JP7460359B2 - Measurement method, management method and optical component manufacturing method - Google Patents

Description

The present invention relates to a measurement method, a management method, and a manufacturing method for optical components.

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

Japanese Patent Application Publication No. 2000-24565

In the laminate of the first member layer and the second member layer, the first end of the first member layer and the second end of the second member layer (on the same side as the first end side of the first member layer) If the end-to-end distance between the two ends (ends) deviates 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 this happens, the coating liquid may leak out of the first member layer in the process after forming the coating layer and may coat other members (e.g., rollers, members to be bonded to the first member layer, etc.). The industrial fluid may become contaminated. Alternatively, when the laminate is one component, if the distance between the ends deviates from a predetermined range, the arrangement relationship between the first member layer and the second member layer deviates from a desired state. Therefore, there is a possibility that the component as a laminate may not be able to exhibit the desired performance, or that the component may not be properly incorporated into other devices.

Therefore, in the laminate of the first member layer and the second member layer, the end-to-end distance between the first end of the first member layer and the second end of the second member layer is set within a predetermined range. Appropriate management technology was required.

Therefore, one object of the present invention is to provide a measurement method and a management method for appropriately managing the distance between the end of the first material layer and the end of the second material layer included in the end region of a laminate of the first material layer and the second material layer. Another object of the present invention is to provide a manufacturing method of an optical component using the above management method.

A measuring method according to one aspect of the present invention is a method for measuring an end region of a laminate including a first member layer and a second member layer, the first member layer having a first end, the second member layer having a second end located on the same side as the first end when viewed from the stacking direction of the first member layer and the second member layer in the laminate, the end region being a region in the laminate extending from the first end to the second end, and comprising an irradiation step of irradiating the end region with an inspection light, a detection step of detecting reflected light, which is the inspection light reflected by the end region, and a calculation step of calculating the distance between the first end and the second end based on the detection result of the reflected light.

In the above measurement method, inspection light is irradiated onto the end region and the reflected light is detected. Furthermore, the distance between the first end and the second end is calculated based on the detection result of the reflected light. In this way, the distance between the first end and the second end is calculated based on the optical measurement result, so that the distance between the first end and the second end can be calculated more appropriately.

The first member layer may be a resin film layer, and the second member layer may be a coating layer formed from a pressure-sensitive adhesive or an adhesive.

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

The shape of the stripe pattern may vary periodically. This makes it possible to obtain various optical information about the edge region even with only one device that outputs the inspection light.

For example, the shape of the striped pattern changes periodically between the first pattern and the second pattern, and the extending direction of the bright part and the dark part in the second pattern is different from the bright part in the first pattern. It may be perpendicular to the extending direction of the part and the dark part.

The laminate is a long laminate, and the irradiation step and the detection step may be carried out while the laminate is being 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 a first member layer and a second member layer, wherein the first member layer has a first end region. The second member layer has a second end located on the same side as the first end when viewed from the stacking direction of the first member layer and the second member layer in the laminate, The end region is a region extending from the first end to the second end in the laminate, and includes an irradiation step of irradiating the end region with inspection light and a step of irradiating the inspection light reflected by the end region. a detection step of detecting the reflected light, a calculation step of calculating the distance between the first end and the second end based on the detection result of the reflected light, and a step of calculating the distance between the first end and the second end, and the calculated distance is a predetermined distance. and a determination step of determining whether or not it is within the range.

In the above management method, the end region is irradiated with inspection light and the reflected light is detected. Furthermore, the distance between the first end and the second end is calculated based on the detection result of the reflected light. In this way, since the distance between the first end and the second end is calculated based on the optical measurement results, the distance between the first end and the second end can be more appropriately calculated. Distance can be calculated. Since the determination step is performed based on the distance between the first end and the second end calculated in this way, the distance between the first end and the second end can be determined appropriately. Manageable.

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

The inspection light may have a striped pattern in which light and dark areas are arranged alternately. In this case, it is possible to easily obtain multiple detection results by illuminating the end area from multiple directions. This makes it easy to detect the first end and the second end.

The shape of the stripe pattern may vary periodically. This makes it possible to obtain various optical information about the edge region even with only one device that outputs the inspection light.

The shape of the stripe pattern may vary periodically between the first pattern and the second pattern, and the extension direction of the light and dark areas in the second pattern may be perpendicular to the extension direction of the light and dark areas in the first pattern.

The method may further include a lamination step of laminating the second member layer to a laminate member having the first member layer or to the first member layer prior to the irradiation step.

In the lamination process, the second member layer may be laminated onto the first member by applying a coating material onto the first member layer.

If the calculated distance is not within the predetermined range, the lamination process may further include a modification process for modifying the coating area of the coating material, and the lamination process, irradiation process, detection process, and determination process 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 first end and the second end is within the predetermined range.

The laminate may be a long laminate, and the lamination process, the irradiation process, and the detection process may be performed while the laminate is being transported in the long direction.

A method for manufacturing an optical component according to yet another aspect of the present invention is a method for manufacturing an optical component, which includes the above-described management method according to the present invention.

According to one aspect of the present invention, it is possible to provide a measurement method and a management method for appropriately managing the distance between the end of the first material layer and the end of the second material layer included in the end region of a laminate of the first material layer and the second material layer. According to another aspect of the present invention, it is possible to provide a manufacturing method for an optical component using the above management method.

