

Abstract

Provided is a technique for appropriately managing the distance between the end of a1 st member layer and the end of a2 nd member layer included in the end region of a laminate of the 1 st member layer and the 2 nd member layer. A measurement method according to one embodiment is a method of measuring an end region of a laminate including a1 st member layer and a2 nd member layer, the 1 st member layer having a1 st end, the 2 nd member layer having a2 nd end located on the same side as the 1 st end as viewed in a lamination direction of the 1 st member layer and the 2 nd member layer in the laminate, the end region extending from the 1 st end to the 2 nd end in the laminate, the method including: an irradiation step of irradiating the end region with inspection light; a detection step of detecting reflected light as the inspection light reflected by the end region; and a calculation step of calculating a distance between the 1 st edge and the 2 nd edge based on a detection result of the reflected light.

Description

Measurement method, management method, and method for manufacturing optical component
Technical Field
The invention relates to a measuring method, a management method and a manufacturing method of an optical component.
Background
As described in patent document 1, the following techniques are known: a2 nd member layer formed using a coating liquid is formed on the 1 st member layer (sheet of patent document 1), thereby obtaining a laminate of the 1 st member layer and the 2 nd member layer.
Prior art documents
Patent document
Patent document 1: japanese patent laid-open No. 2000-245765
In the laminate of the 1 st member layer and the 2 nd member layer, various defects may occur when the distance between the 1 st end of the 1 st member layer and the 2 nd end of the 2 nd member layer (the end on the same side as the 1 st end of the 1 st member layer) deviates from a predetermined range. For example, as described in patent document 1, in the case where the 2 nd member layer is a coating layer formed by coating a liquid, if the distance between the end portions is out of a predetermined range, the coating liquid may be squeezed out from the 1 st member layer in a step after the formation of the coating layer, and the coating liquid may contaminate other members (for example, a roller, a member to be bonded to the 1 st member layer, and the like). Alternatively, when the laminated body is a single component, the arrangement relationship between the 1 st member layer and the 2 nd member layer is deviated from a desired state when the distance between the end portions is deviated from a predetermined range. Therefore, the performance of the member of the laminate may not exhibit the required performance, or the member may not be appropriately assembled to another device.
Therefore, in the laminate of the 1 st member layer and the 2 nd member layer, a technique of appropriately managing the end-to-end distance between the 1 st end of the 1 st member layer and the 2 nd end of the 2 nd member layer to be within a given range is required.
Disclosure of Invention
Problems to be solved by the invention
Therefore, an object of the present invention is to provide a measuring method and a managing method for appropriately managing a distance between an end of a1 st member layer and an end of a2 nd member layer included in an end region of a laminate of the 1 st member layer and the 2 nd member layer. Another object of the present invention is to provide a method for manufacturing an optical component using the above management method.
Means for solving the problems
A method of measuring an end region of a laminate including a1 st member layer and a2 nd member layer, the 1 st member layer having a1 st end, the 2 nd member layer having a2 nd end located on the same side as the 1 st end as viewed in a lamination direction of the 1 st member layer and the 2 nd member layer in the laminate, the end region extending from the 1 st end to the 2 nd end in the laminate, the method comprising: an irradiation step of irradiating the end region with inspection light; a detection step of detecting reflected light as the inspection light reflected by the end region; and a calculation step of calculating a distance between the 1 st edge and the 2 nd edge based on a detection result of the reflected light.
In the above-described measuring method, the end region is irradiated with inspection light, and the reflected light thereof is detected. Further, the distance between the 1 st end and the 2 nd end is calculated based on the detection result of the reflected light. Since the distance between the 1 st end and the 2 nd end is calculated based on the optical measurement result in this manner, the distance between the 1 st end and the 2 nd end can be calculated more appropriately.
The 1 st layer may be a resin film layer, and the 2 nd layer may be a coating layer containing an adhesive or a bonding agent.
The inspection light may have a stripe pattern in which bright portions and dark portions are alternately arranged. In this case, a plurality of detection results of illuminating the end region can be easily acquired from a plurality of directions. Therefore, the 1 st end and the 2 nd end are easily detected.
The shape of the stripe pattern may also vary periodically. Thus, even if there is one device for outputting the inspection light, various optical information of the end region can be obtained.
For example, the shape of the stripe pattern may periodically vary between a1 st pattern and a2 nd pattern, and the extending direction of the light portions and the dark portions in the 2 nd pattern may be orthogonal to the extending direction of the light portions and the dark portions in the 1 st pattern.
The irradiation step and the detection step may be performed while the laminate is conveyed in the longitudinal direction.
A management method according to another aspect of the present invention is a method of managing an end region of a laminate including a1 st member layer and a2 nd member layer, the 1 st member layer having a1 st end, the 2 nd member layer having a2 nd end located on the same side as the 1 st end as viewed in a lamination direction of the 1 st member layer and the 2 nd member layer in the laminate, the end region being a region extending from the 1 st end to the 2 nd end in the laminate, the method including: an irradiation step of irradiating the end region with inspection light; a detection step of detecting reflected light as the inspection light reflected by the end region; a calculation step of calculating a distance between the 1 st edge and the 2 nd edge based on a detection result of the reflected light; and a determination step of determining whether or not the calculated distance is within a predetermined range.
In the above management method, the end region is irradiated with inspection light, and the reflected light thereof is detected. Further, the distance between the 1 st end and the 2 nd end is calculated based on the detection result of the reflected light. Since the distance between the 1 st end and the 2 nd end is calculated based on the optical measurement result in this manner, the distance between the 1 st end and the 2 nd end can be calculated more appropriately. Since the determination step is performed based on the calculated distance between the 1 st edge and the 2 nd edge, the distance between the 1 st edge and the 2 nd edge can be appropriately managed.
The 1 st layer may be a resin film layer, and the 2 nd layer may be an application layer containing an adhesive or a bonding agent.
The inspection light may have a stripe pattern in which bright portions and dark portions are alternately arranged. In this case, a plurality of detection results obtained by illuminating the end region from multiple directions can be easily acquired. Therefore, the 1 st end and the 2 nd end are easily detected.
The shape of the stripe pattern may also vary periodically. Thus, even if there is one device for outputting the inspection light, various optical information of the end region can be obtained.
The shape of the stripe pattern periodically varies between a1 st pattern and a2 nd pattern, and the extending direction of the light portions and the dark portions in the 2 nd pattern may be orthogonal to the extending direction of the light portions and the dark portions in the 1 st pattern.
The method may further include a laminating step of laminating the 2 nd member layer on a laminated member having the 1 st member layer or the 1 st member layer before the irradiating step.
In the laminating step, the 2 nd member layer may be laminated on the 1 st member by applying a coating material to the 1 st member layer.
In the case where the calculated distance is not within the predetermined range, the laminating step may further include a changing step of changing a coating region of the coating material, and the laminating step, the irradiating step, the detecting step, and the determining step may be repeated until the calculated distance is within the predetermined range. This makes it possible to more reliably obtain a laminate in which the distance between the 1 st end and the 2 nd end is within a predetermined range.
The lamination process, the irradiation process, and the detection process may be performed while the laminate is transported in the longitudinal direction.
A method for manufacturing an optical component according to still another aspect of the present invention is a method for manufacturing an optical component including the management method according to the present invention.
Effects of the invention
According to one aspect of the present invention, a measuring method and a managing method for appropriately managing a distance between an end of a1 st member layer and an end of a2 nd member layer included in an end region of a laminate of the 1 st member layer and the 2 nd member layer can be provided. According to another aspect of the present invention, there is provided a method for manufacturing an optical component using the management method.
Drawings
Fig. 1 is a diagram for explaining a management method according to an embodiment.
