+

WO2007122843A1 - Method of applying elongate web - Google Patents

Method of applying elongate web Download PDF

Info

Publication number
WO2007122843A1
WO2007122843A1 PCT/JP2007/052664 JP2007052664W WO2007122843A1 WO 2007122843 A1 WO2007122843 A1 WO 2007122843A1 JP 2007052664 W JP2007052664 W JP 2007052664W WO 2007122843 A1 WO2007122843 A1 WO 2007122843A1
Authority
WO
WIPO (PCT)
Prior art keywords
heating roller
web
elongate web
partially cut
thermally
Prior art date
Application number
PCT/JP2007/052664
Other languages
English (en)
Other versions
WO2007122843A8 (fr
Inventor
Kenichi Imoto
Original Assignee
Fujifilm Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Fujifilm Corporation filed Critical Fujifilm Corporation
Publication of WO2007122843A1 publication Critical patent/WO2007122843A1/fr
Publication of WO2007122843A8 publication Critical patent/WO2007122843A8/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
    • B32B37/22—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of both discrete and continuous layers
    • B32B37/223—One or more of the layers being plastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
    • B32B37/22—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of both discrete and continuous layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/02—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
    • G—PHYSICS
    • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
    • G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
    • G03F7/16—Coating processes; Apparatus therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2457/00—Electrical equipment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/0046—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by constructional aspects of the apparatus
    • B32B37/0053—Constructional details of laminating machines comprising rollers; Constructional features of the rollers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method

Definitions

  • the present invention relates to a method of applying an elongate web continuously to substrates by way of thermal compression.
  • Substrates for liquid crystal panels, substrates for printed wiring boards , and substrates for PDP panels have a photosensitive sheet (elongate web) including a photosensitive material (photosensitive resin) layer that is applied to substrate surfaces .
  • the photosensitive sheet comprises a photosensitive material layer and a protective film, which are successively deposited on a flexible plastic support.
  • An applying apparatus for applying such a photosensitive sheet usually operates to feed substrates such as glass substrates, resin substrates, or the like at spaced intervals , peel off the protective film from the photosensitive sheet, and thereafter apply the photosensitive material layer to the substrates.
  • the applying apparatus typically includes a pair of lamination rolls heated to a predetermined temperature by induction heating or the like. The photosensitive sheet and the substrates are gripped by the lamination rolls and thermally compressed against each other.
  • the photosensitive sheet tends to suffer from various defects.
  • a laminated substrate body made up of a substrate with a defective photosensitive sheet applied thereto cannot easily be processed by a regenerating process, because of the need for peeling off the photosensitive material layer in a subsequent process and for preprocessing the substrate. Because the regenerating process is low in efficiency and highly costly, it is also difficult to reuse the substrate. Thus, it has been customary to discard such laminated substrate bodies, which have defective photosensitive sheets applied to respective substrates thereof.
  • Japanese Laid-Open Patent Publication No. 2003-62906 discloses a film laminating method. According to the film laminating method, before a film is laminated onto a substrate, the film is monitored to determine whether the film includes defects or not. If it is judged that the film includes a defect, then a region of the film, which contains the defect, is discarded, and only a non-defective area of the film is applied to the substrate.
  • the film that is positioned upstream of the lamination rolls also tends to be thermally affected thereby and lowered in quality.
  • the loss of many film pieces also makes the conventional film laminating process uneconomical.
  • a method of applying successive lengths of an elongate web to respective substrates by way of thermal compression According to this method, a heating roller, which is disposed in a bonding position, is pressed against the elongate web and rotated so as to thermally compress a portion of the elongate web against a substrate until the heating roller reaches a bonding termination angular position, for thereby producing a laminated body of the elongate web against the substrate.
  • the heating roller is moved angularly through a predetermined angle from the bonding termination angular position, thereby spacing the trailing end of the laminated body which is closest to the heating roller a predetermined distance away from the heating roller.