FIG. 1 is a diagram for explaining a management method according to an embodiment. FIG. 2 is a diagram showing a first pattern which is an example of a stripe pattern. FIG. 3 is a diagram showing a second pattern which is another example of the stripe pattern. FIG. 4 is a flowchart of a management method according to one embodiment. FIG. 5 is a diagram showing the configuration of a retardation plate (optical component) manufactured in the second embodiment. 6A to 6C are diagrams for explaining steps included in the method for manufacturing the retardation plate shown in FIG. FIG. 7 is a diagram for explaining a step subsequent to the step shown in FIG. FIG. 8 is a diagram for explaining a step subsequent to the step shown in FIG. FIG. 9 is a drawing for explaining a case in which the method for manufacturing the retardation plate shown in FIG. 5 is carried out by a roll-to-roll method. FIG. 10 is a diagram for explaining an example of a method for changing the coating area. FIG. 11 is a diagram showing the results of imaging the film end (first end) and the coating end (second end). FIG. 12 is a diagram showing another image capture result of the film end (first end) and the coating end (second end). FIG. 13 is a drawing for explaining modification example 1. FIG. 14 is a diagram for explaining the second modification. FIG. 15 is a diagram for explaining modification example 3. FIG. 16 is a diagram for explaining modification example 3.

Below, an embodiment of the present invention will be described with reference to the drawings. Identical elements are given the same reference numerals, and duplicate explanations will be omitted. The dimensional ratios in the drawings do not necessarily match those in the description.

As shown in FIG. 1, an end (first end) 102a of the first member layer 102 of the laminate 100 and an end 104a (second end) of the second member layer 104 of the laminate 100. A method for managing the distance (distance between ends) D1 between the two ends will be described as a first embodiment. Thereafter, an example using the management method described in the first embodiment will be described as a second embodiment while giving examples of the first member layer 102 and the second member layer 104. Hereinafter, for convenience of explanation, as shown in FIG. 1, the lamination direction of the first member layer 102 and the second member layer 104 will be referred to as the z direction, and the direction perpendicular to the z direction will be referred to as the x direction.

First Embodiment
FIG. 1 is a diagram for explaining a management method according to an embodiment. The laminate 100 shown in FIG. 1 has a first member layer 102 and a second member layer 104. The second member layer 104 is laminated to the first member layer 102. The first member layer 102 and the second member layer 104 may be members formed of, for example, 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 a pressure-sensitive 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 in the first embodiment, the distance D1 between the end 102a of the first member layer 102 in the x direction and the end 104a of the second member layer 104 in the x direction Manage. The end portion 104a is an end portion of both end portions of the second member layer 104 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, etc.), 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 a reflective optical system 106 as shown in FIG. The reflective optical system 106 includes a light source section 108 and an imaging section 110. The end region A1 is a region near the end of the stacked body 100 in the x direction. Specifically, it is a region extending from end 102a to end 104a.

The light source unit 108 outputs inspection light L1 toward the end region A1 of the laminate 100. An example of the wavelength of the inspection light L1 depends on the materials of the first member layer 102 and the second member layer 104, and may be any wavelength that allows an image of the end region A1 to be acquired. 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 illuminate the end region A1 in a planar manner, for example.

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

The imaging unit 110 inputs image data to the image processing device 114. The image processing device 114 creates an image of the end area A1 based on the image data input from the imaging 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 for analyzing the created image to detect the end 102a and the end 104a and a function for calculating the distance D1. The image processing device 114 may have at least one of a function for controlling the imaging timing of the imaging unit 110 and a function for 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 implementing the management method according to the first embodiment. Alternatively, a program for implementing the management method including the image processing may be implemented in a personal computer, and the personal computer may function as the image processing device 114.

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

The shape of the stripe pattern 112 (pattern shape) may change. For example, in FIG. 2 and FIG. 3, the light portion 112a (or the dark portion 112b) may move in the direction of the arrow in FIG. 2 and FIG. 3, or the width of the light portion 112a (or the dark portion 112b) may change, thereby changing the shape of the stripe pattern 112.

Furthermore, the light source unit 108 may be configured to periodically vary between the first pattern 112A and the second pattern 112B when the stripe pattern 112 shown in FIG. 2 is referred to as the first pattern 112A and the stripe pattern 112 shown in FIG. 3 is referred to as the second pattern 112B. The second pattern 112B is a pattern in which the extension direction of the light portion 112a and the dark portion 112b in the second pattern 112B is perpendicular to the extension direction of the light portion 112a and the dark portion 112b in the first pattern 112A. Even when the light portion 112a (or the dark portion 112b) periodically varies between the first pattern 112A and the second pattern 112B, the light portion 112a (or the dark portion 112b) may move in the direction of the arrow in FIG. 2 and FIG. 3, or the width of the light portion 112a (or the dark portion 112b) may vary in each of the first pattern 112A and the second pattern 112B.

When the inspection light L1 has a stripe pattern 112, the light source unit 108 may include, for example, a light source in which multiple point light sources (e.g., LEDs) are arranged two-dimensionally, and a control device that controls the lighting state of each LED. In this case, the control device can form bright areas 112a and dark areas 112b by controlling the lighting state of the multiple LEDs. Furthermore, the stripe pattern 112 formed by the bright areas 112a and dark areas 112b can be changed.

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

The shape of the striped pattern 112 can be controlled, for example, by the image processing device 114 (see FIG. 1). In this case, the image processing device 114 may control the light source section 108 and the imaging section 110 so that they are synchronized.

