JP2011194605A - Device and method for manufacturing photosensitive laminated body - Google Patents

Abstract

When a photosensitive material layer is laminated against a substrate by pressing with a rotating rubber roll, the number of rotations of the rubber roll is stabilized from the initial movement to obtain a product with excellent quality without waste.
When a photosensitive resin layer 28 of photosensitive webs 22a and 22b fed from web feed mechanisms 32a and 32b and a glass substrate 24 fed from a substrate transport mechanism 45 are integrated via a bonding mechanism 46. The rubber roll 80a of the affixing mechanism 46 is made of silicone rubber having a friction coefficient of 0.3 to 0.8 between the roll surface and the support, and the photosensitive resin material is applied to the glass substrate 24 at a stable rotational speed. Laminate.
[Selection] Figure 1

Description

  The present invention provides a photosensitive laminate by feeding a substrate and a long photosensitive web provided with a photosensitive material layer on a support between a pair of pressure-bonding rolls, and affixing the photosensitive material layer to the substrate. The present invention relates to a manufacturing apparatus and a manufacturing method for a photosensitive laminate.

  For example, in a liquid crystal panel substrate, a printed wiring substrate, and a PDP substrate, a photosensitive sheet body (photosensitive web) having a photosensitive resin layer (photosensitive material layer) is attached to the substrate surface. In the photosensitive sheet body, a photosensitive resin layer and a protective film are sequentially laminated on a flexible plastic support.

  A manufacturing apparatus used for attaching this type of photosensitive sheet body usually conveys a glass substrate or a resin substrate such as a glass substrate or a resin substrate spaced apart from each other by a predetermined distance, and a photosensitive resin layer attached to the substrate. Corresponding to this range, a method of peeling the protective film from the photosensitive sheet body is adopted.

  For example, in the manufacturing apparatus disclosed in Patent Document 1, as shown in FIG. 9, a laminated body film (photosensitive sheet body) 1a fed out from a film roll 1 is wound around guide rolls 2a and 2b to be horizontal. It extends along the film transport surface. A rotary encoder 3 that outputs a number of pulse signals corresponding to the feed amount of the laminated film 1a is attached to the guide roll 2b.

  A laminate film 1a extending along a horizontal film transport surface is wound around a suction roll 4, and a half cutter device 5 and a cover film peeling device are provided between the guide roll 2b and the suction roll 4. 6 are provided.

  The half-cutter device 5 includes a pair of disc cutters 5a and 5b that are separated from each other by a predetermined distance in the transport direction of the laminated film 1a. The disc cutters 5a and 5b move along the film width direction of the laminate film 1a, thereby demarcating two boundary portions between the peeled portion and the remaining portion of the cover film (not shown) of the laminate film 1a. It cuts together with the photosensitive resin layer (not shown) on the back side.

  The cover film peeling device 6 strongly presses the pressure-sensitive adhesive tape 7 a fed from the pressure-sensitive adhesive tape roll 7 between the pressure rolls 8 a and 8 b to the peeled portion of the cover film, and then winds it by the take-up roll 9. Thereby, the peeling part of a cover film is peeled from the photosensitive resin layer, and is wound up by the winding roll 9 with the adhesive tape 7a.

  Downstream of the suction roll 4, a pair of lamination rolls that overlap and pressure-bond the peeled portion of the laminated film 1 a from which the cover film has been peeled over the upper surfaces of the plurality of substrates 11 that are transported at predetermined intervals by the substrate transport device 10. 12a and 12b are provided. A support film take-up roll 13 is disposed downstream of the lamination rolls 12a and 12b. The translucent support film (not shown) attached to the substrate 11 is wound around the support film winding roll 13 together with the remaining portion of the cover film in a state where the photosensitive resin layer remains on the substrate 11.

  In the above prior art, the applicant of the present invention is that the laminate film 1a is formed by forming a photosensitive resin layer on a flexible support film and is transported in a tensioned state. The boundary portion may be displaced due to the influence of the generated extension, and when the two laminated films 1a and 1b are applied to one substrate 11 at the same time, It has been found that not only the individual displacements of the positions of the laminated films 1a and 1b attached to the substrate 11, but also the positional deviation between the laminated films 1a and 1b becomes a problem. Further, since the present invention provides the laminating rolls 12a and 12b for pressing the laminated film 1a against the substrate 11 to convey the laminated film 1a with a predetermined frictional force, the outer peripheral surface is made of rubber. It was confirmed that the friction coefficient of the rubber lining was changed due to friction with the laminated film 1a during production, adhesion of a transfer product from the laminated film 1a, and the like. Therefore, even under the influence of such physical condition change, the positional deviation of the laminate film 1a with respect to the substrate 11 occurs, and in this case, the lamination rolls 12a and 12b lined with rubber are physically included including a friction coefficient. It has been found that it is necessary to replace the condition periodically in order to keep the condition within a predetermined range.

  In view of this, the present applicant has proposed an invention “photosensitive laminate manufacturing apparatus and method” (Patent Document 2) in Japanese Patent Application Laid-Open No. 2009-226883 in order to solve the above-mentioned various problems at once.

JP-A-11-34280 JP 2009-226883 A

  The present invention has been made in connection with the above-mentioned invention “photosensitive laminate manufacturing apparatus and method”, and is an improvement of a pressure-bonding roll for pressure-bonding a photosensitive material layer to a substrate. Not only at the time, but also during operation, the coefficient of friction should be as stable as possible, and as a result, variations in the position of the photosensitive material layer on the substrate that occurred during the initial movement of the crimping roll Monitoring of the manufacturing equipment system to reduce the amount of the product, avoid the operation of confirming the defective product due to the variation, suppress the operation loss due to the disposal of the defective product, and detect the presence / absence of the variation in the position where the substrate is adhered. Another object of the present invention is to provide a manufacturing apparatus and a manufacturing method for a photosensitive laminate capable of reducing as much as possible the work related to adjustment and the cleaning frequency of the manufacturing apparatus itself.