Fig. 2 is a diagram showing a1 st pattern as an example of a stripe pattern.
Fig. 3 is a diagram showing a2 nd pattern as another example of the stripe pattern.
Fig. 4 is a flowchart of a management method according to an embodiment.
Fig. 5 is a diagram showing the structure of a phase difference plate (optical component) manufactured in embodiment 2.
Fig. 6 is a diagram for explaining steps included in the method for manufacturing the phase difference plate shown in fig. 5.
Fig. 7 is a diagram illustrating a process subsequent to the process shown in fig. 6.
Fig. 8 is a diagram illustrating a process subsequent to the process shown in fig. 7.
Fig. 9 is a diagram for explaining a case where the method for manufacturing the phase difference plate shown in fig. 5 is performed by a Roll-to-Roll (Roll) method.
Fig. 10 is a diagram for explaining an example of a method of changing the coating region.
Fig. 11 is a diagram showing the results of photographing the film end (1 st end) and the application end (2 nd end).
Fig. 12 is a diagram showing other imaging results of the film end (1 st end) and the coating end (2 nd end).
Fig. 13 is a diagram for explaining modification 1.
Fig. 14 is a drawing for explaining modification 2.
Fig. 15 is a drawing for explaining modification 3.
Fig. 16 is a diagram for explaining modification 3.
Description of the reference numerals
2. 2A: a phase difference plate;
4: a laminate;
11: a resin film (1 st member layer);
11 a: end (1 st end);
20: a coating layer;
20 a: end (2 nd end);
100: a laminate;
102: a1 st member layer;
102 a: end (1 st end);
104: a2 nd member layer;
104 a: an end portion;
112: a stripe pattern;
112 a: a bright section;
112 b: a dark portion;
112A: pattern 1;
112B: pattern 2;
114: an image processing device;
a1, A2: an end region;
d1, D1a, D1b, D1c, D1D, D2, D2 a: distance (inter-end distance);
l1: an inspection light;
l2: reflecting the light.
Detailed Description
Hereinafter, embodiments of the present invention will be described with reference to the drawings. The same elements are denoted by the same reference numerals, and redundant description is omitted. The dimensional ratios in the drawings do not necessarily correspond to the dimensional ratios illustrated.
As shown in fig. 1, a method of managing a distance (inter-end distance) D1 between an end 102a (1 st end) of a1 st member layer 102 included in a laminate 100 and an end 104a (2 nd end) of a2 nd member layer 104 included in the laminate 100 will be described as embodiment 1. Next, an example using the management method described in embodiment 1 will be described as embodiment 2, with reference to examples of the 1 st member layer 102 and the 2 nd member layer 104. For convenience of explanation, the direction in which the 1 st member layer 102 and the 2 nd member layer 104 are stacked is referred to as a z direction, and a direction perpendicular to the z direction is referred to as an x direction, as shown in fig. 1.
(embodiment 1)
Fig. 1 is a diagram for explaining a management method according to an embodiment. The laminate 100 shown in fig. 1 has a1 st component layer 102 and a2 nd component layer 104. The 2 nd component layer 104 is laminated on the 1 st component layer 102. The 1 st member layer 102 and the 2 nd member layer 104 may be members formed of an optically transparent material, for example. For example, the 1 st component layer 102 is a resin film layer, and the 2 nd component layer 104 is a coating layer containing a coating material (e.g., an adhesive or a bonding agent). Examples of the 1 st member layer 102 and the 2 nd member layer 104 are described in detail in other embodiments.
In the management method in embodiment 1, the distance D1 between the end 102a of the 1 st member layer 102 in both ends in the x direction and the end 104a of the 2 nd member layer 104 in both ends in the x direction is managed. The end portion 104a is an end portion located on the same side as the end portion 102a when viewed from the lamination direction (z direction) of the 1 st member layer 102 and the 2 nd member layer 104 among both end portions of the 2 nd member layer 104. In the case where the 2 nd member layer 104 is a coating material, the length of the 2 nd member layer 104 in the x direction is shorter than the length of the 1 st member layer 102. Depending on the 2 nd member layer 104 (e.g., resin film, etc.), the length of the 2 nd member layer 104 in the x direction may be longer than the length of the 1 st member layer 102.
In the management method, the distance D1 is measured using the reflection optical system 106 as shown in fig. 1. The reflection optical system 106 includes a light source unit 108 and an imaging unit 110. The end region a1 is a region near the end of the laminate 100 in the x direction. Specifically, the region extends from the end 102a to the end 104 a.
The light source unit 108 outputs inspection light L1 toward the end region a1 of the laminate 100. As for the wavelength of the inspection light L1, any wavelength may be used as long as it can obtain an image of the end region a1, depending on the materials of the 1 st member layer 102 and the 2 nd member layer 104. An example of the wavelength of the inspection light L1 is a white LED light source having a peak wavelength in 450 ± 30 nm. The inspection light L1 may be configured to illuminate the end region a1 in a planar manner, for example.
The imaging unit 110 is a photodetector that detects reflected light L2 that is inspection light L1 reflected by the end area a 1. The imaging unit 110 is, for example, a 2-dimensional sensor such as a CCD camera or a CMOS camera.
The imaging unit 110 inputs image data to the image processing apparatus 114. The image processing apparatus 114 generates an image of the edge area a1 based on the image data input from the imaging unit 110. Image processing apparatus 114 has a display function of displaying the created image to the user. The image processing apparatus 114 may have a function of analyzing the created image to detect the end portions 102a and 104a and a function of calculating the distance D1. The image processing device 114 may have at least one of a function of controlling the imaging timing of the imaging unit 110 and a function of controlling the output of the inspection light L1 from the light source unit 108. The image processing apparatus 114 may be, for example, a dedicated apparatus for implementing the management method according to embodiment 1. Alternatively, a program for implementing the management method including the image processing described above may be implemented in a personal computer, and the personal computer may be caused to function as the image processing apparatus 114.
An example of the light source section 108 will be described. As shown in fig. 2 and 3, the light source unit 108 may be configured to output the inspection light L1 having the stripe pattern 112 in which the bright portions 112a and the dark portions 112b are alternately arranged. The X direction in fig. 2 shows the extending direction of the bright portion 112a and the dark portion 112b in fig. 2, and the Y direction is a direction perpendicular to the X direction. The X direction and the Y direction in fig. 3 are the same directions as those in fig. 2.
The shape (pattern shape) of the stripe pattern 112 may also vary. For example, in fig. 2 and 3, the shape of the stripe pattern 112 may be changed by moving the bright portion 112a (or the dark portion 112b) in the direction of the arrow in fig. 2 and 3, or by changing the width of the bright portion 112a (or the dark portion 112 b).
Further, when the stripe pattern 112 shown in fig. 2 is referred to as a1 st pattern 112A and the stripe pattern 112 shown in fig. 3 is referred to as a2 nd pattern 112B, the light source section 108 may be configured to periodically vary between the 1 st pattern 112A and the 2 nd pattern 112B. The 2 nd pattern 112B is a pattern in which the extending direction of the bright portion 112A and the dark portion 112B in the 2 nd pattern 112B is orthogonal to the extending direction of the bright portion 112A and the dark portion 112B in the 1 st pattern 112A. Even when the pattern 1 and the pattern 2 periodically fluctuate between the pattern 1 and the pattern 2, the bright portion 112A (or the dark portion 112B) may move in the arrow direction in fig. 2 and 3 or the width of the bright portion 112A (or the dark portion 112B) may fluctuate in the pattern 1 and the pattern 2, respectively.