Figure 4 is a flow chart of an example of a management method. Using Figure 4, the management method will be explained using an example in which the first member layer 102 is a long resin film and the second member layer 104 is a coating layer formed from 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 applying a coating material to become the second member layer 104 while transporting the first member layer 102 in the longitudinal direction. The coating material can be applied, for example, by gravure coating.

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

In the measurement step S02, the inspection light L1 is irradiated toward the end region A1 of the stacked body 100 (irradiation step S02a). The reflected light L2 from the end area A1 is detected by the imaging unit 110 (detection step S02b). Based on the image (detection result) of the end area A1 thus obtained, the distance D1 is calculated (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 identification 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 periodically fluctuates between the first pattern 112A and the second pattern 112B, for example, the image processing device 114 changes the reflected light L2 for 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-mentioned one image, for example, the image processing device 114 may control the timing of shape change of the striped pattern 112 and the imaging timing of the imaging unit 110.

After the measurement step S02, it is determined whether the distance D1 is within a predetermined range (determination step S03). The determination may be performed by the user, or the image processing device 114 may perform the determination by comparing the distance D1 with a predetermined range input in advance.

If it is determined in the determination step S03 that the distance D1 is within the predetermined range ("YES" in the determination step S03), the manufacture of the laminate 100 may be continued under the same conditions as before the determination step S03 was performed.

On the other hand, if it is determined in the determination step S03 that the distance D1 is outside the predetermined range ("NO" in the determination step S03), a change step S04 is carried out in the lamination step S01 to change the lamination conditions in the lamination step S01 (specifically, the coating area of the coating material for forming the second member layer 104).

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

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

For example, in a configuration in which the second member layer 104 is the coating layer and the coating material forming the coating layer is an adhesive or pressure-sensitive adhesive, a pair of nip rollers may be used to bond another member to the first member layer 102 via the second member layer 104. In this case, the predetermined range of the distance D1 is usually set to prevent contamination of each nip roller caused by the coating material spilling onto 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, a product obtained by bonding another member to the first member layer 102 via the second member layer 104 can be efficiently manufactured.

The case where the distance D1 between the end 102a and the end 104a included in the end region A1 is measured and managed has been described. However, as shown in FIG. 1, the distance (end-to-end distance) D2 between the end 102b and the end 104b included in the end region A2 (the region from the end 102b to the end 104b) of the laminate 100 may also be measured and managed in the same way. In this case, the reflection optical system 106 is also arranged on the end 104b side. The end 102b of the first member layer 102 is the end opposite the end 102a in the x direction. The end 104b of the second member layer 104 is the end opposite 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 when viewed from the z direction. However, the arrangement of the light source unit 108 and the imaging unit 110 is not limited to the form in FIG. 1. The light source unit 108 and the imaging unit 110 may be arranged along a direction perpendicular to the x direction and the z direction, for example.

When measuring and managing both distance D1 and distance D2, they may be performed simultaneously. Furthermore, 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 distances D1 and D2, the changing step S04 shown in FIG. 4 may be performed. .

Second Embodiment
A method for manufacturing an optical component using the management method described in the first embodiment will be described. Fig. 5 is a schematic diagram of a retardation plate (optical component) 2 manufactured by a manufacturing method according to a second embodiment. For convenience of explanation, the x-direction and z-direction shown in Fig. 5 may be used in the second embodiment as in 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 certain phase difference to the light incident on the retardation plate 2 using the first retardation layer 13 and the second retardation layer 33. The retardation plate 2 can be used, for example, 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. An embodiment in which the first retardation layer 13 and the second retardation layer 33 are cured products of polymerizable liquid crystal compounds 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 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 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.

Examples of the alignment film 12 include a vertical alignment film, a horizontal alignment film, or an alignment film that tilts the molecular axis of the polymerizable liquid crystal compound, and 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 that is used as a known material for retardation plates. For example, the alignment film 12 can be a cured product obtained by curing a conventionally known monofunctional or polyfunctional (meth)acrylate monomer under a polymerization initiator.

The first retardation layer 13 is a layer that imparts a predetermined phase difference to light incident on the first retardation layer 13. As described above, the first retardation layer 13 is a cured product of a polymerizable liquid crystal compound. In the embodiment 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 bonds the first retardation layer 13 and the second retardation layer 33. The material of the adhesive layer 22 is adhesive or adhesive. The adhesive or adhesive may be any material known in the art related to this disclosure. Examples of adhesives include active energy ray-curable adhesives such as ultraviolet (UV) curable resins, and water-based adhesives such as polyvinyl alcohol resin aqueous solutions. Examples of adhesives include adhesive compositions containing (meth)acrylic resins, rubber resins, urethane resins, ester resins, silicone resins, polyvinyl ether resins, 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 a 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 manufacturing method of the retardation plate 2 will be outlined with reference to Figures 6 to 8. When manufacturing the retardation plate 2, the first optical laminate 10 and the second optical laminate 30 shown in Figure 6 are prepared. The first optical laminate 10 and the second optical laminate 30 extend in a direction perpendicular to the x direction and the z direction. Figures 6 to 8 are schematic diagrams of cross sections perpendicular to the longitudinal direction of the first optical laminate 10 and the second optical laminate 30.

The first optical laminate 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 longitudinal direction of the first optical laminate 10. Therefore, the first optical laminate 10 is a long laminated member.