  • the bonding termination angular position refers to an angular position in which the heating roller is stopped from rotating before a portion of the elongate web is thermally compressed against a substrate, when successive portions of the elongate web are thermally compressed against respective substrates to produce laminated bodies.
  • the elongate web comprises a laminated multilayer web having at least a first layer and a second layer, wherein the method further comprises the step of partially cutting the elongate web while leaving a transverse portion of the laminated multilayer web, in order to form partially cut regions in the elongate web at spaced intervals each depending on the length of the substrate.
  • the heating roller is moved angularly until at least a portion of the elongate web between adjacent ones of the partially cut regions is placed on an outer circumferential surface of the heating roller, and thereafter, the heating roller is stopped from rotating.
  • the elongate web comprises a laminated multilayer web having at least a first layer and a second layer
  • the method further comprises the step of partially cutting the elongate web while leaving a transverse portion of the laminated multilayer web, in order to form partially cut regions in the elongate web at spaced ⁇ intervals each depending on the length of the substrate.
  • a partially cut region for stoppage in the elongate web is formed at a position spaced a predetermined distance from one of the partially cut regions.
  • the heating roller is rotated until at least a portion of the elongate web between the one of the partially cut regions and the partially cut region for stoppage is placed on an outer circumferential surface of the heating roller, and thereafter, the heating roller is stopped from rotating.
  • the predetermined distance between the one of the partially cut regions and the partially cut region for stoppage is smaller than an interval between adjacent ones of the partially cut regions and greater than a length of the elongate web that is thermally affected by the heating roller.
  • the method additionally comprises the step of holding a region of the elongate web, which is kept in contact with or close to the heating roller and thermally affected by the heating roller, so as to be spaced away from the heating roller. If the elongate web is to be thermally compressed once again, then the method further comprises the step of feeding a thermally affected region of the elongate web, which is judged as being kept in contact with or close to the heating roller and thermally affected by the heating roller, out of the bonding position.
  • the heating roller is rotated to thermally compress another region of the elongate web, other than the thermally affected region, against a subs ⁇ rate.
  • the heating roller is further rotated through a predetermined angle so as to space the trailing end of the laminated body, which is closest to the heating roller, a desired distance away from the heating roller. Therefore, the trailing end of the laminated body is not exposed to radiant heat from the heating roller for a long period of time.
  • a photosensitive resin layer which serves as the elongate web, is kept in good quality.
  • the laminated body is thereby prevented, in accordance with a simple process, from being thermally affected by the heating roller when it is held at rest, and the laminated body is produced efficiently and effectively with high quality.
  • FIG. 1 is a schematic side elevational view of a manufacturing apparatus , which carries out a method of applying an elongate web according to a first embodiment of the present invention
  • FIG. 2 is an enlarged fragmentary cross-sectional view of an elongate photosensitive web used in the manufacturing apparatus shown in FIG. 1
  • FIG. 3 is a fragmentary plan view of the elongate photosensitive web with adhesive labels applied thereto;
  • FIG. 4 is a diagram showing an operation sequence of the method of applying an elongate web
  • FIG. 5 is a schematic view of a portion of the manufacturing apparatus, showing the manner in which a glass substrate enters between rubber rollers;
  • FIG. 6 is a schematic view of a portion of the manufacturing apparatus , showing the manner in which the trailing end of the glass substrate is about to move out from between the rubber rollers ;
  • FIG. 7 is a schematic view illustrating a process of forming partially cut regions when a laminating process stop command is applied
  • FIG. 8 is a schematic view of a portion of the manufacturing apparatus, showing the manner in which the laminating process is stopped for a predetermined period of time
  • FIG. 9 is a schematic view of a portion of the manufacturing apparatus, showing the manner in which the apparatus operates in order to carry out a method of applying an elongate web according to a second embodiment of the present invention.
