JP2021089240A - Measurement method, management method and manufacturing method of optical component - Google Patents

Abstract

To provide technique for appropriately managing distance between an end of a first member layer and an end of a second member layer that are included in the end region of a laminate of the first and second member layers.SOLUTION: A measurement method according to one embodiment is a method for measuring an end region of a laminate that includes a first member layer and a second member layer, the first member layer has a first end, the second member layer has a second end located on the same side as the first end as seen from the lamination direction of the first and second member layers of the laminate, the end region extends from the first end to the second end of the laminate. This measurement method comprises: an irradiation step of irradiating the end region with inspection light; a detection step of detecting reflected light that is the inspection light having been reflected by the end region; and a calculation step of calculating the distance between the first and second ends on the basis of the result of the detection of the reflected light.SELECTED DRAWING: Figure 1

Description

The present invention relates to a measuring method, a management method, and a method for manufacturing an optical component.

As described in Patent Document 1, a second member layer formed by the coating liquid is formed on the first member layer (sheet-like material of Patent Document 1), and the first member layer and the second member layer are formed. There is a known technique for obtaining a laminate of.

Japanese Unexamined Patent Publication No. 2000-24565

In the laminated body of the first member layer and the second member layer, the first end portion of the first member layer and the second end portion of the second member layer (on the same side as the first end portion side of the first member layer). If the distance between the ends) is deviated from a predetermined range, various problems occur. For example, as described in Patent Document 1, when the second member layer is a coating layer formed by applying a coating liquid, the distance between the ends deviates from a predetermined range. If so, in the process after forming the coating layer, the coating liquid protrudes from the first member layer and coats another member (for example, a roller, a member to be bonded to the first member layer, etc.). The working liquid may be contaminated. Alternatively, when the laminated body is one component and the distance between the ends is deviated from a predetermined range, the arrangement relationship between the first member layer and the second member layer is deviated from the desired state. Therefore, there is a risk that the performance of the component as the laminated body may not exhibit the desired performance, or the component may not be properly incorporated into another device.

Therefore, in the laminated body of the first member layer and the second member layer, the distance between the ends of the first end portion of the first member layer and the second end portion of the second member layer is set within a predetermined range. There was a need for technology to manage it properly.

Therefore, one object of the present invention is to set the distance between the end portion of the first member layer and the end portion of the second member layer included in the end region of the laminated body of the first member layer and the second member layer. It is to provide a measurement method and a management method for proper management. Another object of the present invention is to provide a method for manufacturing an optical component using the above control method.

The measuring method of one aspect of the present invention is a method of measuring an end region of a laminate including a first member layer and a second member layer, and the first member layer has a first end portion. The second member layer has a second end portion located on the same side as the first end portion when viewed from the stacking direction of the first member layer and the second member layer in the laminated body, and the end portion. The region is a region extending from the first end portion to the second end portion in the laminated body, and is an irradiation step of irradiating the end region region with inspection light and the inspection light reflected by the end region. The present invention includes a detection step of detecting the reflected light and a calculation step of calculating the distance between the first end portion and the second end portion based on the detection result of the reflected light.

In the above measurement method, the inspection light is irradiated to the end region, and the reflected light is detected. Further, the distance between the first end portion and the second end portion is calculated based on the detection result of the reflected light. In order to calculate the distance between the first end portion and the second end portion based on the optical measurement result in this way, the distance between the first end portion and the second end portion is more appropriately calculated. The distance can be calculated.

The first member layer may be a resin film layer, and the second member layer may be a coating layer formed of an adhesive or an adhesive.

The inspection light may have a striped pattern in which bright parts and dark parts are alternately arranged. In this case, it is possible to easily obtain a plurality of detection results that illuminate the end region from multiple directions. Therefore, it is easy to detect the first end portion and the second end portion.

The shape of the striped pattern may change periodically. Thereby, even if there is only one device that outputs the inspection light, it is possible to obtain various optical information of the end region.

For example, the shape of the striped pattern varies periodically between the first pattern and the second pattern, and the extending direction of the bright portion and the dark portion in the second pattern is the bright portion in the first pattern. It may be orthogonal to the extending direction of the portion and the dark portion.

The laminated body is a long laminated body, and the irradiation step and the detection step may be carried out while transporting the laminated body in the long direction.

A management method according to another aspect of the present invention is a method of managing an end region of a laminate including a first member layer and a second member layer, and the first member layer has a first end portion. The second member layer has a second end portion located on the same side as the first end portion when viewed from the stacking direction of the first member layer and the second member layer in the laminated body. The end region is a region extending from the first end portion to the second end portion in the laminated body, and is an irradiation step of irradiating the end region region with inspection light and the inspection light reflected by the end region. The detection step of detecting the reflected light, the calculation step of calculating the distance between the first end portion and the second end portion based on the detection result of the reflected light, and the calculated distance are predetermined. It is provided with a determination step of determining whether or not it is within the range of.

In the above management method, the inspection light is irradiated to the end region, and the reflected light is detected. Further, the distance between the first end portion and the second end portion is calculated based on the detection result of the reflected light. In order to calculate the distance between the first end portion and the second end portion based on the optical measurement result in this way, the distance between the first end portion and the second end portion is more appropriately calculated. The distance can be calculated. Since the determination step is performed based on the distance between the first end portion and the second end portion calculated in this way, the distance between the first end portion and the second end portion is appropriately set. It is manageable.

The first member layer may be a resin film layer, and the second member layer may be a coating layer formed of an adhesive or an adhesive.

The inspection light may have a striped pattern in which bright parts and dark parts are alternately arranged. In this case, it is possible to easily obtain a plurality of detection results that illuminate the end region from multiple directions. Therefore, it is easy to detect the first end portion and the second end portion.

The shape of the striped pattern may change periodically. Thereby, even if there is only one device that outputs the inspection light, it is possible to obtain various optical information of the end region.

The shape of the striped pattern varies periodically between the first pattern and the second pattern, and the extending directions of the bright portion and the dark portion in the second pattern are the bright portion and the bright portion in the first pattern. It may be orthogonal to the extending direction of the dark portion.

Prior to the irradiation step, a laminating step of laminating the second member layer on the laminating member having the first member layer or the first member layer may be further included.

In the laminating step, the second member layer may be laminated on the first member by applying a coating material on the first member layer.

When the calculated distance is not included in the predetermined range, the laminating step further includes a changing step of changing the coating area of the coating material, and the calculated distance is included in the predetermined range. The laminating step, the irradiation step, the detection step, and the determination step may be repeated until. Thereby, it is possible to more reliably obtain a laminated body in which the distance between the first end portion and the second end portion is within a predetermined range.

The laminated body is a long laminated body, and the laminating step, the irradiation step, and the detecting step may be carried out while transporting the laminated body in the long direction.

The 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.

According to one aspect of the present invention, the distance between the end portion of the first member layer and the end portion of the second member layer included in the end region of the laminated body of the first member layer and the second member layer is appropriate. It is possible to provide a measurement method and a management method for managing the invention. According to another aspect of the present invention, it is possible to provide a method for manufacturing an optical component using the above control method.