The first optical laminate 10 illustrated in FIG. 6 can be manufactured by sequentially forming an alignment film 12 and a first retardation layer 13 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 coating. The first retardation layer 13 can be formed, for example, by coating a material for the first retardation on the resin film 11 on which the alignment film 12 is formed and curing the coating. The relationship in the x-direction length of the alignment film 12 and the first retardation layer 13 on the resin film 11 is as described using FIG. 5.

The second optical laminate 30 illustrated in FIG. 6 is a laminated member in which a resin film 31, an alignment film 32, and a second phase difference layer 33 are laminated. The second optical laminate 30 is a long laminated member similar to the first optical laminate 10. An 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 the material of the resin film 11, or may be different. The alignment film 32 is an alignment film corresponding to the second phase difference layer 33. The relationship of the lengths in the x direction of the resin film 31, the alignment film 32, and the second phase difference layer 33 is the same as the relationship of the lengths in the x direction of the resin film 11, the alignment film 12, and the first phase difference layer 13 of the first optical laminate 10. Therefore, the length in the x direction of the second phase difference layer 33 of the second optical laminate 30 is longer than the length of the second phase difference layer 33 of the phase difference plate 2 shown in FIG. 5.

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

Then, the coating layer 20 is irradiated with active energy rays such as ultraviolet rays to harden the adhesive that forms the coating layer 20. This causes the first optical laminate 10 and the second optical laminate 30 to be bonded together via the adhesive layer 22, which is the hardened 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 off from the first optical laminate 10 to obtain the retardation plate 2, as shown in FIG. 8.

The bonding strength of the adhesive layer 22 to the second phase difference layer 33 is set to be stronger than the bonding strength of the alignment film 32 to the second phase difference layer 33. Furthermore, the length of the adhesive layer 22 in the x direction is shorter than the length of the second phase difference layer 33 in the x direction, and the second phase difference 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 phase difference layer 33 outside the adhesive layer 22 in the x direction and the alignment film 32 are also peeled off from the first optical laminate 10 together with the resin film 31.

For ease of explanation, the member that is generated separately from the retardation film 2 when the resin film 31 is peeled off from the first optical laminate 10 will be referred to as the peeled off member 6 below.

In the second embodiment, the management method described in the first embodiment is implemented using the resin film 11 as the first member layer 102 and the coating layer 20 as the second member layer 104. A management method applied to the above manufacturing method will be explained using 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 ends 11a and 11b of the resin film 11 correspond to the ends 102a and 102b, respectively, and the ends 20a and 20b of the coating layer 20 correspond to the ends 104a and 104b. Further, the distance D1a between the end portion 11a and the end portion 11b corresponds to the distance D1, and the distance D2a between the end portion 20a and the end portion 20b corresponds to the distance D2.

The step of forming the coating layer 20 shown in FIG. 6 corresponds to the lamination step S01 shown in FIG. 4. After the step of forming the coating layer 20 (lamination step S01), the measurement step S02 shown in FIG. 4 is carried out to measure the distance D1a between the end 11a of the resin film 11 and the end 20a of the coating layer 20. In the second embodiment, the distance D2a between the end 11b of the resin film 11 and the end 20b of the coating 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 respectively within predetermined ranges set for the distance D1a and the distance D2a. The predetermined ranges corresponding to distance D1a and distance D2a may be the same or different.

If it is determined in the determination step S03 that the distance D1a and the distance D2a are within the corresponding predetermined range, the manufacture of the retardation film 2 is continued under the same adhesive coating conditions (specifically, the same coating area) as when the coating layer 20 for which the measurement was performed was formed. On the other hand, if it is determined in the determination step S03 that at least one of the distance D1a and the distance D2a is outside the corresponding predetermined range, the change step S04 is performed to change the adhesive coating area (lamination conditions).

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

An example of a method for manufacturing the retardation plate 2 to which the management method described in the first embodiment is applied will be described in further detail using FIG. 9. Below, as shown in FIG. 9, a case will be described in which the retardation plate 2 is manufactured using a roll-to-roll method.

The roll-shaped first optical laminate 10 and the roll-shaped second optical laminate 30 are set in the unwinding section 40a and the unwinding section 40b. The first optical laminate 10 is conveyed in the longitudinal direction of the first optical laminate 10 toward a pair of nip rollers 44 by the conveyance roller 42 . Similarly, the second optical laminate 30 is transported in the longitudinal direction of the second optical laminate 30 toward a pair of nip rollers 44 by the transport roller 42 . Since the pair of nip rollers 44 also contribute to the conveyance of the first optical laminate 10 and the second optical laminate 30, the pair of nip rollers 44 also serve as conveyance rollers.

An adhesive is applied onto the first retardation layer 13 of the first optical laminate 10 by a coating device 50 disposed on the transport path of the first optical laminate 10 from the unwinding part 40a to the pair of nip rollers 44. The coating layer 20 is formed by coating (corresponding to the lamination step S01 in FIG. 4).

The coating device 50 includes an adhesive supply section 52 and a coating roller 54. The adhesive supply unit 52 is a source of adhesive to the surface of the coating roller 54. The coating roller 54 is a roller that coats the adhesive onto the first retardation layer 13 of the first optical laminate 10 that is being transported. An example of a coating roller is a gravure roller.