In order to achieve the above object, the invention specified in claim 1 of the present application is to deliver a long photosensitive web in which a photosensitive material layer and a protective film are laminated in order on a support, and the protective film. A processing portion corresponding to the boundary position between the peeled portion and the remaining portion is formed in a portion extending from the protective film to the photosensitive material layer, and the peeled portion of the protective film is peeled and supplied at a predetermined interval. A photosensitive laminate is manufactured by feeding between a pair of pressure-bonding rolls heated together with the substrate, placing the remaining portion of the protective film between the substrates, and attaching the exposed photosensitive material layer to the substrate. In the photosensitive laminate manufacturing apparatus,
The friction coefficient between the surface of at least one of the pressure-bonding rolls and the support is in the range of 0.3 to 0.8.

The invention specified in claim 2 of the present application is the photosensitive laminate manufacturing apparatus according to claim 1,
The surface which presses any one of the pair of pressure-bonding rolls is non-adhesive.

In the invention specified in claim 3 of the present application, a long photosensitive web in which a photosensitive material layer and a protective film are sequentially laminated on a support is sent out, and the boundary between the peeled portion and the remaining portion of the protective film is sent. A pair of pressure-bonding rolls formed with a processing part corresponding to the position in a part extending from the protective film to the photosensitive material layer, peeling off the peeling part of the protective film, and being heated together with a substrate supplied at a predetermined interval In the manufacturing apparatus of the photosensitive laminate, the photosensitive laminate is manufactured by sending the intermediate film between the substrates, placing the remaining portion of the protective film between the substrates, and attaching the exposed photosensitive material layer to the substrate.
The photosensitive material layer is pressed while being rotated against the substrate by a pressure-sensitive roll having a friction coefficient of 0.3 to 0.8 between at least one surface of the pressure-bonded roll and the support among the pair of pressure-sensitive rolls. And

The invention specified in claim 4 of the present application is the method for producing a photosensitive laminate according to claim 3,
The surface of the pressure-bonding roll that presses the photosensitive material layer is non-adhesive.

  According to the first and third aspects of the present invention, when the pressure-sensitive roll having a friction coefficient of 0.3 to 0.8 is used to press and paste the photosensitive material layer on the substrate while rotating, the friction coefficient is predetermined. In this range, the position where the photosensitive material layer is attached to the substrate becomes constant, thereby improving the quality of the photosensitive laminate and improving the yield.

  In addition, this eliminates the need for monitoring the position where the photosensitive material layer is attached to the substrate and adjusting the equipment required for it through the system, thereby providing the advantage of further improving production efficiency.

  According to the second and fourth aspects of the invention, since the surface of the pressure-bonding roll that presses the photosensitive material layer is made of a non-adhesive material, contamination from fine particles or the like existing during operation or in the environment. Can be avoided. This reduces the number of cleanings for the pressure-bonding roll, and also shortens the cleaning time, so that the production efficiency can be further improved.

  According to the present invention, when the substrate and the photosensitive material layer are integrated, the operation is performed because the lamination is performed while rotating using the pressure roll having a friction coefficient of 0.3 to 0.8 between the roll surface and the support. As a result, the position of the photosensitive material layer on the substrate is stable, the quality of the photosensitive laminate as a product is improved, and the yield of the substrate and the photosensitive material layer is improved.

It is a schematic block diagram of the manufacturing apparatus which concerns on embodiment of this invention. It is sectional drawing of the elongate photosensitive web used for the said manufacturing apparatus. It is explanatory drawing of the state by which the adhesive label was adhere | attached on the said elongate photosensitive web. It is explanatory drawing of the manufacturing apparatus from a sticking mechanism to a base automatic peeling mechanism. It is a circuit block diagram for adjusting the tension of the long photosensitive web before and after the press roll. It is a circuit block diagram for adjusting the processing position of a half cut part. It is a flowchart of the tension adjustment process after replacement | exchange of a crimping | compression-bonding roll. It is a graph which shows the relationship between the friction coefficient of a crimping | compression-bonding roll, rotation amount, and the number of crimping | compression-bonding. It is a schematic block diagram of the manufacturing apparatus of a prior art.

  FIG. 1 is a schematic configuration diagram of a photosensitive laminate manufacturing apparatus 20 according to an embodiment of the present invention. In the manufacturing apparatus 20, a long photosensitive layer is manufactured in a manufacturing process of a liquid crystal or a color filter for organic EL. An operation of thermally transferring the photosensitive resin layers 28 (described later) of the webs 22a and 22b to the glass substrate 24 in parallel is performed. The photosensitive webs 22a and 22b are each set to a predetermined width dimension.

  FIG. 2 is a cross-sectional view of the photosensitive webs 22 a and 22 b used in the manufacturing apparatus 20. The photosensitive webs 22a and 22b are formed by laminating a flexible base film (support) 26, a photosensitive resin layer (photosensitive material layer) 28, and a protective film 30.

  As shown in FIG. 1, the manufacturing apparatus 20 accommodates two (or more than two) photosensitive web rolls 23a and 23b obtained by winding photosensitive webs 22a and 22b in a roll shape. First and second web feed mechanisms 32a and 32b capable of synchronously feeding the photosensitive webs 22a and 22b from the photosensitive web rolls 23a and 23b, the protective film 30 and the photosensitive film of each of the fed photosensitive webs 22a and 22b. First and second processing mechanisms 36a and 36b (processing position adjusting means) for forming a half-cut portion (processing portion) 34 that is a boundary position that can be cut in the width direction on the conductive resin layer 28, and a part that is not bonded First and second label adhering mechanisms 40a and 40b for adhering an adhesive label 38 (see FIG. 3) having 38a to each protective film 30 are provided.