When the inspection light L1 has the stripe pattern 112, the light source section 108 may include, for example, a light source in which a plurality of point light sources (for example, LEDs) are arranged in 2-dimensional and a control device that controls the lighting state of each LED. In this case, the bright portion 112a and the dark portion 112b can be formed by controlling the lighting state of the plurality of LEDs by the control device. Further, the stripe pattern 112 formed by the bright portion 112a and the dark portion 112b can be varied.
The light source 108 may output the planar inspection light L1 without the bright portion 112a and the dark portion 112b as shown in fig. 2 and 3, for example. In this case, the light source section 108 may be a surface-emitting light source or a light source in which a plurality of point light sources (for example, LEDs) are arranged in 2 dimensions. In the following description, the "planar inspection light L1" means a state in which the bright portion 112a and the dark portion 112b are not present as described above.
The shape of the stripe pattern 112 may be controlled by, for example, an image processing apparatus 114 (refer to fig. 1). In this case, the image processing apparatus 114 may control them so that the light source section 108 and the imaging section 110 are synchronized.
Fig. 4 is a flowchart of an example of a management method. The management method will be described by taking an example in which the 1 st member layer 102 is a long resin film and the 2 nd member layer 104 is a coating layer containing a coating material, with reference to fig. 4.
As shown in fig. 4, the 2 nd member layer 104 is laminated on the 1 st member layer 102 (laminating step S01). The 2 nd layer 104 can be formed by, for example, applying a coating material to be the 2 nd layer 104 while conveying the 1 st layer 102 in the longitudinal direction. The coating of the coating material can be performed, for example, by gravure coating.
Next, the distance D1 (see fig. 1) is measured by the measurement method according to one embodiment while the 1 st member layer 102 is conveyed (measurement step S02).
In the measurement step S02, inspection light L1 is irradiated toward the end region a1 of the laminate 100 (irradiation step S02 a). The reflected light L2 from the end area a1 is detected by the imaging unit 110 (detection step S02 b). Based on the thus obtained image (detection result) of the end region a1, the distance D1 is calculated (calculating process S02 c). Specifically, the end portion 102a and the end portion 104a are determined based on the image obtained by the imaging portion 110, thereby calculating the distance therebetween. The determination of the end 102a and the end 104a and the calculation of the distance D1 based on these may be performed by the image processing apparatus 114, or may be performed by the user based on an image created by the image processing apparatus 114. When the inspection light L1 periodically fluctuates between the 1 st pattern 112A and the 2 nd pattern 112B, for example, the image processing apparatus 114 creates one image using image data obtained for the reflected light L2 in the case of each of the 1 st pattern 112A and the 2 nd pattern 112B. In order to obtain the single image, for example, the image processing device 114 may control the timing of the shape change of the stripe pattern 112 and the imaging timing of the imaging unit 110.
After the above-described measuring step S02, it is determined whether or not the distance D1 is within a predetermined range (determining step S03). The determination may be made by the user, or may be made by the image processing apparatus 114 by comparing a predetermined range and the distance D1, which are input in advance.
In the determination step S03, when the distance D1 is determined to be within the predetermined range (YES in the determination step S03), the production of the laminate 100 may be continued under the same conditions as those before the determination step S03 is performed.
On the other hand, in the determination step S03, when the distance D1 is determined to be outside the predetermined range ("NO" in the determination step S03), in the laminating step S01, a changing step S04 of changing the laminating conditions (specifically, the coating region of the coating material for forming the 2 nd member layer 104) in the laminating step S01 is performed.
When the changing step S04 is performed, the stacking step S01, the measuring step S02, the determining step S03, and the changing step S04 are performed until the distance D1 is determined to be within the predetermined range in the determining step S03.
By performing the above-described management method, the distance D1 between the end 102a and the end 104a in the laminate 100 can be appropriately managed within a predetermined range.
For example, in the case where the 2 nd layer 104 is the above-described coating layer and the coating material forming the coating layer is an adhesive or a pressure-sensitive adhesive, another member may be bonded to the 1 st layer 102 through the 2 nd layer 104 by a pair of rollers. In this case, in general, the given range of the distance D1 is set to prevent contamination of each of the press rollers due to extrusion of the coating material to the pair of press rollers. Therefore, by managing the distance D1 to the above-described given range, contamination of each press roller can be reliably prevented. As a result, a product obtained by bonding another member to the 1 st member layer 102 via the 2 nd member layer 104 can be efficiently produced.
The case where the distance D1 between the end 102a and the end 104a included in the end region a1 is measured and managed is described. However, as shown in fig. 1, the distance (inter-end distance) D2 between the end 102b and the end 104b included in the end region a2 (the region extending from the end 102b to the end 104 b) of the laminate 100 may be measured and managed in the same manner. In this case, the reflection optical system 106 is also disposed on the end 104b side. The end 102b of the 1 st member layer 102 is the end opposite to the end 102a in the x direction. The end 104b of the 2 nd member layer 104 is an end opposite to the end 104a in the x direction. In fig. 1, the light source unit 108 and the imaging unit 110 are arranged along the x direction as viewed from the z direction. However, the arrangement state of the light source unit 108 and the imaging unit 110 is not limited to the embodiment of fig. 1. The light source unit 108 and the imaging unit 110 may be arranged along a direction orthogonal to the x direction and the z direction, for example.
When both the distance D1 and the distance D2 are measured and managed, these may be performed simultaneously. Further, in the determination step S03, as long as at least one of the distance D1 and the distance D2 is out of the predetermined range set for the distance D1 and the distance D2, respectively, the changing step S04 shown in fig. 4 may be performed.
(embodiment 2)
A method for manufacturing an optical component by the management method described in embodiment 1 will be described. Fig. 5 is a schematic view of a phase difference plate (optical member) 2 manufactured by the manufacturing method according to embodiment 2. In embodiment 2, for convenience of explanation, the x direction and the z direction shown in fig. 5 may be used as in embodiment 1.
The retardation plate 2 includes a resin film 11, an alignment film 12, a1 st retardation layer 13, an adhesive layer 22, and a2 nd retardation layer 33. The retardation plate 2 is an optical component (or an optical element) that imparts a certain phase difference to light entering the retardation plate 2 through the 1 st retardation layer 13 and the 2 nd retardation layer 33. The retardation plate 2 can be used as a part of a circularly polarizing plate for optical compensation in an image display device such as a liquid crystal image display device or an organic EL image display device. The embodiment in which the 1 st retardation layer 13 and the 2 nd retardation layer 33 are cured products of polymerizable liquid crystal compounds will be described.
The resin film 11 is a support for supporting the alignment film 12, the 1 st retardation layer 13, the adhesive layer 22, and the 2 nd retardation layer 33. Examples of the material of the resin film 11 include triacetyl cellulose (TAC), polyethylene terephthalate (PET), polycycloolefin (COP). Examples of the thickness of the resin film 11 are 20 μm to 120 μm. An example of the length of the resin film 11 in the x direction is 500mm to 2000 mm.
The alignment film 12 is laminated on the resin film 11. In the embodiment shown in fig. 5, the length of the alignment film 12 in the x direction is shorter than the length of the resin film 11.
The thickness of the alignment film 12 is usually in the range of 0.01 to 10 μm, preferably in the range of 0.05 to 5 μm, and more preferably in the range of 0.1 to 3 μm.
Examples of the alignment film 12 include a vertical alignment film, a horizontal alignment film, and an alignment film in which the molecular axis of a polymerizable liquid crystal compound is aligned in an oblique manner, and can be selected according to the 1 st retardation layer 13. The material of the alignment film 12 is not limited as long as it is a resin used as a known material for a retardation plate. For example, as the alignment film 12, a cured product obtained by curing a conventionally known monofunctional or polyfunctional (meth) acrylate monomer with a polymerization initiator can be used.