  • FIG. 10 is a schematic view illustrating a method of applying an elongate web according to a third embodiment of the present invention. Best Mode for Carrying Out the Invention
  • FIG. 1 shows in schematic side elevation an apparatus 20, which carries out a method of applying an elongate web according to a first embodiment of the present invention.
  • the manufacturing apparatus 20 operates so as to thermally transfer a photosensitive resin layer 29 (described later) of an elongate photosensitive web (elongate web) 22 onto glass substrates 24, and more specifically relates to a process for manufacturing color filters for use in liquid crystal panels or organic EL panels.
  • FIG. 2 shows in cross section the photosensitive web 22 that is employed in the manufacturing apparatus 20.
  • the photosensitive web 22 comprises a laminated assembly made up of a flexible base film (support layer) 26, a cushion layer (thermoplastic resin layer) 27, an intermediate layer
  • the photosensitive web 22 may comprise a base film 26, a photosensitive resin layer 29, and a protective film 30.
  • the base film 26 is made of PET (polyethylene terephthalate) .
  • the cushion layer 27 is made of a copolymer of ethylene and vinyl oxide.
  • the intermediate layer 28 is made of polyvinyl alcohol.
  • the photosensitive resin layer 29 is made up of a colored photosensitive resin composition, including an alkali-soluble binder, a monomer, a photopolymerization initiator, and a colorant.
  • the protective film 30 is made of polyethylene, polypropylene, or the like .
  • the manufacturing apparatus 20 comprises a web reel-out mechanism 32 for accommodating a photosensitive web roll 22a in the form of a rolled photosensitive web 22, and reeling out the photosensitive web 22 from the photosensitive web roll 22a, a partial cutting mechanism 36 for forming partially cut regions 34 (see FIG. 3), which are transversely severable in the protective film 30 of the photosensitive web 22 that is reeled out from the photosensitive web roll 22a, and a label bonding mechanism 40 for bonding adhesive labels 38 (see FIG. 3) having non-adhesion areas 38a onto the protective film 30.
  • Two partial cutting mechanisms 36 may be provided at a spaced interval in the direction indicated by the arrow A, for simultaneously forming two respective partially cut regions 34.
  • a reservoir mechanism 42 for changing the feed mode of the photosensitive web 22 from a tact feed mode (i.e., an intermittent feed mode) to a continuous feed mode, a peeling mechanism 44 for peeling certain lengths of the protective film 30 from the photosensitive web 22, a heating mechanism 45 for heating a glass substrate 24 to a predetermined temperature and for feeding the heated glass substrate 24 to a bonding position, and a bonding mechanism 46 for bonding the photosensitive resin layer 29 , which has been exposed by peeling off the protective film 30, to the glass substrate 24.
  • a joining base 49 for joining a trailing end of a - photosensitive web 22 that has essentially been used up and a leading end of a photosensitive web 22 that is to be newly used, is disposed downstream of and closely to the web reel- out mechanism 32.
  • the joining base 49 is followed downstream by a film end position detector 51, which controls a transverse shift of the photosensitive web 22 due to winding irregularities in the photosensitive web roll 22a.
  • the partial cutting mechanism 36 is disposed downstream of a pair of rollers 50 that calculate the diameter of the photosensitive web roll 22a wound in the web reel-out mechanism 32.
  • the partial cutting mechanism 36 includes a slide base 52 movable back and forth in directions perpendicular to the direction (indicated by the arrow A) in which the photosensitive web 22 is fed.
  • a rotary circular blade (cutter) 54 is fixedly mounted on the slide base 52, and a cutter bearing base 56 is disposed below the rotary circular blade 54 in confronting relation thereto, with the photosensitive web 22 interposed therebetween. As shown in FIG. 2, partially cut regions 34 need to be formed across at least the protective film 30.
  • the rotary circular blade 54 is designed to cut into both the photosensitive resin layer 29 and the intermediate layer 28, in order to reliably cut the protective film 30.
  • the partially cut regions 34 may be formed by a cutting process using a fixed circular blade or ultrasonic energy, or a cutting process using a knife blade, a strip-shaped pressing blade (Thompson blade) as described later, or the like, rather than the rotary circular blade 54.