  Downstream of the first and second label adhering mechanisms 40a and 40b are first and second reservoir mechanisms 42a and 42b for changing the photosensitive webs 22a and 22b from tact feed to continuous feed, and the respective photosensitive webs. First and second peeling mechanisms 44a and 44b for peeling the protective film 30 from the 22a and 22b at a predetermined length interval, and a substrate transport mechanism 45 for transporting the glass substrate 24 to a pasting position while being heated to a predetermined temperature. (Affixing position adjusting means) and an adhering mechanism 46 for adhering the photosensitive resin layer 28 exposed by peeling off the protective film 30 to the glass substrate 24 integrally and in parallel are disposed.

  First and second detection mechanisms (processing part position detecting means) for detecting the positions of the respective half-cut parts 34, which are the boundary positions of the photosensitive webs 22a and 22b, in the vicinity of the attaching position in the attaching mechanism 46. ) 47a and 47b are disposed.

  In the vicinity of the downstream of the first and second web feed mechanisms 32a and 32b, the rear ends of the substantially used photosensitive webs 22a and 22b and the tips of the newly used photosensitive webs 22a and 22b are pasted, respectively. Is attached. A film terminal position detector 51 is disposed downstream of the attachment table 49 in order to control the displacement in the width direction due to the winding displacement of the photosensitive web rolls 23a and 23b. Here, the film terminal position adjustment is performed by moving the first and second web feed mechanisms 32a and 32b in the width direction, but may be performed by attaching a position adjustment mechanism combined with a roll. The first and second web feed mechanisms 32a and 32b are configured with a multi-axis such as a biaxial or triaxial feeding shaft for loading the photosensitive web rolls 23a and 23b and feeding the photosensitive webs 22a and 22b. May be.

  The first and second processing mechanisms 36a and 36b are provided with a roll pair 50 for calculating the roll diameter of each photosensitive web roll 23a and 23b accommodated and wound in the first and second web feed mechanisms 32a and 32b. Arranged downstream. Each of the first and second processing mechanisms 36a and 36b includes a single round blade 52, and the round blade 52 travels in the width direction of the photosensitive webs 22a and 22b, and the remaining portion 30b of the protective film 30 ( Half-cut portions 34 are formed at two predetermined positions across FIG.

  As shown in FIG. 2, the half-cut portion 34 needs to cut at least the protective film 30 and the photosensitive resin layer 28, and the cutting depth of the round blade 52 is set so as to cut into the base film 26 in practice. The The round blade 52 is fixed without rotating and moves in the width direction of the photosensitive webs 22a and 22b to form a half-cut portion 34, or without sliding on the photosensitive webs 22a and 22b. A method of moving in the width direction while rotating to form the half-cut portion 34 is employed. In place of the round blade 52, the half-cut portion 34 may employ, for example, a method of forming with a knife blade, a push cutting blade (Thomson blade) or the like in addition to a cutting method using laser light or ultrasonic waves. .

  Two first and second processing mechanisms 36a and 36b are disposed in the conveying direction of the photosensitive webs 22a and 22b (in the direction of arrow A), separated by a distance corresponding to the width of the remaining portion 30b, respectively, for protection. Two half-cut portions 34 may be formed simultaneously with the remaining portion 30b (FIG. 2) of the film 30 interposed therebetween.

  For example, when the photosensitive resin layer 28 is attached to the glass substrate 24, the half-cut portion 34 is set so as to be in a position that enters into the inside by 10 mm from both ends of the glass substrate 24, for example. The remaining portion 30b of the protective film 30 between the glass substrates 24 functions as a mask when the photosensitive resin layer 28 is attached to the glass substrate 24 in a frame shape in an attaching mechanism 46 described later.

  The first and second label bonding mechanisms 40a and 40b connect the peeling portion 30aa at the front side of the peeling side and the peeling portion 30ab at the back side of the peeling side in order to leave the remaining portion 30b of the protective film 30 correspondingly between the glass substrates 24. An adhesive label 38 is supplied. As shown in FIG. 2, the protective film 30 has a remaining portion 30 b sandwiched between the first peeled portion 30 aa and the later peeled portion 30 ab.

  As shown in FIG. 3, the adhesive label 38 is formed in a strip shape, and is formed of, for example, the same resin material as the protective film 30. The adhesive label 38 has a non-adhesive portion (including a slight adhesion) 38a to which a pressure-sensitive adhesive is not applied at the center, and the front side of the non-adhesive portion 38a, that is, both ends in the longitudinal direction of the adhesive label 38 It has the 1st adhesion part 38b adhered to exfoliation part 30aa, and the 2nd adhesion part 38c adhered to back exfoliation part 30ab.

  As shown in FIG. 1, each of the first and second label bonding mechanisms 40a and 40b includes suction pads 54a to 54g, each of which can attach a maximum of seven adhesive labels 38 with a predetermined interval between them. A pedestal 56 for holding the photosensitive webs 22a and 22b from below is disposed so as to be movable up and down at the position where the adhesive label 38 is attached by the pads 54a to 54g.

  The first and second reservoir mechanisms 42a and 42b are arranged to absorb the speed difference between the tact conveyance of the upstream photosensitive webs 22a and 22b and the continuous conveyance of the downstream photosensitive webs 22a and 22b. A dancer roll 60 that can swing in a direction is provided. The second reservoir mechanism 42b includes a dancer for adjusting the lengths of the conveyance paths until the photosensitive webs 22a and 22b sent from the first and second web delivery mechanisms 32a and 32b reach the attaching mechanism 46. A roll 61 is disposed.

  The first and second peeling mechanisms 44a and 44b arranged downstream of the first and second reservoir mechanisms 42a and 42b block the tension fluctuation on the delivery side of the photosensitive webs 22a and 22b, respectively, and the tension at the time of lamination is reduced. A suction drum 62 is provided for stabilization. In the vicinity of each suction drum 62, a peeling roll 63 is disposed, and the protective film 30 peeled off from the photosensitive webs 22a and 22b through the peeling roll 63 at an acute peeling angle except for the remaining portion 30b. Then, the film is wound around the protective film winding section 64.