The 1 st retardation layer 13 is a layer that imparts a predetermined retardation to light incident on the 1 st retardation layer 13. As described above, the 1 st retardation layer 13 is a cured product of a polymerizable liquid crystal compound. In the embodiment shown in fig. 5, the length of the 1 st retardation layer 13 in the x direction is shorter than the length of the resin film 11 and longer than the length of the alignment film 12. Therefore, both ends of the alignment film 12 in the x direction are covered with the 1 st retardation layer 13. Examples of the thickness of the 1 st retardation layer 13 are usually 0.2 μm to 3 μm, and preferably 0.2 μm to 2 μm.
The adhesive layer 22 is provided on the 1 st retardation layer 13 and bonds the 1 st retardation layer 13 and the 2 nd retardation layer 33. The material of the adhesive layer 22 is an adhesive or bonding agent. The adhesive or bonding agent may be a material well known in the art to which the present disclosure relates. Examples of the adhesive include active energy ray-curable adhesives such as Ultraviolet (UV) curable resins, and aqueous adhesives such as aqueous polyvinyl alcohol resin solutions. Examples of the adhesive include adhesive compositions containing a (meth) acrylic resin, a rubber resin, a urethane resin, an ester resin, a silicone resin, a polyvinyl ether resin, and the like as main components. Hereinafter, a case where the adhesive forming the adhesive layer 22 is an active energy ray-curable adhesive such as a UV curable resin will be described.
The length of the adhesive layer 22 in the x direction is shorter than the length of the 1 st retardation layer 13. The thickness of the adhesive layer 22 is, for example, 0.1 to 10 μm, preferably 0.5 to 5 μm, and more preferably 1 to 3 μm.
The 2 nd retardation layer 33 is a layer that imparts a predetermined retardation to light entering the 2 nd retardation layer 33. As described above, the 2 nd retardation layer 33 is a cured product of a polymerizable liquid crystal compound. In the retardation plate 2 shown in fig. 5, the length of the 2 nd retardation layer 33 in the x direction is the same as the length of the adhesive layer 22. Examples of the thickness of the 2 nd retardation layer 33 are usually 0.2 μm to 3 μm, and preferably 0.2 μm to 2 μm.
A method for manufacturing the phase difference plate 2 will be described schematically with reference to fig. 6 to 8. In the case of manufacturing the phase difference plate 2, the 1 st optical laminate 10 and the 2 nd optical laminate 30 shown in fig. 6 are prepared. The 1 st optical laminate 10 and the 2 nd optical laminate 30 extend in a direction orthogonal to the x direction and the z direction. Fig. 6 to 8 are schematic views of cross sections perpendicular to the longitudinal direction of the 1 st optical laminate 10 and the 2 nd optical laminate 30.
The 1 st optical laminate 10 is a laminate member obtained by laminating a resin film 11, an alignment film 12, and a1 st retardation layer 13. The resin film 11, the alignment film 12, and the 1 st retardation layer 13 extend in the longitudinal direction of the 1 st optical laminate 10. Therefore, the 1 st optical laminate 10 is a long laminate member.
The 1 st optical laminate 10 illustrated in fig. 6 can be produced by forming an alignment film 12 and a1 st retardation layer 13 in this order on a resin film 11. The alignment film 12 can be formed, for example, by coating a material for the alignment film 12 on the resin film 11 and curing the coated film. The 1 st retardation layer 13 can be formed, for example, by coating a material for the 1 st retardation on the resin film 11 on which the alignment film 12 is formed, and curing the coating film. The relationship between the length of the resin film 11 in the x direction of the alignment film 12 and the 1 st retardation layer 13 is as described with reference to fig. 5.
The 2 nd optical laminate 30 illustrated in fig. 6 is a laminate member obtained by laminating a resin film 31, an alignment film 32, and a2 nd retardation layer 33. The 2 nd optical laminate 30 is a long laminate member in the same manner as the 1 st optical laminate 10. The example of the resin film 31 is the same as the example of the resin film 11. The material of the resin film 31 may be the same as or different from that of the resin film 11. The alignment film 32 is an alignment film corresponding to the 2 nd retardation layer 33. The relationship among the lengths of the resin film 31, the alignment film 32, and the 2 nd retardation layer 33 in the x direction is the same as the relationship among the lengths of the resin film 11, the alignment film 12, and the 1 st retardation layer 13 in the x direction included in the 1 st optical laminate 10. Therefore, the length of the 2 nd retardation layer 33 in the x direction of the 2 nd optical laminate 30 is longer than the length of the 2 nd retardation layer 33 of the retardation plate 2 shown in fig. 5.
After the 1 st optical laminate 10 and the 2 nd optical laminate 30 are prepared, the 1 st retardation layer 13 is coated with an adhesive to form a coating layer 20. Next, the 1 st optical laminate 10 and the 2 nd optical laminate 30 are stacked with the overcoat layer 20 interposed therebetween such that the overcoat layer 20 and the 2 nd retardation layer 33 are in contact with each other. Thereby, a laminate 4 shown in fig. 7 was obtained.
Then, the coating layer 20 is irradiated with active energy rays such as ultraviolet rays to cure the adhesive forming the coating layer 20. In this way, the 1 st optical laminate 10 and the 2 nd optical laminate 30 are bonded together via the adhesive layer 22 which is a cured product of the coating layer 20.
After the 1 st optical laminate 10 and the 2 nd optical laminate 30 are bonded, as shown in fig. 8, the resin film 31 is peeled off from the 1 st optical laminate 10, thereby obtaining the phase difference plate 2.
The bonding force of the adhesive layer 22 to the 2 nd retardation layer 33 is set to be stronger than the bonding force of the alignment film 32 to the 2 nd retardation layer 33. Further, the length of the adhesive layer 22 in the x direction is shorter than the length of the 2 nd retardation layer 33 in the x direction, and the 2 nd retardation layer 33 is also bonded to the resin film 31. Therefore, when the resin film 31 is peeled, as shown in fig. 8, the portion of the 2 nd retardation layer 33 on the outer side in the x direction than the adhesive layer 22 and the alignment film 32 are also peeled from the 1 st optical laminate 10 together with the resin film 31.
Hereinafter, for convenience of explanation, a member which is generated separately from the phase difference plate 2 when the resin film 31 is peeled from the 1 st optical layered body 10 will be referred to as a peeling member 6.
In embodiment 2, the management method described in embodiment 1 is performed by using the resin film 11 as the 1 st member layer 102 and the coating layer 20 as the 2 nd member layer 104. A management method applied to the above-described manufacturing method will be described with reference to fig. 4 and 6.
As shown in fig. 6, the resin film 11 corresponds to the 1 st layer 102, and the coating layer 20 corresponds to the 2 nd layer 104. Therefore, the end 11a and the end 11b of the resin film 11 correspond to the end 102a and the end 102b, respectively, and the end 20a and the end 20b of the overcoat layer 20 correspond to the end 104a and the end 104b, respectively. Further, a distance D1a between the end portions 11a and 11b corresponds to the distance D1, and a distance D2a between the end portions 20a and 20b corresponds to the distance D2.
The step of forming the coated layer 20 shown in fig. 6 corresponds to the laminating step S01 shown in fig. 4. After the step of forming the overcoat layer 20 (the laminating step S01), the distance D1a between the end 11a of the resin film 11 and the end 20a of the overcoat layer 20 is measured by performing the measuring step S02 shown in fig. 4. In embodiment 2, the distance D2a between the end 11b of the resin film 11 and the end 20b of the coat layer 20 is also measured.
Next, the determination step S03 shown in fig. 4 is performed to determine whether the distance D1a and the distance D2a are within the predetermined ranges set for the distance D1a and the distance D2a, respectively. The given ranges corresponding to distance D1a and distance D2a, respectively, may be the same or different.