  • the pressing blade may be pressed vertically or obliquely into the protective film 30.
  • the partially cut regions 34 serve to set a spaced interval between two adjacent glass substrates 24. Specifically, such an interval is represented by the spaced interval between two adjacent glass substrates 24 + the distance by which the partially cut regions 34 are spaced inwardly from respective edges of the glass substrates 24 - the dimension of a frame.
  • these partially cut regions 34 are formed in the protective film 30 at positions that are 10 mm spaced inwardly from respective edges of the glass substrates 24.
  • the section of the protective film 30 that is interposed between the partially cut regions 34 functions as a mask when the photosensitive resin layer 29 is applied as a frame to the glass substrate 24 in the bonding mechanism 46, as shall be described later.
  • the label bonding mechanism 40 supplies adhesive labels 38 for interconnecting a front peel-off section 30aa and a rear peel-off section 30ab, in order to leave a residual section 30b of the protective film 30 between the glass substrates 24.
  • the front peel-off section 30aa which is to be peeled off initially, and the rear peel-off section 30ab which is to be peeled off subsequently, are positioned respectively on both sides of the residual section 30b.
  • a shorter section of the protective film 30, which extends between two adjacent partially cut regions 34 has a length Ll corresponding to the interval between the partially cut regions 34
  • a longer section of the protective film 30, which extends between two adjacent partially cut regions 34 has a length L2 corresponding to a substrate length along the front peel- off section 30aa or the rear peel-off section 30ab, i.e., the length of the glass substrate 24 + the distance by which the partially cut regions 34 are spaced inwardly from the respective edges of the glass substrates 24 - the dimension of the frame.
  • each of the adhesive labels 38 has a rectangular strip shape and is made of the same resin material as the protective film 30.
  • Each of the adhesive labels 38 includes a non-adhesion (or slightly adhesive) area 38a positioned centrally, which is free of an adhesive, and a first adhesion area 38b and a second adhesion area 38c, which are disposed respectively on longitudinally opposite ends of the non-adhesion area 38a, i.e., on longitudinally opposite end portions of the adhesive label 38.
  • the first adhesion area 38b and the second adhesion area 38c are bonded respectively to the front peel-off section 30aa and to the rear peel-off section 30ab.
  • the label bonding mechanism 40 has suction pads 58a through 58e, for applying a maximum of five adhesive labels 38 at spaced intervals.
  • a support base 59 • which is movable vertically for holding the photosensitive web 22 from below, is disposed in a position where the adhesive labels 38 are applied to the photosensitive web 22 by suction pads 58a through 58e.
  • the reservoir mechanism 42 serves to absorb a speed difference between a tact feed mode, in which the photosensitive web 22 is fed upstream of the reservoir mechanism 42, and a continuous feed mode, in which the photosensitive web 22 is fed downstream of the reservoir mechanism 42.
  • the reservoir mechanism 42 preferably has a dancer 61, comprising two swingable ganged rollers 60, for preventing the photosensitive web 22 from experiencing variations in tension.
  • the dancer 61 may have one to three or more ganged rollers 60, depending on the length of the photosensitive web 22 being reserved.
  • the peeling mechanism 44 which is disposed downstream of the reservoir mechanism 42, comprises a suction drum 62 and a peeling roller 64 that is held in line contact with the outer circumferential surface of the suction drum 62, with the photosensitive web 22 being interposed therebetween.
  • the protective film 30 that is peeled off from the photosensitive web 22 at a sharp peel-off angle through the peeling roller 64 is wound, except for a residual section 30b thereof, by a protective film takeup shaft 66.
  • the protective film takeup shaft 66 is coupled to a torque motor 68, for example, for applying a predetermined tension to the protective film 30.
  • a tension control mechanism 76 which imparts tension to the photosensitive web 22, is disposed downstream of the peeling mechanism 44.