FIG. 1 is a drawing for explaining a management method according to an embodiment. FIG. 2 is a drawing showing a first pattern which is an example of a striped pattern. FIG. 3 is a drawing showing a second pattern, which is another example of the striped pattern. FIG. 4 is a flowchart of the management method according to the embodiment. FIG. 5 is a drawing showing a configuration of a retardation plate (optical component) manufactured in the second embodiment. FIG. 6 is a drawing for explaining a process included in the manufacturing method of the retardation plate shown in FIG. FIG. 7 is a drawing illustrating a step after the step shown in FIG. FIG. 8 is a drawing illustrating a step after the step shown in FIG. FIG. 9 is a drawing for explaining a case where the method for manufacturing the retardation plate shown in FIG. 5 is carried out by a roll-to-roll method. FIG. 10 is a drawing for explaining an example of a method of changing the coating area. FIG. 11 is a drawing showing the imaging results of the film end portion (first end portion) and the coating end portion (second end portion). FIG. 12 is a drawing showing other imaging results of the film end portion (first end portion) and the coating end portion (second end portion). FIG. 13 is a drawing for explaining the first modification. FIG. 14 is a drawing for explaining the second modification. FIG. 15 is a drawing for explaining the modified example 3. FIG. 16 is a drawing for explaining the modified example 3.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. The same elements are designated by the same reference numerals, and duplicate description will be omitted. The dimensional ratios in the drawings do not always match those described.

As shown in FIG. 1, the end portion (first end portion) 102a of the first member layer 102 included in the laminated body 100 and the end portion 104a (second end portion) of the second member layer 104 included in the laminated body 100. A method of managing the distance (distance between ends) D1 from the above will be described as the first embodiment. After that, an example using the management method described in the first embodiment will be described as the second embodiment with reference to examples of the first member layer 102 and the second member layer 104. Hereinafter, for convenience of explanation, as shown in FIG. 1, the stacking direction of the first member layer 102 and the second member layer 104 is referred to as the z direction, and the direction orthogonal to the z direction is referred to as the x direction.

(First Embodiment)
FIG. 1 is a drawing for explaining a management method according to an embodiment. The laminated body 100 shown in FIG. 1 has a first member layer 102 and a second member layer 104. The second member layer 104 is laminated on the first member layer 102. The first member layer 102 and the second member layer 104 can be, for example, members formed of an optically transparent material. For example, the first member layer 102 is a resin film layer, and the second member layer 104 is a coating layer formed of a coating material (for example, an adhesive or an adhesive). Examples of the first member layer 102 and the second member layer 104 will be described in detail in other embodiments.

In the management method according to the first embodiment, the distance D1 between the end 102a of both ends of the first member layer 102 in the x direction and the end 104a of both ends of the second member layer 104 in the x direction. To manage. The end portion 104a is an end portion of both ends of the second member layer 104 that is located on the same side as the end portion 102a when viewed from the stacking direction (z direction) of the first member layer 102 and the second member layer 104. When the second member layer 104 is a coating material, the length of the second member layer 104 in the x direction is shorter than the length of the first member layer 102. Depending on the second member layer 104 (for example, a resin film or the like), the length of the second member layer 104 in the x direction may be longer than the length of the first member layer 102.

In the management method, the distance D1 is measured using the reflection optical system 106 as shown in FIG. The catadioptric 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 laminated body 100 in the x direction. Specifically, it is a region extending from the end portion 102a to the end portion 104a.

The light source unit 108 outputs the inspection light L1 toward the end region A1 of the laminated body 100. The example of the wavelength of the inspection light L1 depends on the material of the first member layer 102 and the second member layer 104, and may be a wavelength that can acquire an image of the end region A1. An example of the wavelength of the inspection light L1 is a white LED light source having a peak wavelength of 450 ± 30 nm. The inspection light L1 may be configured to, for example, illuminate the end region A1 in a planar manner.

The imaging unit 110 is a photodetector that detects the reflected light L2, which is the inspection light L1 reflected by the end region A1. The image pickup unit 110 is, for example, a two-dimensional sensor such as a CCD camera or a CMOS camera.

The image capturing unit 110 inputs image data to the image processing device 114. The image processing device 114 creates an image of the end region A1 based on the image data input from the image capturing unit 110. The image processing device 114 has a display function for displaying the created image to the user. The image processing device 114 may have a function of analyzing the created image to detect the end portion 102a and the end portion 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 of the light source unit 108. The image processing device 114 may be, for example, a dedicated device for carrying out the management method according to the first embodiment. Alternatively, the personal computer may implement a program for implementing the management method including the image processing, and the personal computer may function as the image processing device 114.

An example of the light source unit 108 will be described. As shown in FIGS. 2 and 3, the light source unit 108 may be configured to output the inspection light L1 having the striped pattern 112 in which the bright portions 112a and the dark portions 112b are alternately arranged. The X direction in FIG. 2 indicates the extending direction of the bright portion 112a and the dark portion 112b in FIG. 2, and the Y direction is a direction orthogonal to the X direction. The X direction and the Y direction in FIG. 3 are the same directions as the X direction and the Y direction in FIG.

The shape (pattern shape) of the striped pattern 112 may change. For example, in FIGS. 2 and 3, the bright portion 112a (or the dark portion 112b) moves in the direction of the arrow in FIGS. 2 and 3, or the width of the bright portion 112a (or the dark portion 112b) fluctuates, resulting in a striped pattern. The shape of 112 may change.

Further, when the striped pattern 112 shown in FIG. 2 is referred to as the first pattern 112A and the striped pattern 112 shown in FIG. 3 is referred to as the second pattern 112B, the light source unit 108 refers to the first pattern 112A and the second pattern. It may be configured to fluctuate periodically with 112B. The second pattern 112B is a pattern in which the extending direction of the bright portion 112a and the dark portion 112b) in the second pattern 112B is orthogonal to the extending direction of the bright portion 112a and the dark portion 112b in the first pattern 112A. Even when the first pattern 112A and the second pattern 112B periodically fluctuate, the bright portion 112a (or the dark portion 112b) is indicated by the arrows in FIGS. 2 and 3 in each of the first pattern 112A and the second pattern 112B. It may move in the direction, or the width of the bright portion 112a (or the dark portion 112b) may vary.

When the inspection light L1 has the striped pattern 112, the light source unit 108 may include, for example, a light source in which a plurality of point light sources (for example, LEDs) are two-dimensionally arranged, and a control device for controlling 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 with the control device. Further, the striped pattern 112 formed by the bright portion 112a and the dark portion 112b can be varied.

The light source unit 108 may output, for example, a planar inspection light L1 having no bright portion 112a and a dark portion 112b as shown in FIGS. 2 and 3. In this case, the light source unit 108 may be a surface light emitting light source, or may be a light source in which a plurality of point light sources (for example, LEDs) are arranged two-dimensionally. In the following description, the "plane inspection light L1" means a state in which the bright portion 112a and the dark portion 112b are not provided, as described above.