In the determination step S03, when it is determined that the distance D1a and the distance D2a are within the corresponding predetermined ranges, the manufacturing of the retardation plate 2 is continued under the same application conditions of the adhesive (specifically, the same application region) as in the case of forming the applied layer 20 to be measured. On the other hand, in the determination step S03, when at least one of the distance D1a and the distance D2a is determined to be out of the corresponding predetermined range, the changing step S04 is performed to change the application region (lamination condition) of the adhesive.
When the changing step S04 is performed, the stacking step S01 to the changing step S04 are repeated until it is determined in the determining step S03 that the distance D1a and the distance D2a are both within the corresponding predetermined range.
An example of a method for manufacturing a retardation plate 2 to which the management method described in embodiment 1 is applied will be described in detail with reference to fig. 9. Next, as shown in fig. 9, a case of manufacturing the phase difference plate 2 by a roll-to-roll method will be described.
The 1 st optical layered body 10 and the 2 nd optical layered body 30 in a roll shape are provided in the unwinding section 40a and the unwinding section 40 b. The 1 st optical laminate 10 is conveyed in the longitudinal direction of the 1 st optical laminate 10 by the conveying roller 42 toward the pair of pressing rollers 44. Similarly, the 2 nd optical layered body 30 is conveyed in the longitudinal direction of the 2 nd optical layered body 30 by the conveying roller 42 toward the pair of press rollers 44. The pair of press rollers 44 also contribute to the conveyance of the 1 st optical layered body 10 and the 2 nd optical layered body 30, and therefore the pair of press rollers 44 are also conveyance rollers.
The adhesive is applied to the 1 st retardation layer 13 of the 1 st optical laminate 10 by the application device 50 disposed on the transport path of the 1 st optical laminate 10 from the unwinding section 40a to the pair of press rollers 44, thereby forming the application layer 20 (corresponding to the laminating step S01 in fig. 4).
The coating device 50 includes an adhesive supply section 52 and a coating roller 54. The adhesive supply section 52 is a supply source of the adhesive to the surface of the application roller 54. The application roller 54 is a roller for applying the adhesive to the 1 st retardation layer 13 of the 1 st optical laminate 10 being transported. One example of an application roller is a gravure roller.
When the adhesive is applied by the application device 50, the contact area between the 1 st optical laminate 10 (specifically, the 1 st retardation layer 13) and the application roller 54 is adjusted by the application area adjuster 60. Fig. 10 is a diagram showing an example of the coating region adjuster 60. In fig. 10, a1 st optical stack 10 is schematically illustrated as a single sheet of film. In fig. 10, the longitudinal direction of the 1 st optical laminate 10 is the conveying direction of the 1 st optical laminate 10.
The coating area adjuster 60 includes a pair of separated claw portions 62 and a support portion 64 that supports the pair of claw portions 62 along the transport direction of the 1 st optical layered body 10. The application region adjuster 60 is disposed such that the pair of claw portions 62 are in contact with the application side of the adhesive in the 1 st optical laminate 10. By moving the application region adjuster 60 in the width direction (direction orthogonal to the longitudinal direction) of the 1 st optical layered body 10, the region between the pair of claw portions 62 in the 1 st optical layered body 10 can be prevented from coming into contact with the application roller 54. Therefore, the application area of the adhesive can be adjusted by adjusting the position of the application area adjuster 60 in the width direction of the 1 st optical laminate 10. Fig. 9 and 10 illustrate a case where the application region adjuster 60 is disposed on one edge portion side in the width direction of the 1 st optical laminate 10. However, in the method of manufacturing the retardation plate 2 described with reference to fig. 9, the coating region adjuster 60 is also disposed on the other edge portion side in the width direction of the 1 st optical layered body 10. In fig. 9, a pair of claw portions 62 of the coating region adjuster 60 is schematically shown.
Referring back to fig. 9, a process after the adhesive is applied to the 1 st optical laminate 10 by the application device 50 will be described. As shown in fig. 9, the 1 st optical laminate 10 applied with the adhesive is conveyed between a pair of press rollers 44. In fig. 9, the coating layer 20 formed on the 1 st optical laminate 10 is shown in the region from the coating device 50 to the press roll 44 for the purpose of explanation.
The 2 nd optical stack 30 is conveyed together with the 1 st optical stack 10 by a pair of press rollers 44. At this time, the transport paths of the 1 st optical laminate 10 and the 2 nd optical laminate 30 are adjusted so that the 2 nd retardation layer 33 of the 2 nd optical laminate 30 faces the application layer 20 and the centers of the 1 st optical laminate 10 and the 2 nd optical laminate 30 in the width direction coincide with each other.
The 1 st optical laminate 10 and the 2 nd optical laminate 30 fed to the pair of press rollers 44 are pressed in the thickness direction by the pair of press rollers 44 and are pre-bonded with the coating layer 20 interposed therebetween.
The 1 st optical laminate 10 and the 2 nd optical laminate 30, which are fed out from the pair of press rollers 44, are transported in the longitudinal direction of the 1 st optical laminate 10 and the 2 nd optical laminate 30.
An active energy ray irradiation unit 56 is disposed downstream of the pair of press rollers 44 (at a stage subsequent to the pair of press rollers 44) in the conveyance direction of the 1 st optical laminate 10 and the 2 nd optical laminate 30. The active energy ray irradiation unit 56 irradiates the laminate 4 with active energy rays to cure the coating layer 20. In this way, the adhesive layer 22, which is a cured product of the adhesive, can be formed, and the 1 st optical laminate 10 and the 2 nd optical laminate 30 can be bonded together.
The resin film 31 included in the 2 nd optical laminate 30 is peeled from the laminate 4 by a peeling roller 46 disposed downstream of the active energy ray irradiation unit 56 (at a stage subsequent to the active energy ray irradiation unit 56) in the transport direction of the laminate 4. This allows the phase difference plate 2 and the peeling member 6 to be separated from the laminated body 4. Since the peeling roller 46 also contributes to conveyance of the stacked body 4, the phase difference plate 2, and the peeling member 6, the peeling roller 46 is also a conveyance roller.
The obtained phase difference plate 2 may be wound in a roll shape by a winding portion, for example. The peeling member 6 may be discarded as it is, or may be discarded after one end is wound into a roll shape by a winding portion.
In the manufacturing method illustrated in fig. 9, the step of forming the coating layer 20 on the 1 st optical laminate 10 by the coating device 50 corresponds to the laminating step S01 illustrated in fig. 4. Further, in the transport path of the 1 st optical layered body 10, a reflection optical system 106 shown in fig. 1 is disposed between the coating device 50 and the pair of press rollers 44 (for example, at a position indicated by an arrow α 1 or an arrow α 2). The distance D1a and the distance D2a of the 1 st optical laminate 10 being transported are measured by the reflection optical system 106 (measurement step S02 in fig. 4).
In the measurement step S02, as schematically indicated by an arrow α 1 in fig. 9, the distance D1a and the distance D2a in the region between the transport rollers 42 and 42 in the 1 st optical laminate 10 may be measured. Alternatively, as schematically indicated by the arrow α 2, the distance D1a and the distance D2a may be measured in the region of the 1 st optical layered body 10 located on the conveying roller 42. In the measurement between the transport rollers as indicated by the arrow α 1, the measurement may be performed from the side opposite to the coated layer 20. Here, the description has been given of the case of measurement at the position of the arrow α 1, but the same applies to measurement between the conveyance rollers.