When coating the adhesive with the coating device 50, the coating area adjuster 60 adjusts the area between the first optical laminate 10 (specifically, the first retardation layer 13) and the coating roller 54. 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 longitudinal 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 claws 62 spaced apart along the conveying direction of the first optical laminate 10, and a pair of support parts 64 that support the claws 62. The coating area adjuster 60 is arranged so that the pair of claws 62 contact the coating side of the adhesive in the first optical laminate 10. By moving the coating area adjuster 60 in the width direction (direction perpendicular to the longitudinal direction) of the first optical laminate 10, contact between the area between the pair of claws 62 of the first optical laminate 10 and the coating 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. Figures 9 and 10 illustrate a case in which the coating area adjuster 60 is arranged on one edge side in the width direction of the first optical laminate 10. However, in the manufacturing method of the retardation plate 2 described using Figure 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 shows a schematic of a pair of claws 62 of the coating area adjuster 60.

Returning to FIG. 9, the steps 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 adhesive is conveyed between a pair of nip rollers 44. In FIG. 9, for explanation, the coating layer 20 formed on the first optical laminate 10 is illustrated in a region between the coating device 50 and the nip roller 44.

The second optical laminate 30 is conveyed along with the first optical laminate 10 to the pair of nip rollers 44 . At this time, so that 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, 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 together with the coating layer 20 interposed therebetween.

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

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

In the transport direction of the laminate 4, the resin film 31 of the second optical laminate 30 is peeled off from the laminate 4 by a peeling roller 46 arranged downstream of the active energy ray irradiation section 56 (after the active energy ray irradiation section 56). This separates the retardation film 2 and the peeling member 6 from the laminate 4. The peeling roller 46 also contributes to the transport of the laminate 4, the retardation film 2, and the peeling member 6, so the peeling roller 46 is also a transport roller.

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

In the manufacturing method illustrated in FIG. 9, the process of forming the coating layer 20 on the first optical laminate 10 by the coating device 50 corresponds to the lamination process S01 illustrated in FIG. 4. Furthermore, in the transport path of the first optical laminate 10, the reflective optical system 106 illustrated in FIG. 1 is disposed between the coating device 50 and the pair of nip rollers 44 (e.g., the position indicated by the arrow α1 or the arrow α1). Using this reflective optical system 106, the distances D1a and D2a of the first optical laminate 10 being transported are measured (measurement process S02 in FIG. 4).

In the measurement step S02, as schematically shown 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 may be measured in the region of the first optical laminate 10 located on the conveyance roller 42. In the measurement between the conveying rollers as indicated by arrow α1, the measurement may be performed from the side opposite to the coating layer 20. Here, the case of measurement at the position of arrow α1 has been described, but the same applies to measurement between the conveyance rollers.

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

When the inspection light L1 is a stripe pattern 112 that periodically changes to a plurality of patterns (e.g., periodically changes between a first pattern 112A and a second pattern 112B), the period of change of the first pattern 112A and the second pattern 112B and the imaging speed of the imaging unit can be set in consideration of the transport speed of the first optical laminate 10. Specifically, the period of change of the stripe pattern 112 and the imaging speed of the imaging unit can be set to an extent that images of substantially the same area of the first optical laminate 10 being transported can be acquired while the stripe pattern 112 changes between the plurality of patterns a certain number of times.

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

On the other hand, in the determination step S03, if it is determined that at least one of the distance D1a and the distance D2a is outside the corresponding predetermined range, the coating area adjuster 60 is used to adjust the adhesive coating area. A change step S04 for adjustment is carried out. Specifically, the adhesive coating area 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, the step of coating the adhesive onto the first optical laminate 10 (the step of coating the adhesive on the first optical laminate 10) Step S01), the measuring step S02 and the determining step S03 shown in FIG. 4, and the above-mentioned changing step S04 are repeated.

As shown in FIG. 9, when the first optical laminate 10 and the second optical laminate 30 are pressed and bonded together by a pair of nip rollers 44, the respective predetermined ranges for the distances D1a and D2a are set so that the adhesive forming the coating layer 20 does not come into contact with the nip rollers 44 and the nip rollers 44, and are set so that the desired configuration of the retarder 2 is obtained when the peeling member 6 (see FIG. 8 and FIG. 9) is peeled off from the laminate 4 of the first optical laminate 10 and the second optical laminate 30.

Therefore, for example, if the distance D1a and the distance D2a are outside the respective predetermined ranges, there is a risk that the adhesive may adhere to the nip rollers 44 and contaminate the two nip rollers 44, for example. Alternatively, when the peeling member 6 is peeled off from the laminate 4, the portion to be peeled off may remain on the side of the retardation plate 2 that is to be a product.

On the other hand, in the method for manufacturing the retardation plate 2 described above, the management method described in the first embodiment is implemented. In the measurement step S02 of the management method, the distance D1a and the distance D2a are calculated using an image optically acquired using the reflective optical system 106 shown in FIG. Therefore, it is possible to efficiently and accurately calculate the distance D1a and the distance D2a while transporting the first optical laminate 10. Thereby, it is possible to appropriately determine whether the distance D1a and the distance D2a are within corresponding predetermined ranges.

If at least one of the distance D1a and the distance D2a is outside the predetermined range, a changing step S04 is performed to change the adhesive coating area. Further, in the determination step S03, the changing 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 distances D1a and D2a within corresponding predetermined ranges. As a result, it is possible to prevent the adhesive from adhering to the nip roller 44 as described above. In this case, maintenance of the nip roller 44 due to adhesion of adhesive, for example, can be avoided, thereby improving the manufacturing efficiency of the retardation plate 2. Since the distance D1a and the distance D2a can be set within a predetermined range, it is also possible to prevent the problem that the part to be peeled remains on the side of the retardation plate 2 that is to be made into a product. Therefore, manufacturing of the retardation plate 2 as a defective product is avoided, and as a result, the manufacturing yield of the retardation plate 2 is improved.