The shape of the fringe pattern 112 can be controlled, for example, by an image processing device 114 (see FIG. 1). In this case, the image processing device 114 may control the light source unit 108 and the image pickup unit 110 so as to synchronize them.

FIG. 4 is a flowchart of an example of the management method. The management method will be described with reference to FIG. 4 by exemplifying a case where the first member layer 102 is a long resin film and the second member layer 104 is a coating layer formed of a coating material. ..

As shown in FIG. 4, the second member layer 104 is laminated on the first member layer 102 (lamination step S01). The second member layer 104 can be formed, for example, by coating the coating material to be the second member layer 104 while transporting the first member layer 102 in the longitudinal direction. The coating of the coating material can be carried out, for example, by gravure coating.

Next, the distance D1 (see FIG. 1) is measured by the measuring method according to the embodiment while transporting the first member layer 102 (measurement step S02).

In the measurement step S02, the inspection light L1 is irradiated toward the end region A1 of the laminated body 100 (irradiation step S02a). The image pickup unit 110 detects the reflected light L2 from the end region A1 (detection step S02b). The distance D1 is calculated based on the image (detection result) of the end region A1 thus obtained (calculation step S02c). Specifically, the end portion 102a and the end portion 104a are specified based on the image obtained by the imaging unit 110, and the distance between them is calculated. The identification of the end portion 102a and the end portion 104a and the calculation of the distance D1 based on the end portion 102a may be performed by the image processing device 114, or may be performed by the user based on the image created by the image processing device 114. When the inspection light L1 fluctuates periodically between the first pattern 112A and the second pattern 112B, for example, the image processing device 114 with respect to the reflected light L2 in each of the first pattern 112A and the second pattern 112B. One image is created using the obtained image data. In order to obtain the above one 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 measurement step S02, it is determined whether or not the distance D1 is within a predetermined range (determination step S03). The determination may be made by the user, or may be made by comparing the predetermined range input in advance by the image processing device 114 with the distance D1.

When the distance D1 is determined to be within a predetermined range in the determination step S03 (“YES” in the determination step S03), the production of the laminated body 100 may be continued under the same conditions as before the determination step S03 is performed.

On the other hand, when it is determined in the determination step S03 that the distance D1 is out of the predetermined range (“NO” in the determination step S03), in the lamination step S01, the lamination conditions in the lamination step S01 (specifically, the second The change step S04 for changing the coating area of the coating material for forming the member layer 104) is carried out.

When the change step S04 is carried out, the stacking step S01, the measurement step S02, the determination step S03, and the change step S04 are carried out until the distance D1 is determined to be within a predetermined range in the determination step S03.

By implementing the above management method, the distance D1 between the end portion 102a and the end portion 104a in the laminated body 100 can be appropriately managed within a predetermined range.

For example, in a form in which the second member layer 104 is the coating layer and the coating material forming the coating layer is an adhesive or an adhesive, a pair of nip rollers is used to form a first member layer 102 on the first member layer 102. Another member may be bonded via the two member layer 104. In this case, the predetermined range of the distance D1 is usually set to prevent contamination of each nip roller due to the protrusion of the coating material to the pair of nip rollers. Therefore, by controlling the distance D1 within the above-mentioned predetermined range, contamination of each nip roller can be reliably prevented. As a result, it is possible to efficiently manufacture a product obtained by laminating another member to the first member layer 102 via the second member layer 104.

The case where the distance D1 between the end portion 102a and the end portion 104a included in the end portion region A1 is measured and managed has been described. However, as shown in FIG. 1, the distance (distance between ends) D2 between the end portions 102b and the end portions 104b included in the end portion region A2 (the region extending from the end portion 102b to the end portion 104b) of the laminated body 100. May be measured and managed in the same manner. In this case, the reflective optical system 106 is also arranged on the end portion 104b side. The end 102b of the first member layer 102 is an end opposite to the end 102a in the x direction. The end portion 104b of the second member layer 104 is an end portion opposite to the end portion 104a in the x direction. In FIG. 1, the light source unit 108 and the imaging unit 110 are arranged along the x direction when 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 form shown in FIG. The light source unit 108 and the imaging unit 110 may be arranged along directions orthogonal to, for example, the x-direction and the z-direction.

When measuring and managing both the distance D1 and the distance D2, they may be carried out at the same time. Further, in the determination step S03, if at least one of the distance D1 and the distance D2 is outside the predetermined range set for each of the distance D1 and the distance D2, the change step S04 shown in FIG. 4 may be carried out. ..

(Second Embodiment)
A method of manufacturing an optical component using the management method described in the first embodiment will be described. FIG. 5 is a schematic view of a retardation plate (optical component) 2 manufactured by the manufacturing method according to the second embodiment. Also in the second embodiment, for convenience of explanation, the x-direction and the z-direction shown in FIG. 5 may be used as in the case of the first embodiment.

The retardation plate 2 includes a resin film 11, an alignment film 12, a first retardation layer 13, an adhesive layer 22, and a second retardation layer 33. The retardation plate 2 is an optical component (or optical element) that imparts a constant retardation to the light incident on the retardation plate 2 by the first retardation layer 13 and the second 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 form in which the first retardation layer 13 and the second retardation layer 33 are cured products of a polymerizable liquid crystal compound will be described.

The resin film 11 is a support that supports the alignment film 12, the first retardation layer 13, the adhesive layer 22, and the second retardation layer 33. Examples of materials for the resin film 11 include triacetyl cellulose (TAC), polyethylene terephthalate (PET), and polycycloolefin (COP). An example of the thickness of the resin film 11 is 20 μm to 120 μm. An example of the length of the resin film 11 in the x direction is 500 mm to 2000 mm.

The alignment film 12 is laminated on the resin film 11. In the form 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 μm to 10 μm, preferably in the range of 0.05 μm to 5 μm, and more preferably in the range of 0.1 μm to 3 μm.

An example of the alignment film 12 is a vertical alignment film, a horizontal alignment film, or an alignment film for tilting the molecular axis of the polymerizable liquid crystal compound, which can be selected according to the first 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 used for the retardation plate. For example, as the alignment film 12, a cured product obtained by curing a conventionally known monofunctional or polyfunctional (meth) acrylate-based monomer under a polymerization initiator can be used.

The first retardation layer 13 is a layer that imparts a predetermined retardation to the light incident on the first retardation layer 13. As described above, the first retardation layer 13 is a cured product of the polymerizable liquid crystal compound. In the form shown in FIG. 5, the length of the first 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 first retardation layer 13. An example of the thickness of the first retardation layer 13 is usually 0.2 μm to 3 μm, preferably 0.2 μm to 2 μm.