  Tension control mechanisms 66a and 66b (upstream tension adjusting means) including a tension roll 65 are disposed on the downstream side of the first and second peeling mechanisms 44a and 44b. Each of the tension control mechanisms 66a and 66b includes a cylinder 68. When the tension dancer 70 is oscillated and displaced under the driving action of the cylinder 68, the tension of the photosensitive webs 22a and 22b with which the tension dancer 70 is slidably contacted. Is adjustable.

  The first and second detection mechanisms 47a and 47b that detect the position of the half-cut portion 34 on the basis of the positions of the rubber rolls 80a and 80b (compression-bonding rolls) constituting the pasting mechanism 46 are the transport roll 73 and the transport rolls 71a and 71b. The long photosensitive webs 22a and 22b between the two are disposed in a linear portion. The first and second detection mechanisms 47a and 47b are configured by a CCD camera (described later) that captures an image of the long photosensitive webs 22a and 22b including the half-cut portion 34.

  The substrate transport mechanism 45 includes a plurality of sets of substrate heating units (for example, heaters) 74 disposed so as to sandwich the glass substrate 24 and a transport unit 76 that transports the glass substrate 24 in the direction of arrow C. In the substrate heating unit 74, the temperature of the glass substrate 24 is constantly monitored. When an abnormality occurs, the conveyance unit 76 is stopped or alarmed, and abnormal information is transmitted to cause the abnormal glass substrate 24 to be NG discharged and quality control in a subsequent process. Or it can be used for production management. An air levitation plate (not shown) is disposed in the conveyance unit 76, and the glass substrate 24 is levitated and conveyed in the direction of arrow C. The glass substrate 24 can be transported by a roll conveyor.

  The temperature measurement of the glass substrate 24 is preferably performed in the substrate heating unit 74 or immediately before the attachment position. The measuring method may be a contact type (for example, thermocouple) or a non-contact type.

  A substrate stocker 71 that accommodates a plurality of glass substrates 24 is provided upstream of the substrate heating unit 74. Each glass substrate 24 accommodated in the substrate stocker 71 is sucked and taken out by a suction pad 79 provided in the hand portion 75 a of the robot 75 and inserted into the substrate heating portion 74.

  The affixing mechanism 46 includes rubber rolls 80a and 80b that are arranged vertically and heated to a predetermined temperature. In this case, in the present embodiment, a material having a friction coefficient of 0.3 to 0.8 is selected on at least the surface of the rubber roll 80a. As the material, it has been experimentally confirmed that it is a silicone rubber having a friction coefficient of 0.3 to 0.8 as described above. If necessary, silicone rubber having a friction coefficient of 0.3 to 0.8 may be adopted for the rubber roll 80b as well as the rubber roll 80a. This is because in the case of silicone rubber, the coefficient of friction is easily adjusted and the adhesive is rich in non-adhesiveness. It is also suitable for avoiding contamination by dust. Backup rolls 82a and 82b are in sliding contact with the rubber rolls 80a and 80b. One backup roll 82b is pressed toward the rubber roll 80b by the pressure cylinders 84a and 84b constituting the roll clamp part 83.

  In the vicinity of the rubber roll 80a, a contact prevention roll 86 for preventing the photosensitive webs 22a and 22b from contacting the rubber roll 80a is movably disposed. In the vicinity of the upstream of the attaching mechanism 46, a preheating unit 87 for preheating the photosensitive webs 22a and 22b to a predetermined temperature is disposed. This preheating part 87 is provided with heating means, such as an infrared bar heater, for example.

  The glass substrate 24 is transported from the pasting mechanism 46 via a transport path 88 extending in the direction of arrow C. In the transport path 88, film transport rolls 90a and 90b and a substrate transport roll 92 are disposed. The distance between the rubber rolls 80 a and 80 b and the substrate transport roll 92 is preferably set to be equal to or shorter than the length of one glass substrate 24. In the vicinity of the downstream side of the substrate transport roll 92, a substrate front end detection sensor 94 that detects the front end of the transported glass substrate 24 is disposed. The substrate front end detection sensor 94 is configured such that when the half cut portion 34 at the rear end portion of the photosensitive resin layer 28 attached to the glass substrate 24 is disposed between the rubber rolls 80a and 80b of the attaching mechanism 46, It arrange | positions in the position which detects a front-end | tip part (refer FIG. 4).

  Further, a cooling mechanism 122 and base automatic peeling mechanisms 142a and 142b are provided downstream of the substrate transport roll 92. The automatic base peeling mechanisms 142a and 142b continuously extend the long base films 26 of the long photosensitive webs 22a and 22b attached to the glass substrates 24 spaced apart from each other by a predetermined distance from the glass substrate 24. It peels and includes a pre-peeling portion 144, a relatively small-diameter peeling roll 146, a take-up shaft 148, and an automatic pasting machine 150. The winding shaft 148 applies a predetermined tension to the base film 26 by controlling the torque during driving. The pre-peeling portion 144 includes a peeling bar 156 that can move up and down between the glass substrates 24.

  A measuring instrument 158 for measuring the area position of the photosensitive resin layer 28 actually attached to the glass substrate 24 is disposed downstream of the automatic base peeling mechanisms 142a and 142b. The measuring device 158 includes, for example, a CCD camera 160 that photographs the glass substrate 24 on which the photosensitive resin layer 28 is attached.

  Further, a photosensitive laminate stocker 132 that accommodates a plurality of photosensitive laminates 106 is provided downstream of the measuring instrument 158. The photosensitive laminate 106 from which the base film 26 and the remaining portion 30b have been peeled off by the automatic base peeling mechanism 142a, 142b is sucked and taken out by the suction pad 136 provided on the hand portion 134a of the robot 134, and is then exposed to the photosensitive laminate. Housed in the stocker 132.