When implementing the management method, an example of the test light L1 output by the light source unit 108 may be the test light L1 having the striped pattern 112 described in the first embodiment, or the planar test light L1. . In the case of the planar inspection light L1 and the inspection light L1 of the striped pattern 112, for example, the angular dependence of the irradiation area of the inspection light L1 with respect to the extending direction of the end (or end) is greater than when using the linear test light. The position of the end portion 11a and the end portion 20a and the end portion 11b and the end portion 20b can be easily detected. Furthermore, when the inspection light L1 has the striped pattern 112, it is possible to simultaneously acquire a plurality of images in which the end region is illuminated from multiple directions. Therefore, it is easy to detect the end portion 11a and the end portion 20a, and the end portion 11b and the end portion 20b. By periodically changing the shape of the striped pattern 112 as shown by the arrows in FIGS. 2 and 3, or by periodically changing the shape between the first pattern 112A and the second pattern 112B, A plurality of pieces of imaging information can be acquired with one reflective optical system 106. Therefore, even when imaging an optically transparent member such as the resin film 11 and coating layer 20 used in the retardation plate 2, the positions of the ends 11a and 20a, and the ends 11b and 20b cannot be determined. 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. FIG. 11 shows an area of the first optical laminate 10 that is not located above the conveyance roller 42 (between the conveyance rollers 42 or between the conveyance roller 42 and a pair of nip rollers 44), as shown by arrow α1 in FIG. This is an image obtained by capturing an image of the area between the two regions. "I" in the inspection light column in FIG. 11 means planar inspection light L1. "II" in the inspection light column in FIG. 11 means the inspection light L1 having the striped pattern 112 that periodically changes between the first pattern 112A and the second pattern 112B. Furthermore, the "film end" in FIG. 11 corresponds to the end 11a, and the "coating end" corresponds to the end 20a. As shown in FIG. 11, both the planar inspection light L1 and the striped pattern 112 inspection light L1 can detect the end 11a (film end) and the end 20a (coating end). be understood.

In the striped pattern 112, bright parts 112a and dark parts 112b are arranged alternately. Therefore, it is possible to obtain multiple images with lights turned on from multiple directions. In this case, the obtained image can be immediately analyzed and an uneven image or texture image can be generated, so that stable inspection can be performed without depending on the surface condition or the measurement environment.

When the first optical laminate 10 is placed on the conveyance roller 42, for example, specular reflection occurs due to the surface of the conveyance roller 42. For example, by using the striped pattern 112, it is possible to capture a plurality of images with lights turned on from multiple directions. The influence of specular reflection by the surface of the roller 42 is reduced. Therefore, it is easy to detect the end 11a and the end 20a as well as the end 11b and the end 20b. In other words, even in an environment susceptible to specular reflection, the ends 11a and 20a and the ends 11b and 20b can be easily detected. FIG. 12 shows that, as illustrated by the arrow α2 in FIG. 3 is a drawing showing an image taken of a coating layer 20. FIG. The meanings of "II" in the inspection light column and "film end" and "coating end" in the image in FIG. 12 are the same as in the case of FIG. 11. As can be understood from FIG. 12, by using the striped pattern 112 also in the area above the conveyance roller 42 in the first optical laminate 10, the edge 11a (film edge) and the edge 20a (coated edge) It can be seen that this can be detected.

In the embodiment illustrated in FIG. 9, after the laminate 4 is formed, the peeling member 6 is peeled off from the laminate 4. However, the laminate 4 may be wound up to form a roll. In this case, the peeling member 6 is peeled off from the laminate 4 while the laminate 4 is unwound from the roll of the laminate 4. The retardation film 2 obtained by peeling the peeling member 6 from the laminate 4 can be transported without the retardation surface (the surface of the retardation film 2 opposite the resin film 11) coming into contact with a transport roll or the like, and can be subjected to a process such as laminating a polarizing plate to the retardation film 2. In this case, for example, damage to the retardation surface can be prevented.

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

(Variation 1)
The management method may be performed on the laminate 4 transported between a pair of nip rollers 44 and a peeling roller 46, as illustrated by the arrow β in FIG. 9. In this case, as illustrated 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 layer 104 described in the first embodiment, and the management method described in the first embodiment is performed. In the first modification, the end 11a of the resin film 11 corresponds to the end 102a, and the end 31a of the resin film 31 corresponds to the end 104a. Furthermore, 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 shifted from the center (center in the x direction) of the first optical laminate 10 is illustrated.

In the first modification, a reflection optical system 106 is disposed with respect to the laminate 4 transported between a pair of nip rollers 44 and a peeling roller 46, and the measurement step S02 of the management method is carried out to measure the distance D1b. Furthermore, in the determination step S03, it is determined whether the distance D1b is within a predetermined range.

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

If the distance D1b is within the predetermined range, manufacturing of the retardation plate 2 is continued. On the other hand, if the distance D1b is outside the predetermined range, for example, in the changing step S04, the manufacturing conditions are changed so that the distance D1b falls within the predetermined range. For example, the transport routes (conditions) of the first optical laminate 10 and the second optical laminate 30 are changed. This changing step S04 is repeated until the distance D1b falls within a predetermined range in the determining step S03. For example, the manufacturing process of the retardation plate 2 up to implementing the determination process S03 and the changing process S04 are repeated.