The adhesive layer 22 is provided on the first retardation layer 13, and is a layer that joins the first retardation layer 13 and the second retardation layer 33. The material of the adhesive layer 22 is an adhesive or an adhesive. The adhesive or pressure-sensitive adhesive may be a material known in the art of the present disclosure. Examples of the adhesive include an active energy ray-curable adhesive such as an ultraviolet (UV) curable resin and a water-based adhesive such as an aqueous polyvinyl alcohol-based resin. Examples of the pressure-sensitive adhesive include a pressure-sensitive adhesive composition containing (meth) acrylic resin, rubber-based resin, urethane-based resin, ester-based resin, silicone-based resin, polyvinyl ether-based 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 first retardation layer 13. An example of the thickness of the adhesive layer 22 is 0.1 μm to 10 μm, preferably 0.5 μm to 5 μm, and more preferably 1 μm to 3 μm.

The second retardation layer 33 is a layer that imparts a predetermined retardation to the light incident on the second retardation layer 33. As described above, the second retardation layer 33 is a cured product of the polymerizable liquid crystal compound. In the retardation plate 2 shown in FIG. 5, the length of the second retardation layer 33 in the x direction is the same as the length of the adhesive layer 22. An example of the thickness of the second retardation layer 33 is usually 0.2 μm to 3 μm, preferably 0.2 μm to 2 μm.

The outline of the manufacturing method of the retardation plate 2 will be described with reference to FIGS. 6 to 8. When manufacturing the retardation plate 2, the first optical laminate 10 and the second optical laminate 30 shown in FIG. 6 are prepared. The first optical laminate 10 and the second optical laminate 30 extend in directions orthogonal to the x-direction and the z-direction. 6 to 8 are schematic views of cross sections of the first optical laminate 10 and the second optical laminate 30 orthogonal to each other in the longitudinal direction.

The first optical laminated body 10 is a laminated member in which a resin film 11, an alignment film 12, and a first retardation layer 13 are laminated. The resin film 11, the alignment film 12, and the first retardation layer 13 extend in the elongated direction of the first optical laminate 10. Therefore, the first optical laminated body 10 is a long laminated member.

The first optical laminate 10 illustrated in FIG. 6 can be manufactured by forming an alignment film 12 and a first retardation layer 13 in this order on the resin film 11. The alignment film 12 can be formed, for example, by applying a material for the alignment film 12 on the resin film 11 and curing the coating film. The first retardation layer 13 can be formed, for example, by applying a material for the first retardation onto the resin film 11 on which the alignment film 12 is formed and curing the coating film. The relationship between the lengths of the alignment film 12 and the first retardation layer 13 in the x direction on the resin film 11 is as described with reference to FIG.

The second optical laminated body 30 illustrated in FIG. 6 is a laminated member in which a resin film 31, an alignment film 32, and a second retardation layer 33 are laminated. The second optical laminated body 30 is a long laminated member like the first optical laminated body 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 the material of the resin film 11. The alignment film 32 is an alignment film corresponding to the second retardation layer 33. The relationship between the lengths of the resin film 31, the alignment film 32, and the second retardation layer 33 in the x direction is such that the resin film 11, the alignment film 12, and the first retardation layer 13 of the first optical laminate 10 are in the x direction. It is the same as the relationship of length. Therefore, the length of the second retardation layer 33 of the second optical laminate 30 in the x direction is longer than the length of the second retardation layer 33 of the retardation plate 2 shown in FIG.

After preparing the first optical laminate 10 and the second optical laminate 30, the coating layer 20 is formed by applying an adhesive on the first retardation layer 13. Next, the first optical laminate 10 and the second optical laminate 30 are laminated via the coating layer 20 so that the coating layer 20 and the second retardation layer 33 are in contact with each other. As a result, the laminated body 4 shown in FIG. 7 is obtained.

After that, the coating layer 20 is irradiated with active energy rays such as ultraviolet rays to cure the adhesive forming the coating layer 20. As a result, the first optical laminate 10 and the second optical laminate 30 are bonded together via the adhesive layer 22 which is a cured product of the coating layer 20.

After the first optical laminate 10 and the second optical laminate 30 are bonded together, the resin film 31 is peeled from the first optical laminate 10 as shown in FIG. 8 to obtain a retardation plate 2.

The bonding force of the adhesive layer 22 to the second retardation layer 33 is set to be stronger than the bonding force of the alignment film 32 to the second retardation layer 33. Further, the length of the adhesive layer 22 in the x direction is shorter than the length of the second retardation layer 33 in the x direction, and the second retardation layer 33 is also bonded to the resin film 31. Therefore, when the resin film 31 is peeled off, as shown in FIG. 8, the portion of the second retardation layer 33 outside the adhesive layer 22 and the alignment film 32 in the x direction are also subjected to the first optical process together with the resin film 31. It is peeled off from the laminate 10.

Hereinafter, for convenience of explanation, a member generated separately from the retardation plate 2 when the resin film 31 is peeled from the first optical laminate 10 is referred to as a peeling member 6.

In the second embodiment, the resin film 11 is used as the first member layer 102, and the coating layer 20 is used as the second member layer 104, and the management method described in the first embodiment is carried out. A management method applied to the above manufacturing method will be described with reference to FIGS. 4 and 6.

As shown in FIG. 6, the resin film 11 corresponds to the first member layer 102, and the coating layer 20 corresponds to the second member layer 104. Therefore, the end portion 11a and the end portion 11b of the resin film 11 correspond to the end portion 102a and the end portion 102b, respectively, and the end portion 20a and the end portion 20b of the coating layer 20 correspond to the end portion 104a and the end portion 104b, respectively. Further, the distance D1a between the end 11a and the end 11b corresponds to the distance D1, and the distance D2a between the end 20a and the end 20b corresponds to the distance D2.

The step of forming the coating layer 20 shown in FIG. 6 corresponds to the laminating step S01 shown in FIG. By carrying out the measurement step S02 shown in FIG. 4 after the step of forming the coating layer 20 (lamination step S01), the distance D1a between the end portion 11a of the resin film 11 and the end portion 20a of the coating layer 20 To measure. In the second embodiment, the distance D2a between the end portion 11b of the resin film 11 and the end portion 20b of the coating layer 20 is also measured.

Next, the determination step S03 shown in FIG. 4 is performed to determine whether or not the distance D1a and the distance D2a are within the predetermined ranges set for each of the distance D1a and the distance D2a, respectively. The predetermined ranges corresponding to the distances D1a and the distance D2a may be the same or different.

When it is determined in the determination step S03 that the distance D1a and the distance D2a are within the corresponding predetermined ranges, the same adhesive coating conditions as when the coating layer 20 on which the measurement is performed are formed (specifically). The production of the retardation plate 2 is continued in the same coating area). On the other hand, when it is determined in the determination step S03 that at least one of the distance D1a and the distance D2a is out of the corresponding predetermined range, the change step S04 is performed to apply the adhesive (lamination condition). To change.

When the change step S04 is carried out, the stacking step S01 to the change step S04 are repeated until it is determined in the determination step S03 that both the distance D1a and the distance D2a are within the corresponding predetermined ranges.

An example of a manufacturing method of the retardation plate 2 to which the management method described in the first embodiment is applied will be described in more detail with reference to FIG. Hereinafter, as shown in FIG. 9, a case where the retardation plate 2 is manufactured by using the roll-to-roll method will be described.