  In the manufacturing apparatus 20 configured as described above, the first and second web feed mechanisms 32a and 32b, the first and second processing mechanisms 36a and 36b, the first and second label bonding mechanisms 40a and 40b, the first and second The second reservoir mechanisms 42a and 42b, the first and second peeling mechanisms 44a and 44b, and the first and second tension control mechanisms 66a and 66b are separated from each other by the partition 110 having the penetrating portion 114, and the upper clean room 112a of the attaching mechanism 46. On the other hand, the first and second detection mechanisms 47a and 47b, the pasting mechanism 46, the cooling mechanism 122, the base automatic peeling mechanisms 142a and 142b, and the measuring device 158 are disposed in the lower clean room 112b. In addition, each mechanism arrange | positioned in the upper clean room 112a and the lower clean room 112b may be arrange | positioned upside down, and the said whole manufacturing apparatus 20 may be comprised linearly.

  FIG. 5 is a circuit block diagram for adjusting the upstream tension and the downstream tension of the long photosensitive webs 22a and 22b by controlling the tension control mechanisms 66a and 66b and the automatic base peeling mechanisms 142a and 142b. is there. The tension of the long photosensitive webs 22a and 22b on the upstream side of the rubber rolls 80a and 80b constituting the attaching mechanism 46 is defined as the upstream tension (back tension TB), and the long side on the downstream side of the rubber rolls 80a and 80b. The tension of the photosensitive webs 22a and 22b is set as the downstream tension (peel tension TP).

  A back tension detector 170 (upstream tension detecting means) for detecting the back tension TB of the long photosensitive webs 22a and 22b is connected to each tension roll 65 constituting the tension control mechanisms 66a and 66b. The winding shafts 148 constituting the base automatic peeling mechanisms 142a and 142b are rotationally controlled by a winding torque motor 172 (downstream tension adjusting means). The take-up torque motor 172 is connected to a peel tension calculating unit 174 (downstream tension detecting means) for calculating the tension applied to the long photosensitive webs 22a and 22b from the torque of the take-up torque motor 172. The

  Based on the tension set by the tension setting unit 178, the tension control unit 176 (tension control means) detects the back tension TB detected by the back tension detector 170, and the peel tension TP calculated by the peel tension calculation unit 174. To control. The tension setting unit 178 stores the tension setting table storage unit 184 based on the number of manufactured photosensitive laminates 106 counted by the number-of-manufactured counter 180 or the number of rotations of the rubber rolls 80a and 80b detected by the rubber roll rotation number detector 182. The stored back tension TB and peel tension TP are read out and set in the tension control unit 176. The production number counter 180 can be constituted by, for example, a counter that counts the number of photosensitive laminates 106 laminated on the photosensitive laminate stocker 132, and the rubber roll rotation number detector 182 includes the backup roll 82a. It can be configured by an encoder connected to the rotating shaft.

  FIG. 6 is a circuit for adjusting the attachment positions of the long photosensitive webs 22a and 22b on the glass substrate 24 based on the positions of the half-cut portions 34 detected by the first and second detection mechanisms 47a and 47b. It is a block diagram.

  Each of the first and second detection mechanisms 47a and 47b has a CCD camera 186. The half-cut position calculation unit 188 is based on the images of the long photosensitive webs 22a and 22b including the half-cut part 34 photographed by each CCD camera 186, and the half-cut part 34 based on the positions of the rubber rolls 80a and 80b. The position of is calculated. The half-cut position correcting unit 192 calculates the correction amount of the position of the half-cut part 34 formed on the long photosensitive webs 22a and 22b based on the position of each half-cut part 34 calculated by the half-cut position calculating unit 188. calculate. The first and second processing mechanisms 36a and 36b correct the formation position of the half cut portion 34 according to the calculated correction amount, and form the half cut portion 34 on the long photosensitive webs 22a and 22b.

  The operation of the manufacturing apparatus 20 configured as described above will be described below in relation to the manufacturing method according to the present invention.

  First, the photosensitive webs 22a and 22b are sent out from the respective photosensitive web rolls 23a and 23b attached to the first and second web delivery mechanisms 32a and 32b. The photosensitive webs 22a and 22b are conveyed to the first and second processing mechanisms 36a and 36b.

  In the first and second processing mechanisms 36a and 36b, the round blade 52 moves in the width direction of the photosensitive webs 22a and 22b, and the photosensitive webs 22a and 22b are moved from the protective film 30 to the photosensitive resin layer 28 to the base film. Cut to 26 to form a half-cut portion 34 (see FIG. 2). Further, the photosensitive webs 22 a and 22 b are stopped after being conveyed in the direction of arrow A corresponding to the width M of the remaining portion 30 b of the protective film 30, and a half-cut portion 34 is formed under the running action of the round blade 52. The Thus, the photosensitive webs 22a and 22b are provided with a front peeling portion 30aa and a rear peeling portion 30ab with the remaining portion 30b interposed therebetween (see FIG. 2).

  The width M of the remaining portion 30b is set based on the distance between the glass substrates 24 supplied between the rubber rolls 80a and 80b of the attaching mechanism 46 on the assumption that the photosensitive webs 22a and 22b do not extend. Shall. In addition, a set of half-cut portions 34 formed with a width M is formed by separating the long photosensitive web 22a at intervals of a reference length L (see FIG. 4) of the photosensitive resin layer 28 attached to the glass substrate 24. 22b.

  Next, the respective photosensitive webs 22 a and 22 b are conveyed to the first and second label adhering mechanisms 40 a and 40 b, and a predetermined application site of the protective film 30 is arranged on the cradle 56. In the first and second label adhering mechanisms 40a and 40b, a predetermined number of adhesive labels 38 are adsorbed and held by the adsorbing pads 54b to 54g, and each adhering label 38 straddles the remaining portion 30b of the protective film 30, and a front peeling portion. 30aa and the rear peeling portion 30ab are integrally bonded (see FIG. 3).