When the inspection light L1 output from the light source unit 108 of the reflection optical system 106 is a stripe pattern 112 as shown in fig. 2 and 3, for example, the X direction or the Y direction shown in fig. 2 and 3 may be set as the transport direction of the 1 st optical laminate 10.
When the inspection light L1 is the stripe pattern 112 that periodically changes into a plurality of patterns (for example, periodically fluctuates between the 1 st pattern 112A and the 2 nd pattern 112B), the fluctuation cycle of the 1 st pattern 112A and the 2 nd pattern 112B and the imaging speed of the imaging unit can be set in consideration of the transport speed of the 1 st optical laminate 10. Specifically, while the stripe pattern 112 changes a certain number of times among the plurality of patterns, the cycle of the change of the stripe pattern 112 and the imaging speed of the imaging unit may be set to such an extent that images of substantially the same region in the 1 st optical laminate 10 during conveyance can be acquired.
After the distances D1a and D2a are measured, the determination step S03 is performed. In the determination step S03, when it is determined that both the distance D1a and the distance D2a are within the corresponding predetermined ranges, the manufacturing of the phase difference plate 2 is continued.
On the other hand, in the determination step S03, when it is determined that at least one of the distance D1a and the distance D2a is out of the corresponding predetermined range, a changing step S04 of adjusting the application region of the adhesive using the application region adjuster 60 is performed. Specifically, the application area of the adhesive is changed by adjusting the position of the position adjuster in the width direction of the 1 st optical laminate 10. When the changing step S04 is performed, the step of applying an adhesive to the 1 st optical laminate 10 (the laminating step S01), the measuring step S02 and the determining step S03 shown in fig. 4, and the changing step S04 are repeated until the determining step S03 determines that the distance D1a and the distance D2a are within the predetermined range.
As shown in fig. 9, when the 1 st optical laminate 10 and the 2 nd optical laminate 30 are pressed by a pair of pressing rollers 44 to be bonded, the adhesive forming the coating layer 20 is set so as not to contact the pressing rollers 44 and the pressing rollers 44 for each predetermined range of the distance D1a and the distance D2a, and the desired configuration can be obtained as the phase difference plate 2 when the release member 6 is peeled from the laminate 4 of the 1 st optical laminate 10 and the 2 nd optical laminate 30 (see fig. 8 and 9).
Therefore, for example, in a case where the distance D1a and the distance D2a are outside the predetermined ranges set for them, for example, the adhesive may adhere to the pressure roller 44, thereby contaminating 2 pressure rollers 44. Alternatively, when the peeling member 6 is peeled from the laminate 4, a portion to be peeled may remain on the side of the phase difference plate 2 to be a product.
In contrast, in the method for manufacturing the phase difference plate 2, the management method described in embodiment 1 is performed. In the measurement step S02 of the management method, the distance D1a and the distance D2a are calculated using the reflection optical system 106 shown in fig. 1 and the optically acquired image. Therefore, the distance D1a and the distance D2a can be calculated efficiently and accurately while the 1 st optical layered body 10 is being transported. Thus, it is possible to appropriately determine whether or not each of the distance D1a and the distance D2a is in the corresponding predetermined range.
When at least one of the distance D1a and the distance D2a is out of the predetermined range, a changing step S04 of changing the application region of the adhesive is performed. Further, in the determination step S03, the changing step S04 is performed until both the distance D1a and the distance D2a fall within the predetermined range. Therefore, the distance D1a and the distance D2a can be set within predetermined ranges. As a result, such a problem that the adhesive adheres to the pressure roller 44 as described above can be prevented. In this case, for example, maintenance of the pressure roller 44 to which the adhesive is attached can be avoided, and thus the manufacturing efficiency of the phase difference plate 2 is improved. Since the distance D1a and the distance D2a can be set within the predetermined ranges, it is possible to prevent a defect that a portion to be peeled remains on the side of the phase difference plate 2 to be a product. Therefore, the production of the phase difference plate 2 as a defective product can be avoided, and as a result, the production yield of the phase difference plate 2 is improved.
In the case of implementing the control method, the inspection light L1 output from the light source unit 108 may be the inspection light L1 having the stripe pattern 112 described in embodiment 1, or may be the planar inspection light L1. With respect to the planar inspection light L1 and the inspection light L1 of the stripe pattern 112, for example, as compared with the case of using a linear inspection light, the angle dependence of the irradiation region of the inspection light L1 with respect to the extending direction of the end (or the end) can be reduced, and the positions of the ends 11a, 20a, 11b, and 20b can be easily detected. Further, in the case where the inspection light L1 has the stripe pattern 112, a plurality of images illuminating the end region from multiple directions can be acquired at once. Therefore, the ends 11a and 20a and the ends 11b and 20b are easily detected. By periodically changing the shape of the stripe pattern 112 as shown by the arrows in fig. 2 and 3 or by periodically changing the stripe pattern between the 1 st pattern 112A and the 2 nd pattern 112B, a plurality of pieces of imaging information can be acquired by one reflection optical system 106. Therefore, even when an optically transparent member such as the resin film 11 and the coating layer 20 serving as the retardation plate 2 is imaged, the positions of the end portions 11a and 20a and the positions of the end portions 11b and 20b can be detected more reliably.
Fig. 11 is a diagram showing an image obtained by imaging the coating layer 20 actually coated on the resin film 11 of the 1 st optical laminate 10. Fig. 11 is an image obtained when a region of the 1 st optical layered body 10 not located on the conveying roller 42 (a region between the conveying roller 42 or between the conveying roller 42 and the pair of press rollers 44) is imaged as indicated by an arrow α 1 in fig. 9. The "I" in the column of the inspection light in fig. 11 means the planar inspection light L1. The "II" in the column of the inspection light in fig. 11 means the inspection light L1 having the stripe pattern 112 that periodically fluctuates between the 1 st pattern 112A and the 2 nd pattern 112B. Further, "film end" in fig. 11 corresponds to the end 11a, and "coating end" corresponds to the end 20 a. As shown in fig. 11, it can be understood that both the end 11a (film end) and the end 20a (coated end) were detected by the planar inspection light L1 and the inspection light L1 of the stripe pattern 112.
In the stripe pattern 112, bright portions 112a and dark portions 112b are alternately arranged. Therefore, a plurality of images in which the illumination is lit from multiple directions can be obtained. In this case, since the obtained image can be analyzed in real time and the concave-convex image and the texture image can be generated, stable inspection can be performed without depending on the surface state and the measurement environment.
When the 1 st optical layered body 10 is disposed on the conveying roller 42, for example, regular reflection occurs due to the surface of the conveying roller 42. For example, since a plurality of images in which illumination is lit from multiple directions can be captured by using the stripe pattern 112, even when the surface of the conveyance roller 42 is a mirror surface, for example, the influence of regular reflection on the surface of the conveyance roller 42 can be reduced. Therefore, the ends 11a and 20a and the ends 11b and 20b are easily detected. In other words, even in an environment susceptible to the influence of regular reflection, the end portions 11a and 20a and the end portions 11b and 20b are easily detected. Fig. 12 is a diagram showing an image obtained by imaging the coating layer 20 coated on the resin film 11 included in the 1 st optical laminate 10 in the region of the 1 st optical laminate 10 positioned on the conveying roller 42, as illustrated by an arrow α 2 in fig. 9. The meanings of "II" in the column of the inspection light in fig. 12, "film edge" and "coating edge" in the image are the same as those in the case of fig. 11. As can be understood from fig. 12, it can be understood that even in the region on the conveying roller 42 in the 1 st optical laminate 10, the end 11a (film end) and the end 20a (coating end) are detected by using the stripe pattern 112.