The roll-shaped first optical laminate 10 and the roll-shaped second optical laminate 30 are set in the unwinding portion 40a and the unwinding portion 40b. The first optical laminate 10 is conveyed by the transfer roller 42 toward the pair of nip rollers 44 in the long direction of the first optical laminate 10. Similarly, the second optical laminated body 30 is conveyed by the conveying roller 42 toward the pair of nip rollers 44 in the long direction of the second optical laminated body 30. Since the pair of nip rollers 44 also contribute to the transport of the first optical laminate 10 and the second optical laminate 30, the pair of nip rollers 44 are also transport rollers.

The coating device 50 arranged on the transport path of the first optical laminate 10 from the unwinding portion 40a to the pair of nip rollers 44 applies an adhesive on the first retardation layer 13 of the first optical laminate 10. It is coated to form a coating layer 20 (corresponding to the laminating step S01 in FIG. 4).

The coating device 50 has an adhesive supply unit 52 and a coating roller 54. The adhesive supply unit 52 is a source of the adhesive on the surface of the coating roller 54. The coating roller 54 is a roller that coats the first retardation layer 13 of the first optical laminate 10 being conveyed with an adhesive. An example of a coating roller is a gravure roller.

When the adhesive is applied by the coating device 50, the coating area adjuster 60 causes the first optical laminate 10 (specifically, the first retardation layer 13) and the coating roller 54 to be brought into contact with each other. Adjust the contact area. FIG. 10 is a drawing showing an example of the coating area adjuster 60. In FIG. 10, the first optical laminate 10 is schematically shown as a single film. In FIG. 10, the long direction of the first optical laminate 10 is the transport direction of the first optical laminate 10.

The coating area adjuster 60 has a pair of claw portions 62 separated from each other along the transport direction of the first optical laminate 10, and a pair of support portions 64 for supporting the claw portions 62. The coating area adjuster 60 is arranged so that the pair of claw portions 62 are in contact with the coating side of the adhesive in the first optical laminate 10. By moving the coating area adjuster 60 in the width direction (direction orthogonal to the elongated direction) of the first optical laminate 10, the area between the pair of claws 62 in the first optical laminate 10 is coated. Contact with the work roller 54 is avoided. Therefore, the coating area of the adhesive is adjusted by adjusting the position of the coating area adjuster 60 in the width direction of the first optical laminate 10. 9 and 10 illustrate a case where the coating area adjuster 60 is arranged on one edge side of the first optical laminate 10 in the width direction. However, in the method of manufacturing the retardation plate 2 described with reference to FIG. 9, the coating area adjuster 60 is also arranged on the other edge side in the width direction of the first optical laminate 10. FIG. 9 schematically shows a pair of claw portions 62 of the coating area adjuster 60.

Returning to FIG. 9, the process after the adhesive is applied to the first optical laminate 10 by the coating device 50 will be described. As shown in FIG. 9, the first optical laminate 10 coated with the adhesive is conveyed between the pair of nip rollers 44. In FIG. 9, for the sake of explanation, the coating layer 20 formed on the first optical laminate 10 is illustrated in the region between the coating device 50 and the nip roller 44.

The second optical laminate 30 is conveyed to the pair of nip rollers 44 together with the first optical laminate 10. At this time, the second retardation layer 33 of the second optical laminate 30 faces the coating layer 20, and the centers of the first optical laminate 10 and the second optical laminate 30 in the width direction coincide with each other. The transport paths of the first optical laminate 10 and the second optical laminate 30 are adjusted.

The first optical laminate 10 and the second optical laminate 30 fed into the pair of nip rollers 44 are pressed in the thickness direction by the pair of nip rollers 44 and temporarily bonded via the coating layer 20.

The laminated body 4 of the first optical laminated body 10 and the second optical laminated body 30 sent out from the pair of nip rollers 44 is conveyed in the long direction of the first optical laminated body 10 and the second optical laminated body 30.

In the transport direction of the first optical laminate 10 and the second optical laminate 30, the active energy ray irradiation unit 56 is arranged downstream of the pair of nip rollers 44 (after the pair of nip rollers 44). The active energy ray irradiation unit 56 irradiates the laminated body 4 with active energy rays to cure the coating layer 20. As a result, the adhesive layer 22 as a cured product of the adhesive is formed, and the first optical laminate 10 and the second optical laminate 30 are bonded together.

In the transport direction of the laminated body 4, the second optical laminated body 30 has the second optical laminated body 30 from the laminated body 4 by the peeling roller 46 arranged downstream of the active energy ray irradiation unit 56 (the latter stage of the active energy ray irradiation unit 56). The resin film 31 is peeled off. As a result, the retardation plate 2 and the peeling member 6 are separated from the laminated body 4. Since the release roller 46 also contributes to the transfer of the laminate 4, the retardation plate 2, and the release member 6, the release roller 46 is also a transfer roller.

The obtained retardation plate 2 may be wound in a roll shape at a winding portion, for example. The peeling member 6 may be discarded as it is, or may be discarded after being wound into a roll at one end by a winding portion.

In the manufacturing method illustrated in FIG. 9, the step of forming the coating layer 20 on the first optical laminate 10 by the coating apparatus 50 corresponds to the lamination step S01 shown in FIG. Further, in the transport path of the first optical laminate 10, the reflection optical system 106 shown in FIG. 1 is provided between the coating device 50 and the pair of nip rollers 44 (for example, the positions indicated by the arrows α1 or α1). Have been placed. Using this catadioptric system 106, the distance D1a and the distance D2a of the first optical laminate 10 being conveyed are measured (measurement step S02 in FIG. 4).

In the measurement step S02, as shown schematically by the arrow α1 in FIG. 9, the distance D1a and the distance D2a in the region between the transport rollers 42 and 42 in the first optical laminate 10 may be measured. Alternatively, as schematically shown by the arrow α2, the distance D1a and the distance D2a in the region of the first optical laminate 10 located on the transport roller 42 may be measured. In the measurement between the transport rollers as shown by the arrow α1, the measurement may be performed from the side opposite to the coating layer 20. Here, the case of the measurement at the position of the arrow α1 has been described, but the same applies to the measurement between the transport rollers.

When the inspection light L1 output from the light source unit 108 of the catadioptric system 106 is, for example, a striped pattern 112 as shown in FIGS. 2 and 3, for example, in the X direction or Y shown in FIGS. 2 and 3. The direction can be set to the transport direction of the first optical laminate 10.

When the inspection light L1 is a striped pattern 112 that periodically changes into a plurality of patterns (for example, periodically fluctuates between the first pattern 112A and the second pattern 112B), the first pattern 112A and the second pattern 112B The fluctuation period and the imaging speed of the imaging unit can be set in consideration of the transport speed of the first optical laminate 10. Specifically, while the striped pattern 112 changes a certain number of times among the plurality of patterns, the change of the striped pattern 112 to the extent that an image of substantially the same region in the first optical laminated body 10 being conveyed can be acquired. The period and the imaging speed of the imaging unit can be set.