If the distance D1b is outside the predetermined range, the second optical laminate 30 is not bonded to the first optical laminate 10 at the desired position. Therefore, the positional 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 off from the laminate 4, a problem may arise in that the portion to be peeled remains on the side of the retardation plate 2 that is to become a product.

On the other hand, as in Modification 1, by applying the management method described in the first embodiment to the laminate 4 between the pair of nip rollers 44 and the peeling roller 46, the above-mentioned problems can be prevented. As a result, a good quality retardation plate 2 is easily manufactured, and the manufacturing yield of the retardation plate 2 is improved.

(Modification 2)
The management method may be performed on the retardation plate 2 obtained by peeling the peeling member 6 from the laminate 4 using the peeling roller 46, as illustrated by the arrow γ1 shown in FIG. . Alternatively, the management method may be performed on the peeling member 6 obtained by peeling the peeling member 6 from the laminate 4 using the peeling roller 46, as illustrated by the arrow γ2.

As shown by the arrow γ1, the case where the management method is performed on the retardation film 2 will be described. In this case, as shown in FIG. 14, the management method is performed 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 performed on the retardation film 2, the end 11a of the resin film 11 corresponds to the end 102a, and the end 33a of the second retardation layer 33 corresponds to the end 104a. Furthermore, the distance D1c in the x direction between the end 11a and the end 33a corresponds to the distance D1.

When the control method is performed at the position of the arrow γ1, a reflection optical system 106 is placed with respect to the retardation film 2 downstream of the peeling roller 46, and the measurement step S02 of the control method is performed to measure the distance D1c. In the determination step S03, it is determined whether the distance D1c is within a predetermined range.

If the peeling member 6 is appropriately peeled off by the peeling roller 46, the distance D1c between the end portion 11a and the end portion 33a is constant in the longitudinal direction of the retardation plate 2. On the other hand, if peeling by the peeling roller 46 is not performed properly, 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 of the retardation plate 2 changes.

If the distance D1c is outside the predetermined range (a range that takes into account manufacturing errors in the initially set distance), for example, the part of the second retardation layer 33 that should be peeled off is on the retardation plate 2 side. It is considered that there is a problem (or abnormality) in which the problem remains. Therefore, by determining whether the distance D1c is within a predetermined range in the determination step S03 of the management process, it is possible to detect whether or not there is an abnormality when the peeling member 6 is peeled off from the laminate 4. If an abnormality is detected, in a changing step S04, the manufacturing conditions are changed so that the distance D1c falls within a predetermined range. 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 performed on the peeling member 6 at the rear of the peeling roller 46, as shown in FIG. 14, the resin film 31 of the peeling member 6 is the first member layer 102, and the second retardation layer 33 of the peeling member 6 is the second member layer 104. In this case, the end 31a of the resin film 31 corresponds to the end 102a, and the end 33a of the second retardation layer 33 of the peeling member 6 corresponds to the end 104a. Furthermore, the distance D1d in the x direction between the end 31a and the end 33a corresponds to the distance D1. The method of performing the management method on the peeling member 6 is the same as the method of performing the management method on the retardation plate 2, 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.

(Variation 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 first optical laminate 10 in that the first phase difference layer 13 does not cover both ends of the alignment film 12 in the x direction. Similarly, the second optical laminate 30A differs from the second optical laminate 30 in that the second phase difference layer 33 does not cover both ends of the alignment film 32 in the x direction. Usually, the length of the first phase difference layer 13 in the x direction is shorter than the length of the alignment film 12, and the length of the second phase difference layer 33 in the x direction is shorter than the length of the alignment film 32. In this case, with the peeling roller 46 shown in FIG. 9, the resin film 31 of the second optical laminate 30A is selectively peeled off as shown in FIG. 16. As a result, a retardation plate 2A can be manufactured 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. The manufacturing method of the retardation plate 2A to which the management method is applied is the same as that described with reference to Figures 6 to 9. Therefore, the modified example 3 also has the same effect as that of manufacturing the retardation plate 2.

The above describes the embodiments and modifications of the present invention. However, the present invention is not limited to the exemplified embodiments and modifications, but includes the scope indicated by the claims, and is intended to include all modifications within the meaning and scope equivalent to the claims.

The manufacturing method of a retardation plate to which the management method is applied has been described in the case where the optical component is a retardation plate. However, the optical component to which the manufacturing method of the present invention is applied is not limited to a retardation plate. Other examples of optical components include a polarizing plate in which a polarizing film (polarizer layer) and a protective film are laminated, and a circular polarizing plate (including an elliptical polarizing plate) in which a retardation plate and a polarizing plate are bonded with an adhesive layer. An example of the polarizer layer is a PVA layer.

When the optical component is the circular polarizing plate, for example, the above-mentioned management method may be applied to a first member layer (e.g., a member corresponding to the resin film 11 shown in FIG. 5) of the retardation plate or polarizing plate and a coating layer to be an adhesive layer between the retardation plate and the polarizing plate as the second member layer. Alternatively, as described in the above modification example 1, the above-mentioned management 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 a laminate having, for example, a polarizing film or a polarizing plate containing a polarizing film (first member layer) and a coating layer (second member layer). The management method according to the present invention may be applied, for example, to a case where a coating layer (second member layer) is formed directly on a resin film (first member layer).