In the embodiment illustrated in fig. 9, after the laminate 4 is formed, the peeling member 6 is peeled from the laminate 4. However, the stacked body 4 may be temporarily wound to form a roll body. In this case, the peeling member 6 is peeled from the stacked body 4 while the stacked body 4 is rewound from the roller body of the stacked body 4. The treatment of, for example, bonding a polarizing plate to the retardation plate 2 can be performed while conveying the retardation plate 2 obtained by peeling the peeling member 6 from the laminated body 4 without contacting the retardation surface (the surface of the retardation plate 2 opposite to the resin film 11) with a conveying roller or the like. In this case, for example, damage to the retardation surface can be prevented.
The 1 st optical laminate 10 may be an optical laminate in which the 1 st retardation layer 13 is directly laminated on the resin film 11. The 2 nd optical layered body 30 may be obtained by directly layering the 2 nd retardation layer 33 on the resin film 31.
(modification 1)
The management method may be performed for the laminate 4 conveyed between the pair of press rollers 44 and the peeling roller 46 as illustrated by an arrow β shown in fig. 9. In this case, as shown in fig. 13, the management method described in embodiment 1 is performed with the resin film 11 of the 1 st optical laminate 10 and the resin film 31 of the 2 nd optical laminate 30 being the 1 st member layer 102 and the 2 nd member layer 104 described in embodiment 1. In modification 1, end 11a of resin film 11 corresponds to end 102a, and end 31a of resin film 31 corresponds to end 104 a. Further, the distance D1b in the x direction between the end 11a and the end 31a corresponds to the distance D1. In fig. 13, in order to clearly show the distance D1b, the center of the 2 nd optical stack 30 is shown as being shifted from the center of the 1 st optical stack 10 (the center in the x direction).
In modification 1, the reflection optical system 106 is disposed on the laminate 4 conveyed between the pair of press rollers 44 and the peeling roller 46, and the measurement step S02 included in the management method is performed to measure the distance D1 b. Further, in the determination step S03, it is determined whether or not the distance D1b is within a predetermined range.
In general, in order to stack the 1 st optical stack 10 and the 2 nd optical stack 30 so that their centers coincide with each other in the x direction, the positions of the end portions 11a and 31a are the same in the x direction. Thus, for example, a given range for distance D1b is a range that includes certain manufacturing errors relative to the case where the distance is 0.
In the case where the distance D1b is within the given range, the manufacturing of the phase difference plate 2 is continued. On the other hand, when the distance D1b is out of the predetermined range, for example, in the changing step S04, the manufacturing conditions are changed so that the distance D1b is within the predetermined range. For example, the transport paths (conditions) of the 1 st optical stack 10 and the 2 nd optical stack 30 are changed. This changing step S04 is repeated until the distance D1b becomes within the predetermined range in the determining step S03. For example, the manufacturing process of the phase difference plate 2 and the changing process S04 are repeated until the determining process S03 is performed.
With distance D1b outside the given range, the 2 nd optical stack 30 is not bonded in the desired position relative to the 1 st optical stack 10. Therefore, the arrangement relationship between the adhesive layer 22 and the 2 nd optical laminate 30 is also shifted from the desired position. As a result, when the peeling member 6 is peeled from the laminate 4, there is a possibility that a defect occurs in which a portion to be peeled remains on the side of the phase difference plate 2 to be a product.
In contrast, as in modification 1, the above-described problem can be prevented by applying the management method described in embodiment 1 to the laminate 4 between the pair of press rollers 44 and the peeling roller 46. As a result, the good phase difference plate 2 can be easily manufactured, and the manufacturing yield of the phase difference plate 2 can be improved.
(modification 2)
The management method may be performed for the phase difference plate 2 obtained by peeling the peeling member 6 from the laminate 4 by the peeling roller 46, as illustrated by the arrow γ 1 shown in fig. 9. Alternatively, the management method may be performed for the peeling member 6 obtained by peeling the peeling member 6 from the laminate 4 by the peeling roller 46, as illustrated by the arrow γ 2.
A case will be described in which the management method is performed for the phase difference plate 2 as shown by the arrow γ 1. In this case, as shown in fig. 14, the management method is performed by using the resin film 11 as the 1 st member layer 102 and the 2 nd retardation layer 33 on the adhesive layer 22 as the 2 nd member layer 104. When the management method is performed for the retardation plate 2, the end 11a of the resin film 11 corresponds to the end 102a, and the end 33a of the 2 nd retardation layer 33 corresponds to the end 104 a. Further, the distance D1c in the x direction between the end 11a and the end 33a corresponds to the distance D1.
When the management method is performed at the position of the arrow γ 1, the reflection optical system 106 is disposed with respect to the retardation plate 2 in the subsequent stage of the peeling roller 46, and the measurement step S02 included in the management method is performed to measure the distance D1 c. In the determination step S03, it is determined whether or not the distance D1c is within a predetermined range.
If the peeling member 6 is appropriately peeled by the peeling roller 46, the distance D1c between the end 11a and the end 33a in the longitudinal direction of the phase difference plate 2 is constant. On the other hand, when the peeling by the peeling roller 46 cannot be performed properly, the peeled portion of the 2 nd retardation layer 33 of the 2 nd optical laminate 30 remains on the side of the retardation plate 2. Therefore, for example, the distance D1c between the end 11a and the end 33a in the phase difference plate 2 varies.
If the distance D1c is outside the predetermined range (i.e., the range in which manufacturing errors are considered in the first set distance), it is considered that a defect (or abnormality) occurs in which, for example, the portion of the 2 nd retardation layer 33 to be peeled remains on the side of the retardation plate 2. Therefore, by determining whether or not the distance D1c is within the predetermined range in the determination step S03 of the management step, the presence or absence of an abnormality in the case where the peeling member 6 is peeled from the laminate 4 can be detected. If it is assumed that an abnormality is detected, the manufacturing conditions are changed in the changing step S04 so that the distance D1c falls within a predetermined range. For example, the state of lamination of the 1 st optical laminate 10 and the 2 nd optical laminate 30, the peeling force of the adhesive layer 22, and the like may be appropriately adjusted.
When the management method is performed for the peeling member 6 in the subsequent stage of the peeling roller 46 as shown by the arrow γ 2, the management method is performed with the resin film 31 included in the peeling member 6 as the 1 st member layer 102 and the 2 nd retardation layer 33 included in the peeling member 6 as the 2 nd member layer 104 as shown in fig. 14. In this case, end 31a of resin film 31 corresponds to end 102a, and end 33a of 2 nd retardation layer 33 of peeling member 6 corresponds to end 104 a. Further, the distance D1D in the x direction between the end 31a and the end 33a corresponds to the distance D1. The method of managing the peeling member 6 is the same as the method of managing the retardation plate 2, except that the 1 st member layer 102 and the 2 nd member layer 104 are the resin film 31 and the 2 nd retardation layer 33 included in the peeling member 6.
(modification 3)
Instead of the 1 st optical laminate 10 and the 2 nd optical laminate 30, the 1 st optical laminate 10A and the 2 nd optical laminate 30A shown in fig. 15 may be used. The 1 st optical laminate 10A is different from the 1 st optical laminate 10 in the structure in that the 1 st retardation layer 13 does not cover both ends of the alignment film 12 in the x direction. Similarly, the 2 nd optical laminate 30A is different from the 2 nd optical laminate 30 in the structure in that the 2 nd retardation layer 33 does not cover both ends of the alignment film 32 in the x direction. In general, the length of the 1 st retardation layer 13 in the x direction is shorter than the length of the alignment film 12, and the length of the 2 nd retardation layer 33 in the x direction is shorter than the length of the alignment film 32. In this case, in the peeling roller 46 shown in fig. 9, as shown in fig. 16, the resin film 31 included in the 2 nd optical laminate 30A is selectively peeled off. As a result, the retardation plate 2A can be produced in which the alignment film 12, the 1 st retardation layer 13, the adhesive layer 22, the 2 nd retardation layer 33, and the alignment film 32 are laminated in this order on the resin film 11. The method of manufacturing the retardation plate 2A to which the management method is applied is the same as the case described with reference to fig. 6 to 9. Therefore, the modification 3 also has the same operational effects as those in the case of manufacturing the phase difference plate 2.