After measuring the distance D1a and the distance D2a, the determination step S03 is performed. When it is determined in the determination step S03 that both the distance D1a and the distance D2a are within the corresponding predetermined ranges, the production of the retardation plate 2 is continued.

On the other hand, when it is determined in the determination step S03 that at least one of the distance D1a and the distance D2a is out of the corresponding predetermined range, the coating area adjuster 60 is used to set the coating area of the adhesive. The change step S04 to be adjusted is carried out. Specifically, the coating area of the adhesive is changed by adjusting the position of the position adjuster in the width direction of the first optical laminate 10. When the changing step S04 is carried out, a step of applying an adhesive onto the first optical laminate 10 (lamination) until it is determined in the determination step S03 that the distance D1a and the distance D2a are within a predetermined range. Step S01), the measurement step S02 and the determination step S03 shown in FIG. 4, and the change step S04 are repeated.

As shown in FIG. 9, when the first optical laminate 10 and the second optical laminate 30 are pressed by the pair of nip rollers 44 and bonded to each other, the predetermined ranges with respect to the distance D1a and the distance D2a are painted. The adhesive forming the work layer 20 is set so as not to come into contact with the nip roller 44 and the nip roller 44, and the peeling member 6 from the laminate 4 of the first optical laminate 10 and the second optical laminate 30 (FIGS. 8 and 8). (See FIG. 9) is set so that a desired configuration can be obtained as the retardation plate 2 when the retardation plate 2 is peeled off.

Therefore, for example, when the distance D1a and the distance D2a are outside the predetermined ranges set for each, for example, the adhesive may adhere to the nip roller 44 and contaminate the two nip rollers 44. Alternatively, when the peeling member 6 is peeled from the laminated body 4, the part to be peeled may remain on the retardation plate 2 side to be the product.

On the other hand, in the manufacturing method of the retardation plate 2, the management method described in the first embodiment is carried out. In the measurement step S02 of the management method, the distance D1a and the distance D2a are calculated using the image optically acquired by using the reflection optical system 106 shown in FIG. Therefore, the distance D1a and the distance D2a can be calculated efficiently and accurately while transporting the first optical laminate 10. Thereby, it can be appropriately determined whether or not the distance D1a and the distance D2a are within the corresponding predetermined ranges.

When at least one of the distance D1a and the distance D2a is out of the predetermined range, the changing step S04 for changing the coating area of the adhesive is carried out. Further, in the determination step S03, the change step S04 is performed until both the distance D1a and the distance D2a are within a predetermined range. Therefore, it is possible to set each of the distance D1a and the distance D2a within the corresponding predetermined ranges. As a result, it is possible to prevent the problem that the adhesive adheres to the nip roller 44 as described above. In this case, for example, maintenance of the nip roller 44 due to adhesion of the adhesive can be avoided, so that the manufacturing efficiency of the retardation plate 2 is improved. Since the distance D1a and the distance D2a can be set within a predetermined range, it is possible to prevent a problem that a portion to be peeled off remains on the retardation plate 2 side to be a product. Therefore, the production of the retardation plate 2 as a defective product is avoided, and as a result, the production yield of the retardation plate 2 is improved.

When the management method is implemented, the example of the inspection light L1 output by the light source unit 108 may be the inspection light L1 having the striped pattern 112 described in the first embodiment, or may be the planar inspection light L1. .. In the surface-shaped inspection light L1 and the striped pattern 112 inspection light L1, for example, the angle of the irradiation region of the inspection light L1 with respect to the extending direction of the end (or end) is more dependent than when the line-shaped inspection light is used. The property can be reduced, and the positions of the end portion 11a and the end portion 20a and the end portion 11b and the end portion 20b can be easily detected. Further, when the inspection light L1 has the fringe pattern 112, it is possible to acquire a plurality of images illuminating the end region from multiple directions at once. Therefore, the end portion 11a and the end portion 20a and the end portion 11b and the end portion 20b can be easily detected. By periodically varying the shape of the striped pattern 112 as indicated by the arrows in FIGS. 2 and 3, or by periodically varying between the first pattern 112A and the second pattern 112B. A plurality of imaging information can be acquired by one reflection optical system 106. Therefore, even if an optically transparent member such as the resin film 11 and the coating layer 20 used for the retardation plate 2 is imaged, the positions of the end portion 11a and the end portion 20a and the end portion 11b and the end portion 20b can be determined. It is easier to detect more reliably.

FIG. 11 is a drawing showing an image of the coating layer 20 actually coated on the resin film 11 of the first optical laminate 10. As shown by the arrow α1 in FIG. 9, FIG. 11 shows a region of the first optical laminate 10 that is not located on the transfer roller 42 (between the transfer rollers 42 or between the transfer roller 42 and the pair of nip rollers 44). It is an image when an image is taken (the area in between). “I” in the inspection light column in FIG. 11 means a planar inspection light L1. “II” in the inspection light column in FIG. 11 means the inspection light L1 having the fringe pattern 112 that periodically fluctuates between the first pattern 112A and the second pattern 112B. Further, the "film end" in FIG. 11 corresponds to the end 11a, and the "painted end" corresponds to the end 20a. As shown in FIG. 11, both the planar inspection light L1 and the inspection light L1 of the striped pattern 112 can detect the end portion 11a (film end portion) and the end portion 20a (coating end portion). Can be understood.

In the striped pattern 112, bright portions 112a and dark portions 112b are alternately arranged. Therefore, it is possible to obtain a plurality of images in which the illumination is turned on from multiple directions. In this case, since the obtained image can be immediately analyzed and a concave-convex image or a texture image can be generated, a stable inspection can be performed without depending on the surface condition or the measurement environment.

When the first optical laminate 10 is arranged on the transport roller 42, for example, specular reflection occurs due to the surface of the transport roller 42. For example, by using the striped pattern 112, it is possible to capture a plurality of images in which the illumination is turned on from multiple directions, so that even if the surface of the transport roller 42 is, for example, a mirror surface, the transport roller 42 is transported. The effect of specular reflection on the surface of the roller 42 is reduced. Therefore, the end portion 11a and the end portion 20a and the end portion 11b and the end portion 20b can be easily detected. In other words, the end portion 11a and the end portion 20a and the end portion 11b and the end portion 20b can be easily detected even in an environment susceptible to specular reflection. FIG. 12 is coated on the resin film 11 of the first optical laminate 10 in the region of the first optical laminate 10 located on the transport roller 42, as illustrated by the arrow α2 in FIG. It is a drawing which shows the image which image | photographed the coating layer 20. The meanings of "II" in the inspection light column in FIG. 12, "film edge" and "coating edge" in the image are the same as in FIG. As can be understood from FIG. 12, even in the region on the transport roller 42 in the first optical laminate 10, the end portion 11a (film end portion) and the end portion 20a (coating end portion) are used by using the striped pattern 112. Can be understood to be detected.