  For example, the photosensitive webs 22a and 22b to which the seven adhesive labels 38 are bonded, as shown in FIG. 1, after the first and second reservoir mechanisms 42a and 42b are prevented from changing the tension on the delivery side, It is continuously conveyed to the first and second peeling mechanisms 44a and 44b. In the first and second peeling mechanisms 44a and 44b, the base film 26 of the photosensitive webs 22a and 22b is adsorbed and held by the suction drum 62, and the protective film 30 leaves the remaining portion 30b and the photosensitive webs 22a and 22b. Is peeled off. The protective film 30 is peeled off via a peeling roll 63 and wound around a protective film take-up portion 64 (see FIG. 1).

  Under the action of the first and second peeling mechanisms 44a and 44b, after the protective film 30 is peeled off from the base film 26 leaving the remaining portion 30b, the photosensitive webs 22a and 22b are backed by the tension control mechanisms 66a and 66b. The tension TB is adjusted, and then the half-cut portion 34 is detected by the first and second detection mechanisms 47a and 47b.

  The affixing mechanism 46 conveys and stops the photosensitive webs 22a and 22b so that the half cut portion 34 on the side of the peeling portion 30ab preceding the detected half cut portion 34 is disposed on the rubber rolls 80a and 80b. Then, the glass substrate 24 is transported to the affixing position in a heated state under the action of the substrate transport mechanism 45. The glass substrate 24 is temporarily disposed between the rubber rolls 80a and 80b corresponding to the portion where the photosensitive resin layer 28 of the photosensitive webs 22a and 22b arranged in parallel is attached.

  Next, by raising the backup roll 82b and the rubber roll 80b, the glass substrate 24 is sandwiched between the rubber rolls 80a and 80b with a predetermined pressing pressure. Then, the photosensitive webs 22a and 22b and the glass substrate 24 are conveyed in the direction of arrow C under the rotating action of the rubber roll 80a. As a result, the photosensitive resin layers 28 arranged in parallel are heated and melted and transferred (laminated) to the glass substrate 24.

  The laminating conditions include a speed of 1.0 m / min to 10.0 m / min, a temperature of the rubber rolls 80a and 80b of 80 ° C to 150 ° C, a rubber hardness of the rubber rolls 80a and 80b of 40 ° to 90 °, The press pressure (linear pressure) of the rubber rolls 80a and 80b is 50 N / cm to 400 N / cm.

  In this case, in this embodiment, in addition to the laminating conditions, a rubber roll 80a having a rubber hardness (JIS-A) of 40 degrees to 90 degrees and a friction coefficient of 0.3 to 0.8 is employed. Based on the following findings.

  First, referring to FIG. FIG. 8 is a graph showing the relationship between the friction coefficient of the rubber roll (crimp roll), the amount of rotation, and the number of crimps. The left vertical axis in FIG. 8 shows the value of the coefficient of friction between the surface of the rubber roll and the support, the right vertical axis shows the number of rotations of the rubber roll when one substrate is processed, and the lower horizontal axis shows the number of processed substrates. ing.

  That is, according to the knowledge of the applicant, as is clear from the graph shown in FIG. 8, the glass substrate is fixed to a predetermined pressure using a rubber roll according to the prior art having a friction coefficient exceeding 0.8 and about 1.0. When the photosensitive web is laminated to a glass substrate by heating and melting the photosensitive resin layer, especially when the rubber roll is mounted for the first time including replacement, the friction coefficient is 0.8 to 1. .2 greatly varies in the vicinity (see the specific curve O in FIG. 8). During this time, the number of rotations for processing one glass substrate with a rubber roll also varies greatly from approximately M times to 1.03 M times (see specific curve Q in FIG. 8).

  On the other hand, when the rubber roll 80a according to the present invention is used, the friction coefficient between the surface of the rubber roll 80a and the base film (support) 26 is stable at about 0.6 (see the specific curve P in FIG. 8). In addition, when the photosensitive resin layer 28 is laminated on the glass substrate 24 using the rubber roll 80a, the number of rotations is M ± 0.25, and the number of rotations hardly varies (see the specific curve R in FIG. 8). ). The specific curve R slightly varies depending on the number of processed substrates, but is sufficiently within an allowable range.

  On the other hand, according to another experiment, when the friction coefficient of the rubber roll 80a is less than 0.3, when the photosensitive resin layer 28 is laminated on the glass substrate 24, vertical wrinkles generated during the lamination are caused by the pressure of the rubber roll. It has been confirmed that it is difficult to crush, that is, the disadvantage that air bubbles enclosing air remain between the glass substrate 24 and the photosensitive resin layer 28 is exposed.

  On the other hand, when the friction coefficient of the rubber roll 80a is 0.3 or more, the generation of the bubbles was not confirmed.

  In the next step, the substrate tip detection sensor 94 detects the tip of the glass substrate 24, and when the lamination of one photosensitive web 22a, 22b on the glass substrate 24 is completed via the rubber rolls 80a, 80b, the rubber roll 80a. Is stopped, while the glass substrate 24 (hereinafter also referred to as a bonding substrate 24a) on which the photosensitive webs 22a and 22b are laminated is clamped by the substrate transport roll 92.

  Then, the rubber roll 80b is retracted in a direction away from the rubber roll 80a to release the clamp, and the rotation of the substrate transport roll 92 is started, so that the pasting substrate 24a is left in the direction of arrow C in the remaining portion 30b of the protective film 30. The half cut portion 34 on the peeling portion 30ab side behind the protective film 30 moves to a predetermined position near the lower side of the rubber roll 80a. On the other hand, the next glass substrate 24 is transported toward the attaching position via the substrate transport mechanism 45. By repeating the above operation, the bonded substrate 24a is continuously manufactured.