The embodiments and modifications of the present invention have been described above. However, the present invention is not limited to the illustrated embodiments and modifications, and includes the scope shown in the patent claims, and is intended to include meanings equivalent to the patent claims and all modifications within the scope.
In the case where the optical member is a retardation plate, a method of manufacturing a retardation plate to which a management method is applied will be described. However, the optical component to which the manufacturing method according to the present invention is applied is not limited to the phase difference plate. Examples of other optical components include a polarizing plate obtained by laminating a polarizing film (polarizing element layer) and a protective film, a circularly polarizing plate (including an elliptically polarizing plate) obtained by bonding a retardation plate and a polarizing plate via an adhesive layer, and the like. An example of the polarizing element layer is a PVA layer.
In the case where the optical component is the circularly polarizing plate, the management method may be applied, for example, with the application layer to be the 1 st member layer (for example, a member corresponding to the resin film 11 shown in fig. 5) provided in the retardation plate or the polarizing plate and the adhesive layer between the retardation plate and the polarizing plate as the 2 nd member layer. Alternatively, as described in modification 1, the above-described management method may be applied to position adjustment of the retardation plate and the polarizing plate.
The management method according to the present invention can be applied to a laminate having a resin film (1 st member layer) and a coating layer (2 nd member layer). The management method according to the present invention can be applied to, for example, a laminate including a polarizing plate (1 st member layer) including a polarizing film or a polarizing film and an application layer (2 nd member layer). The management method according to the present invention can be applied to, for example, a case where the coating layer (2 nd member layer) is directly formed on the resin film (1 st member layer).
The management method according to the present invention can be applied to, for example, a case where an adhesive layer formed on a release film is transferred to a1 st member layer (for example, a resin film). In this case, a pressure-sensitive adhesive body was prepared by bonding the release film with the pressure-sensitive adhesive layer to the 1 st member layer via the pressure-sensitive adhesive layer. The release film can be peeled off from the adherend, and the adhesive layer can be laminated on the 1 st member layer. In this case, the adhesive layer may be used as the 2 nd member layer, and the management method may be applied to the laminate. For example, when the pressure-sensitive adhesive body is long, a management method may be applied to a laminate obtained by peeling a release film while conveying the pressure-sensitive adhesive body in the longitudinal direction using the peeling roller 46 in fig. 9. Thus, it is possible to determine whether or not the 1 st member layer is properly transferred to the adhesive layer.
Alternatively, the management method according to the present invention can also be applied to a case where an adhesive layer (2 nd member layer) and a protective film (or a release film) are laminated on a base material (1 st member layer), or a case where the protective film is peeled. For example, in this case, when the laminated member of the base material, the adhesive layer, and the protective film is a long member, the protective film may be peeled off by using the peeling roller 46 in fig. 9, and the management method may be performed on the obtained laminated body of the base material and the adhesive layer. Thus, it is possible to determine whether or not the protective film is properly peeled (whether or not the adhesive layer remains on the protective film side).
Further, the management method according to the present invention can be applied to a laminate having other optical functional films such as a polarizing film, in addition to the base material (1 st member layer) and the adhesive layer (2 nd member layer).
As described in modification 1 of embodiment 2, the management method according to the present invention can also be applied to the management of the presence or absence of an abnormality in the alignment of the 1 st member layer and the 2 nd member layer in the laminate of the 1 st member layer and the 2 nd member layer.

Claims (16)

1. An assay method of assaying an end region of a laminate comprising a1 st member layer and a2 nd member layer,
the 1 st component layer has a1 st end,
the 2 nd member layer has a2 nd end portion located on the same side as the 1 st end portion as viewed from the lamination direction of the 1 st member layer and the 2 nd member layer in the laminate,
the end region is a region extending from the 1 st end to the 2 nd end in the laminated body,
the method comprises the following steps:
an irradiation step of irradiating the end region with inspection light;
a detection step of detecting reflected light as the inspection light reflected by the end region; and
and a calculation step of calculating a distance between the 1 st edge and the 2 nd edge based on a detection result of the reflected light.
2. The method of claim 1, wherein,
the 1 st component layer is a resin film layer, and the 2 nd component layer is a coating layer containing an adhesive or a bonding agent.
3. The method of claim 1 or 2,
the inspection light has a stripe pattern in which bright portions and dark portions are alternately arranged.
4. The method of claim 3, wherein,
the shape of the stripe pattern periodically fluctuates.
5. The method of claim 4, wherein,
the shape of the stripe pattern periodically varies between the 1 st pattern and the 2 nd pattern,
the extending direction of the light portions and the dark portions in the 2 nd pattern is orthogonal to the extending direction of the light portions and the dark portions in the 1 st pattern.
6. The method according to any one of claims 1 to 5,
the laminated body is a long laminated body,
the step of irradiating the inspection light and the step of detecting the reflected light are performed while the laminate is conveyed in the longitudinal direction.
7. A method of managing an end region of a laminate including a1 st member layer and a2 nd member layer,
the 1 st component layer has a1 st end,
the 2 nd member layer has a2 nd end portion located on the same side as the 1 st end portion as viewed from the lamination direction of the 1 st member layer and the 2 nd member layer in the laminate,
the end region is a region extending from the 1 st end to the 2 nd end in the laminated body,
the method comprises the following steps:
an irradiation step of irradiating the end region with inspection light;
a detection step of detecting reflected light as the inspection light reflected by the end region;
a calculation step of calculating a distance between the 1 st edge and the 2 nd edge based on a detection result of the reflected light; and
and a determination step of determining whether or not the calculated distance is within a predetermined range.
8. The method of claim 7, wherein,
the 1 st component layer is a resin film layer, and the 2 nd component layer is a coating layer containing an adhesive or a bonding agent.
9. The method of claim 7 or 8,
the inspection light has a stripe pattern in which bright portions and dark portions are alternately arranged.
10. The method of claim 9, wherein,
the shape of the stripe pattern periodically fluctuates.
11. The method of claim 10, wherein,
the shape of the stripe pattern periodically varies between the 1 st pattern and the 2 nd pattern,
the extending direction of the light portions and the dark portions in the 2 nd pattern is orthogonal to the extending direction of the light portions and the dark portions in the 1 st pattern.
12. The management method according to any one of claims 7 to 11,
the method further comprises, before the irradiation step: and a laminating step of laminating the 2 nd member layer on the 1 st member layer or the laminated member having the 1 st member layer.
13. The method of claim 12, wherein,
in the laminating step, the 2 nd member layer is laminated on the 1 st member by coating a coating material on the 1 st member layer.
14. The method of claim 13, wherein,
a changing step of changing a coating region of the coating material in the laminating step when the calculated distance is not included in a predetermined range,
the laminating step, the irradiating step, the detecting step, and the determining step are repeated until the calculated distance is included in a predetermined range.
15. The method according to any one of claims 12 to 14,
the laminate is a long laminate of a plurality of layers,
the laminating step, the irradiating step, and the detecting step are performed while conveying the laminate in the longitudinal direction.
16. A method for manufacturing an optical component, comprising the management method according to any one of claims 7 to 15.
CN202011367256.8A 2019-12-05 2020-11-27 Measurement method, management method, and method for manufacturing optical component Pending CN112924457A (en)

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