In the embodiment illustrated in FIG. 9, after forming the laminated body 4, the peeling member 6 was subsequently peeled from the laminated body 4. However, the laminated body 4 may be wound once to form a roll body. In this case, the peeling member 6 is peeled from the laminated body 4 while rewinding the laminated body 4 from the roll body of the laminated body 4. While transporting the retardation plate 2 obtained by peeling the peeling member 6 from the laminated body 4 without the retardation surface (the surface of the retardation plate 2 opposite to the resin film 11) coming into contact with the transport roll or the like. For example, a process such as attaching a polarizing plate to the retardation plate 2 can be performed. In this case, for example, damage to the retardation surface can be prevented.

The first optical laminate 10 may be one in which the first retardation layer 13 is directly laminated on the resin film 11. The second optical laminate 30 may be one in which the second retardation layer 33 is directly laminated on the resin film 31.

(Modification example 1)
As illustrated by the arrow β shown in FIG. 9, the management method may be performed on the laminated body 4 conveyed between the pair of nip rollers 44 and the peeling rollers 46. In this case, as shown in FIG. 13, the resin film 11 of the first optical laminate 10 and the resin film 31 of the second optical laminate 30 are the first member layer 102 and the second member described in the first embodiment. As the layer 104, the management method described in the first embodiment is implemented. In the first modification, the end portion 11a of the resin film 11 corresponds to the end portion 102a, and the end portion 31a of the resin film 31 corresponds to the end portion 104a. 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 indicate the distance D1b, a state in which the center of the second optical laminate 30 is deviated from the center of the first optical laminate 10 (center in the x direction) is shown.

In the first modification, the reflection optical system 106 is arranged on the laminated body 4 conveyed between the pair of nip rollers 44 and the peeling rollers 46, the measurement step S02 of the management method is carried out, and the distance D1b is measured. Further, in the determination step S03, it is determined whether or not the distance D1b is within a predetermined range.

Normally, the first optical laminate 10 and the second optical laminate 30 are laminated so that their centers coincide with each other in the x direction. Therefore, the positions of the end portion 11a and the end portion 31a are the same in the x direction. is there. Therefore, for example, the predetermined range with respect to the distance D1b is a range including a certain manufacturing error with respect to the case where the distance is 0.

When the distance D1b is within a predetermined range, the production of the retardation 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 path (condition) of the first optical laminate 10 and the second optical laminate 30 is changed. This change step S04 is repeated in the determination step S03 until the distance D1b is within a predetermined range. For example, the manufacturing process of the retardation plate 2 until the determination step S03 is carried out and the changing step S04 are repeated.

When the distance D1b is out of the predetermined range, the second optical laminate 30 is not bonded to the first optical laminate 10 at a desired position. Therefore, the arrangement relationship between the adhesive layer 22 and the second optical laminate 30 is also deviated from the desired position. As a result, when the peeling member 6 is peeled from the laminated body 4, there is a possibility that a portion to be peeled remains on the retardation plate 2 side to be a product.

On the other hand, as in the first modification, the above-mentioned problem can be prevented by applying the management method described in the first embodiment to the laminated body 4 between the pair of nip rollers 44 and the peeling rollers 46. As a result, the non-defective retardation plate 2 is easily manufactured, and the manufacturing yield of the retardation plate 2 is improved.

(Modification 2)
As illustrated by the arrow γ1 shown in FIG. 9, the management method may be carried out on the retardation plate 2 obtained by peeling the peeling member 6 from the laminated body 4 by the peeling roller 46. .. Alternatively, as illustrated by the arrow γ2, the management method may be carried out on the peeling member 6 obtained by peeling the peeling member 6 from the laminated body 4 by the peeling roller 46.

As shown by the arrow γ1, the case where the management method is implemented for the retardation plate 2 will be described. In this case, as shown in FIG. 14, the management method is carried out with the resin film 11 as the first member layer 102 and the second retardation layer 33 on the adhesive layer 22 as the second member layer 104. When the management method is applied to the retardation plate 2, the end portion 11a of the resin film 11 corresponds to the end portion 102a, and the end portion 33a of the second retardation layer 33 corresponds to the end portion 104a. 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 carried out at the position of the arrow γ1, the reflection optical system 106 is arranged with respect to the retardation plate 2 in the subsequent stage of the peeling roller 46, the measurement step S02 of the management method is carried out, and the distance D1c is measured. To do. 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 properly peeled off by the peeling roller 46, the distance D1c between the end portion 11a and the end portion 33a is constant in the elongated direction of the retardation plate 2. On the other hand, when the peeling by the peeling roller 46 is not properly performed, the peeled portion of the second retardation layer 33 of the second optical laminate 30 remains on the retardation plate 2 side. Therefore, for example, the distance D1c between the end portion 11a and the end portion 33a on the retardation plate 2 changes.

When the distance D1c is out of the predetermined range (the range in which the manufacturing error is taken into consideration in the initially set distance), for example, the portion of the second retardation layer 33 to be peeled off is on the retardation plate 2 side. It is considered that there is a problem (or abnormality) that remains in. Therefore, by determining whether or not the distance D1c is within a predetermined range in the determination step S03 of the control step, it is possible to detect the presence or absence of an abnormality when the peeling member 6 is peeled from the laminated body 4. If an abnormality is detected, the manufacturing conditions are changed so that the distance D1c is within a predetermined range in the changing step S04. For example, the laminated state of the first optical laminate 10 and the second optical laminate 30 may be adjusted, or the peeling force of the adhesive layer 22 may be adjusted as appropriate.

As shown by the arrow γ2, when the management method is applied to the peeling member 6 in the subsequent stage of the peeling roller 46, as shown in FIG. 14, the resin film 31 included in the peeling member 6 is attached to the first member layer 102. Then, the management method is carried out by using the second retardation layer 33 of the peeling member 6 as the second member layer 104. In this case, the end portion 31a of the resin film 31 corresponds to the end portion 102a, and the end portion 33a of the second retardation layer 33 of the peeling member 6 corresponds to the end portion 104a. Further, the distance D1d in the x direction between the end 31a and the end 33a corresponds to the distance D1. The method of implementing the management method for the peeling member 6 is a phase difference except that the first member layer 102 and the second member layer 104 are the resin film 31 and the second retardation layer 33 of the peeling member 6. It is the same as the case where the management method is implemented for the plate 2.

(Modification example 3)
Instead of the first optical laminate 10 and the second optical laminate 30, the first optical laminate 10A and the second optical laminate 30A shown in FIG. 15 may be used. The first optical laminate 10A differs from the configuration of the first optical laminate 10 in that both ends of the alignment film 12 in the x direction are not covered by the first retardation layer 13. Similarly, the second optical laminate 30A differs from the configuration of the second optical laminate 30 in that both ends of the alignment film 32 in the x direction are not covered by the second retardation layer 33. Usually, the length of the first retardation layer 13 in the x direction is shorter than the length of the alignment film 12, and the length of the second 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 second optical laminate 30A is selectively peeled. As a result, a retardation plate 2A in which the alignment film 12, the first retardation layer 13, the adhesive layer 22, the second retardation layer 33, and the alignment film 32 are laminated in this order on the resin film 11 can be manufactured. The manufacturing method of the retardation plate 2A to which the management method is applied is the same as the case described with reference to FIGS. 6 to 9. Therefore, the modification 3 also has the same effect as that in the case of manufacturing the retardation plate 2.