The management method according to the present invention can also be applied, for example, to the case where an adhesive layer formed on a release film is transferred to a first member layer (e.g., a resin film). In this case, a bonded body is prepared in which a release film with an adhesive layer is bonded to a first member layer via the adhesive layer. By peeling the release film from the bonded body, a laminate in which an adhesive layer is laminated on a first member layer is obtained. In this case, the management method can be applied to the laminate with the adhesive layer as the second member layer. For example, if the bonded body is long, the release film can be peeled off using the peeling roller 46 in FIG. 9 while transporting the bonded body in the longitudinal direction, and the management method can be applied to the obtained laminate. This makes it possible to determine whether the transfer of the adhesive layer to the first member layer is appropriate.

Alternatively, in the management method according to the present invention, when an adhesive layer (second member layer) and a protective film (or release film) are laminated on a base material (first member layer), when the protective film is peeled off. It can also be applied to For example, in this case, if the laminated member of the base material, adhesive layer, and protective film is a long member, the protective film is peeled off using the peeling roller 46 in FIG. A management method may be applied to the laminate. Thereby, it can be determined whether the protective film has been appropriately peeled off (whether or not the adhesive layer remains on the protective film side).

Furthermore, the management method according to the present invention can be applied to a laminate having other optically functional films such as a polarizing film in addition to the base material (first member layer) and adhesive layer (second member layer).

As described in variant 1 of the second embodiment, the management method according to the present invention can also be applied to managing the presence or absence of abnormalities in the alignment of the first and second component layers in a laminate of the first and second component layers.

2, 2A... phase difference plate, 4... laminate, 11... resin film (first member layer), 11a... end (first end), 20... coating layer, 20a... end (second end), 100... laminate, 102... first member layer, 102a... end (first end), 104... second member layer, 104a... end, 112... stripe pattern, 112a... light area, 112b... dark area, 112A... first pattern, 112B... second pattern, 114... image processing device, A1, A2... end area, D1, D1a, D1b, D1c, D1d, D2, D2a... distance (distance between ends), L1... inspection light, L2... reflected light.

Claims (13)

A method for measuring an end region of a laminate including a first member layer and a second member layer, the method comprising:
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 when viewed from the stacking direction of the first member layer and the second member layer in the laminate,
The end region is a region extending from the first end to the second end of the laminate,
an irradiation step of irradiating the end region with inspection light;
a detection step of detecting reflected light that is the inspection light reflected by the end region;
a calculation step of calculating a distance between the first end and the second end based on the detection result of the reflected light;
Equipped with
The inspection light has a striped pattern in which bright parts and dark parts are arranged alternately,
The laminate is a long laminate,
The irradiation step and the detection step are carried out while the laminate is conveyed in the longitudinal direction with a plurality of conveyance rollers,
In the irradiation step, the laminate on the conveyance roller is irradiated with the inspection light,
The surface of the conveyance roller that is in contact with the laminate irradiated with the inspection light is a mirror surface.
Measuring method. The first member layer is a resin film layer, and the second member layer is a coating layer formed of a pressure-sensitive adhesive or an adhesive.
The method of claim 1. the shape of the striped pattern varies periodically;
The method according to claim 1 or 2. the shape of the stripe pattern varies periodically between a first pattern and a second pattern;
An extension direction of the bright portion and the dark portion in the second pattern is perpendicular to an extension direction of the bright portion and the dark portion in the first pattern.
The method according to claim 3. 1. A method for managing an edge region of a laminate including a first component layer and a second component layer, comprising:
the first member layer having a first end;
the second member layer has a second end portion located on the same side as the first end portion when viewed from a stacking direction of the first member layer and the second member layer in the stacked body;
the end region is a region of the laminate extending from the first end to the second end,
an irradiation step of irradiating the end region with an inspection light;
a detection step of detecting reflected light, which is the inspection light reflected by the end region;
a calculation step of calculating a distance between the first end and the second end based on a detection result of the reflected light;
a determination step of determining whether the calculated distance is within a predetermined range;
Equipped with
the inspection light has a stripe pattern in which light and dark areas are alternately arranged,
The laminate is a long laminate,
The irradiation step and the detection step are carried out while the laminate is being transported in a longitudinal direction by a plurality of transport rollers;
In the irradiation step, the stack on the transport roller is irradiated with the inspection light,
the surface of the conveying roller that comes into contact with the laminate irradiated with the inspection light is a mirror surface;
Management method. The first member layer is a resin film layer, and the second member layer is a coating layer formed of a pressure-sensitive adhesive or an adhesive.
The method according to claim 5 . the shape of the striped pattern varies periodically;
The method according to claim 5 or 6 . The shape of the striped pattern varies periodically between the first pattern and the second pattern,
The extending direction of the bright part and the dark part in the second pattern is perpendicular to the extending direction of the bright part and the dark part in the first pattern.
The method according to claim 7 . Before the irradiation step, the method further includes a laminating step of laminating the second member layer on the laminated member having the first member layer or the first member layer.
The management method according to any one of claims 5 to 8 . In the lamination step, the second member layer is laminated on the first member layer by coating a coating material on the first member layer.
The method according to claim 9 . If the calculated distance is not within a predetermined range, the layering step further includes a changing step of changing the coating area of the coating material,
repeating the stacking step, the irradiation step, the detection step, and the determination step until the calculated distance is included in a predetermined range;
The method according to claim 10 . Carrying out the laminating step while conveying in the longitudinal direction,
The method according to any one of claims 9 to 11 . A method for manufacturing an optical component, comprising the management method according to any one of claims 5 to 12 .

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