  At that time, as shown in FIG. 4, the end portions of the pasting substrate 24 a are covered with the remaining portions 30 b. Therefore, when the photosensitive resin layer 28 is transferred to the glass substrate 24, the rubber rolls 80a and 80b are not soiled by the photosensitive resin layer 28.

  The pasted substrate 24 a laminated by the pasting mechanism 46 is cooled through the cooling mechanism 122 and then transferred to the pre-peeling portion 144. In the pre-peeling portion 144, the peeling bar 156 enters between the glass substrates 24 and rises, whereby the protective film 30 between the glass substrates 24 is lifted and peeled from the rear end and the leading end of the adjacent glass substrates 24. To do.

  Next, in the automatic base peeling mechanism 142a, 142b, the base film 26 is continuously wound from the pasting substrate 24a under the rotating action of the winding shaft 148. Further, after separation at a trouble stop or after separation at the time of defective product separation, the tip of the base film 26 of the pasted substrate 24a that has been newly laminated and the base film that is wound around the winding shaft 148 26 is automatically pasted via the automatic pasting machine 150. In this case, the peel tension TP applied to the long photosensitive webs 22 a and 22 b is controlled by a winding torque motor 172 that rotates the winding shaft 148.

  The bonded substrate 24a from which the base film 26 has been peeled is placed at an inspection station corresponding to the measuring instrument 158. In this inspection station, images of the glass substrate 24 and the photosensitive resin layer 28 are captured by the four CCD cameras 160 with the glass substrate 24 positioned and fixed. Then, by applying image processing, the pasting position is calculated.

  The attachment substrate 24 a on which the attachment position of the photosensitive resin layer 28 is confirmed is taken out by the robot 134 and accommodated in the photosensitive laminate stocker 132 as the photosensitive laminate 106.

  By the way, in general, a rubber roll for attaching a long photosensitive web to a glass substrate is worn over a long period of time, and the lined rubber is worn away or a long photosensitive surface is formed on the surface. The friction coefficient changes due to adhesion of a transfer product from the web, and the long photosensitive web cannot be transported in an appropriate state, so that the rubber roll may need to be replaced. According to the present embodiment, since the rubber roll 80a is made of silicone rubber and has a friction coefficient of 0.3 to 0.8, the frequency of replacement can be minimized. However, there is no need for replacement.

  Therefore, when the rubber rolls 80a and 80b are replaced with new ones, the position of the photosensitive resin layer 28 and the reference length L (see FIG. 4) between the half-cut portions 34 attached to the glass substrate 24 change, and two rows In some cases, the respective attachment positions of the long photosensitive webs 22a and 22b to be attached to the web may be shifted.

  Accordingly, processing after the rubber rolls 80a and 80b are replaced with new ones will be described with reference to the flowchart of FIG.

  When the rubber rolls 80a and 80b are replaced (step S1), the tension controller 176 first adjusts the back tension TB of the long photosensitive webs 22a and 22b on the upstream side of the rubber rolls 80a and 80b to 100 N / m. At the same time, the peel tension TP on the downstream side of the rubber rolls 80a and 80b is adjusted to 80 N / m. (Step S2).

  In this case, the back tension TB may be set within a range of 100 ± 5 N / m, and the peel tension PTj may be set within a range of 80 ± 5 N / m.

  Therefore, in FIG. 5, the tension setting unit 178 reads each data of back tension TB = 100 N / m and peel tension TP = 80 N / m from the tension setting table storage unit 184 and sets the data in the tension control unit 176. On the other hand, each back tension detector 170 connected to the tension roll 65 constituting the tension control mechanisms 66a and 66b detects the back tension TB of the long photosensitive webs 22a and 22b, and the detected value is used as a tension control unit. 176. Further, the peel tension calculating unit 174 generates a long length from the torque of the winding torque motor 172 that rotates the winding shaft 148 that winds the base film 26 attached to the glass substrate 24 via the photosensitive resin layer 28. The peel tension TP of the photosensitive webs 22a and 22b is calculated, and the calculated value is supplied to the tension controller 176. The tension control unit 176 drives the cylinder 68 to control the tension dancer 70 so that the detected value and the calculated value become the set back tension TB and peel tension TP, and controls the winding torque motor 172. Control.

  Note that the peel tension TP of the photosensitive webs 22a and 22b is calculated and controlled from the torque of the take-up torque motor 172, and similarly to the tension control mechanisms 66a and 66b for controlling the back tension TB, the peeling roll 146 is used. Alternatively, the peel tension TP of the photosensitive webs 22a and 22b between the machine and the automatic pasting machine 150 may be detected, and a tension dancer disposed therebetween may be driven and controlled.

  The first and second processing mechanisms 36a and 36b are based on the position of the half-cut portion 34 detected by the first and second detection mechanisms 47a and 47b, and the long photosensitive web 22a with respect to the glass substrate 24 as necessary. , 22b is adjusted (step S3).

  That is, in FIG. 6, the CCD camera 186 constituting the first and second detection mechanisms 47a and 47b includes the half-cut portion 34 when the half-cut portion 34 reaches a predetermined position between the rubber rolls 80a and 80b. Images of the photoconductive webs 22a and 22b are taken. The half-cut position calculation unit 188 extracts the half-cut part 34 from the photographed image, and calculates the position of the half-cut part 34 with reference to the positions of the rubber rolls 80a and 80b.

  The half-cut position correction unit 192 controls the first and second processing mechanisms 36a and 36b when the amount of positional deviation of the half-cut portion 34 exceeds a predetermined amount, so that each long length from the end of the glass substrate 24 is controlled. The formation positions of the half-cut portions 34 on the respective long photosensitive webs 22a and 22b are corrected so that the distances ΔL1 and ΔL2 to the ends of the strip-like photosensitive webs 22a and 22b become the distance ΔL.