The embodiments and modifications according to the present invention have been described above. However, the present invention is not limited to the illustrated embodiments and modifications, but includes the scope indicated by the claims and all modifications within the meaning and scope equivalent to the claims. Is intended to be included.

When the optical component is a retardation plate, a method of manufacturing the retardation plate to which a management method is applied has been described. However, the optical component to which the manufacturing method according to the present invention is applied is not limited to the retardation plate. Other examples of optical components include, for example, a polarizing plate in which a polarizing film (polarizing element layer) and a protective film are laminated, and a circular polarizing plate (elliptical polarizing plate) in which a retardation plate and a polarizing plate are bonded by an adhesive layer. Including) and the like. An example of the above-mentioned polarizer layer is a PVA layer.

When the optical component is the circular polarizing plate, for example, the retardation plate or the first member layer of the polarizing plate (for example, the member corresponding to the resin film 11 shown in FIG. 5), the retardation plate, and the polarizing plate The above management method may be applied with the coating layer to be the adhesive layer between the two members as the second member layer. Alternatively, as described in the first modification, the above control method may be applied to the 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 (first member layer) and a coating layer (second member layer). The management method according to the present invention can be applied to, for example, a polarizing film or a laminate having a polarizing plate (first member layer) containing a polarizing film and a coating layer (second member layer). The management method according to the present invention may be applied, for example, when the coating layer (second member layer) is directly formed on the resin film (first member layer).

The management method according to the present invention can also be applied, for example, to the case where the adhesive layer formed on the release film is transferred to the first member layer (for example, a resin film). In this case, a bonded body in which the release film with an adhesive layer is bonded to the first member layer via the adhesive layer is prepared. By peeling the release film from the bonded body, a laminated body in which the adhesive layer is laminated on the first member layer is obtained. In this case, the management method may be applied to the laminated body with the adhesive layer as the second member layer. For example, when the bonded body is long, the peeling film is peeled off by using the peeling roller 46 in FIG. 9 while transporting the bonded body in the long direction, and the obtained laminated body is controlled. The method may be implemented. Thereby, it can be determined whether or not the transfer of the adhesive layer to the first member layer is appropriate.

Alternatively, the management method according to the present invention is a case where the protective film is peeled off when the adhesive layer (second member layer) and the protective film (or release film) are laminated on the base material (first member layer). Can also be applied to. 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 is peeled off by using the peeling roller 46 in FIG. 9, and the obtained base material and the adhesive layer are separated. The management method may be implemented for the laminated body. Thereby, it can be determined whether or not the protective film is properly peeled off (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 another optical functional film such as a polarizing film in addition to the base material (first member layer) and the adhesive layer (second member layer).

As described in the first modification of the second embodiment, the management method according to the present invention has an abnormality in the alignment of the first member layer and the second member layer in the laminated body of the first member layer and the second member layer. It can also be applied to the management of the presence or absence.

2,2A ... Phase difference plate, 4 ... Laminated body, 11 ... Resin film (first member layer), 11a ... End (first end), 20 ... Coating layer, 20a ... End (second end) ), 100 ... Laminated body, 102 ... First member layer, 102a ... End (first end), 104 ... Second member layer, 104a ... End, 112 ... Striped pattern, 112a ... Bright part, 112b ... Dark part , 112A ... 1st pattern, 112B ... 2nd pattern, 114 ... Image processing device, A1, A2 ... End region, D1, D1a, D1b, D1c, D1d, D2, D2a ... Distance (distance between ends), L1 ... inspection light, L2 ... reflected light.

Claims (16)

A method of measuring an end region of a laminate including a first member layer and a second member layer.
The first member layer has a first end portion and has a first end portion.
The second member layer has a second end portion located on the same side as the first end portion when viewed from the stacking direction of the first member layer and the second member layer in the laminated body.
The end region is a region extending from the first end portion to the second end portion of the laminated body.
An irradiation step of irradiating the end region with inspection light and
A detection step of detecting the reflected light which is the inspection light reflected by the end region, and
A calculation step of calculating the distance between the first end portion and the second end portion based on the detection result of the reflected light, and a calculation step.
To prepare
Measuring method. The first member layer is a resin film layer, and the second member layer is a coating layer formed of an adhesive or an adhesive.
The method according to claim 1. The inspection light has a striped pattern in which bright and dark areas are alternately arranged.
The method according to claim 1 or 2. The shape of the striped pattern fluctuates periodically,
The method according to claim 3. The shape of the striped pattern varies periodically between the first pattern and the second pattern.
The extending direction of the bright portion and the dark portion in the second pattern is orthogonal to the extending direction of the bright portion and the dark portion in the first pattern.
The method according to claim 4. The laminated body is a long laminated body, and is
The step of irradiating the inspection light and the step of detecting the reflected light are carried out while transporting the laminated body in the elongated direction.
The method according to any one of claims 1 to 5. A method of managing an end region of a laminate including a first member layer and a second member layer.
The first member layer has a first end portion and has a first end portion.
The second member layer has a second end portion located on the same side as the first end portion when viewed from the stacking direction of the first member layer and the second member layer in the laminated body.
The end region is a region extending from the first end portion to the second end portion of the laminated body.
An irradiation step of irradiating the end region with inspection light and
A detection step of detecting the reflected light which is the inspection light reflected by the end region, and
A calculation step of calculating the distance between the first end portion and the second end portion based on the detection result of the reflected light, and a calculation step.
A determination step for determining whether or not the calculated distance is within a predetermined range, and
To prepare
Management method. The first member layer is a resin film layer, and the second member layer is a coating layer formed of an adhesive or an adhesive.
The method according to claim 7. The inspection light has a striped pattern in which bright and dark areas are alternately arranged.
The method according to claim 7 or 8. The shape of the striped pattern fluctuates periodically,
The method according to claim 9. The shape of the striped pattern varies periodically between the first pattern and the second pattern.
The extending direction of the bright portion and the dark portion in the second pattern is orthogonal to the extending direction of the bright portion and the dark portion in the first pattern.
The method according to claim 10. Prior to the irradiation step, a laminating step of laminating the second member layer on the laminating member having the first member layer or the first member layer is further included.
The management method according to any one of claims 7 to 11. In the laminating step, the second member layer is laminated on the first member by applying a coating material on the first member layer.
The method according to claim 12. When the calculated distance is not included in the predetermined range, the laminating step further includes a changing step of changing the coating area of the coating material.
The stacking step, the irradiation step, the detection step, and the determination step are repeated until the calculated distance is included in the predetermined range.
13. The method of claim 13. The laminated body is a long laminated body, and is
The laminating step, the irradiation step, and the detecting step are carried out while transporting the laminated body in the long direction.
The method according to any one of claims 12 to 14. A method for manufacturing an optical component, which comprises the management method according to any one of claims 7 to 15.

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