  As described above, the attaching process of the long photosensitive webs 22a and 22b to the glass substrate 24 is continued while adjusting the attaching position of the long photosensitive webs 22a and 22b to the glass substrate 24 (step S4). ).

  After the base film 26 is peeled off by the base automatic peeling mechanisms 142a and 142b, the sticking substrate 24a in which the long photosensitive webs 22a and 22b are stuck to predetermined portions of the glass substrate 24 is supplied to the measuring device 158. Then, an image inspection process is performed on the bonding state of the photosensitive laminate 106, for example, the bonding position, whether or not air bubbles are mixed between the glass substrate 24 and the photosensitive resin layer 28 (step S5). .

  After the pasting position is stabilized, the process is continued, and the production is finished when the desired number of productions is reached (step S6).

  As described above, in accordance with the number of manufactured photosensitive laminates 106 and the number of rotations of the rubber roll 80a, the back tension TB and the peel tension TP are adjusted for the long photosensitive webs 22a and 22b, and the pasting process is performed. As a result, it is possible to continuously produce a highly accurate photosensitive laminate 106 with the occurrence of defective products being minimized. In this case, the long photosensitive webs 22a and 22b and the glass substrate 24 are not wasted.

  In addition, according to the present embodiment, the silicone having a friction coefficient of 0.3 to 0.8 on the surface of the rubber roll 80a when the photosensitive resin layer 28 constituting the photosensitive webs 22a and 22b is laminated on the glass substrate 24. Since it is rubber, a stable rotational speed can be obtained even when it is mounted on the manufacturing apparatus 20 or at the initial movement after the replacement of the rubber roll 80a, and as a result, the laminate itself is also kept in a stable state, and thereby a product with excellent quality. Can be obtained.

  In the rubber roll according to the prior art, as shown in FIG. 8, when the photosensitive resin layer is laminated on the glass substrate at the initial motion, the number of glass substrates is N1 to N1 * 2, and the number of sheets is one. The number of rotations of the rubber roll with respect to the glass substrate varies greatly, the laminating operation is not stable, and there are cases where products with non-constant quality are manufactured. (Here, N1 indicates the number determined by the size of the substrate.)

  However, as in the present embodiment, by using the rubber roll 80a having a friction coefficient in the range of 0.3 to 0.8, it is sensitive to one glass substrate 24 from the initial movement of the mounted rubber roll 80a. The number of rotations of the rubber roll 80a when laminating the conductive resin layer 28 is within the range of M rotations ± 0.25%. That is, the rotation of the rubber roll 80a is stable.

  In the above-described embodiment, the two photosensitive web rolls 23a and 23b are used. However, the present invention is not limited to this, and one photosensitive web roll or three or more photosensitive web rolls is used. May be adopted.

DESCRIPTION OF SYMBOLS 20 ... Manufacturing apparatus 22a, 22b ... Photosensitive web 24 ... Glass substrate 26 ... Flexible base film 28 ... Photosensitive resin layer 30 ... Protective film 34 ... Half cut part 36a, 36b ... Processing mechanism 45 ... Substrate conveyance mechanism 46 ... Pasting mechanism 47a, 47b ... detection mechanism 65 ... tension roll 66a, 66b ... tension control mechanism 68 ... cylinder 70 ... tension dancer 80a, 80b ... rubber roll 106 ... photosensitive laminate 142a, 142b ... base automatic peeling mechanism 148 ... winding Shaft 170 ... Back tension detector 172 ... Winding torque motor 174 ... Peel tension calculation unit 176 ... Tension control unit 178 ... Tension setting unit 180 ... Manufacturing number counter 182 ... Rubber roll rotation number detector 184 ... Tension setting table storage unit 186 ... CCD camera La 188 ... half-cut position calculating section 192 ... half-cut position correction unit

Claims (4)

A long photosensitive web in which a photosensitive material layer and a protective film are sequentially laminated on a support is fed out, and a processing site corresponding to a boundary position between a peeled portion and a remaining portion of the protective film is transferred from the protective film. The protective film is formed in a portion reaching the photosensitive material layer, the peeling portion of the protective film is peeled off, and sent between a pair of heated crimping rolls together with a substrate supplied at a predetermined interval, and the protective film is interposed between the substrates. In the photosensitive laminate manufacturing apparatus for manufacturing the photosensitive laminate by arranging the remaining portion and attaching the exposed photosensitive material layer to the substrate,
An apparatus for producing a photosensitive laminate, wherein the friction coefficient between the surface of at least one of the pressure-bonding rolls and the support is in the range of 0.3 to 0.8. In the manufacturing apparatus of the photosensitive laminated body of Claim 1,
The apparatus for producing a photosensitive laminate, wherein a surface for pressing one of the pair of pressure-bonding rolls is non-adhesive. A long photosensitive web in which a photosensitive material layer and a protective film are sequentially laminated on a support is fed out, and a processing site corresponding to a boundary position between a peeled portion and a remaining portion of the protective film is transferred from the protective film. The protective film is formed in a portion reaching the photosensitive material layer, the peeling portion of the protective film is peeled off, and sent between a pair of heated crimping rolls together with a substrate supplied at a predetermined interval, and the protective film is interposed between the substrates. In the photosensitive laminate manufacturing apparatus for manufacturing the photosensitive laminate by arranging the remaining portion and attaching the exposed photosensitive material layer to the substrate,
The photosensitive material layer is pressed against at least one of the pair of pressure-bonding rolls while rotating on the substrate with a pressure-sensitive roll having a friction coefficient of 0.3 to 0.8 between the surface of the one pressure-bonding roll and the support. The manufacturing method of the photosensitive laminated body characterized by these. In the manufacturing method of the photosensitive laminated body of Claim 3,
A method for producing a photosensitive laminate, wherein a surface of a pressure-bonding roll for pressing the photosensitive material layer is non-adhesive.

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