  • the tension control mechanism 76 includes a cylinder 78, which is actuatable to angularly displace a tension pickup roller 80, in order to adjust the tension of the photosensitive web 22 that the tension pickup roller 80 is held in rolling contact with.
  • the tension control mechanism 76 may be employed only when necessary, or may be dispensed with.
  • the detecting mechanism 47 includes a photoelectric sensor 82, such as a laser sensor, a photosensor, or the like, for directly detecting a change in the photosensitive web 22 due to wedge-shaped grooves formed in the partially cut regions 34, or due to steps produced by different thicknesses of the protective films 30, or a combination thereof.
  • a detected signal from the photoelectric sensor 82 is used as a boundary position signal that represents a boundary position in the protective film 30.
  • the photoelectric sensor 82 is disposed in confronting relation to a backup roller 83.
  • a non-contact displacement gauge, or an image inspecting means such as a CCD camera or the like, may be employed instead of the photoelectric sensor 82.
  • Positional data of the partially cut regions 34 which are detected by the detecting mechanism 47, can be statistically processed and converted into graphical data in real time.
  • the manufacturing apparatus 20 may generate a warning.
  • the manufacturing apparatus 20 may employ a different system for generating boundary position signals.
  • the partially cut regions 34 are not directly detected, but marks are applied to the photosensitive web 22.
  • holes or recesses may be formed in the photosensitive web 22 near the partially cut regions 34 in the vicinity of the partial cutting mechanism 36, or the photosensitive web 22 may be slit by a laser beam or an aqua jet, or may be marked by an ink jet or a printer.
  • the heating mechanism 45 includes a feed mechanism 84 for feeding glass substrates 24 as workpieces in the direction indicated by the arrow C.
  • the feed mechanism 84 has a plurality of disk-shaped feed rollers 86 formed of synthetic resin, which are arrayed in the direction indicated by the arrow C.
  • the heating mechanism 45 also has a receiver 88 for receiving glass substrates 24, which is disposed upstream of the feed mechanism 84 in the direction indicated by the arrow C.
  • the heating mechanism 45 further includes a plurality of heating furnaces 90 disposed downstream of the receiver 88.
  • the heating mechanism 45 monitors the temperature of the glass substrates 24 at all times. In the event that the - heating mechanism 45 detects an abnormal temperature, the heating mechanism 45 stops the feed rollers 86, or issues a warning, and transmits information indicating a malfunction, which may be used to eject an abnormal glass substrate 24, or which may also be used for quality control or production management.
  • the feed mechanism 84 may have an air-lifting plate (not shown) for lifting the glass. substrates 24 while they are being fed in the direction indicated by the arrow C.
  • a substrate storage frame 100 for storing a plurality of glass substrates 24 is disposed upstream of the heating mechanism 45.
  • the substrate storage frame 100 includes dust removing fan units (or duct units) 102, which are disposed on three respective sides of the substrate storage frame 100, except for a charging slot and a discharging slot portion thereof.
  • the fan units 102 eject electrically neutralizing clean air into the substrate storage frame 100.
  • the glass substrates 24 stored in the substrate storage frame 100 are attracted one by one through suction pads 106 provided on a hand 104a of a robot 104, and are taken out from the substrate storage frame 100 and inserted into the receiver 88.
  • the bonding mechanism 46 has a pair of vertically spaced laminating rubber rollers (heating rollers) 110a, 110b that are heated to a predetermined temperature.
  • Backup rollers 112a, 112b are held in rolling contact with the respective laminating rubber rollers 110a, 110b.
  • the backup roller 112b is pressed against the laminating rubber roller 110b by a roller clamp unit 114.
  • a contact prevention roller 116 is movably disposed near to the rubber roller 110a, for preventing the photosensitive web 22 from contacting the rubber roller 110a.
  • the contact prevention roller 116 is movable by an actuator (not shown) .
  • Film feed rollers 118a and substrate feed rollers 118b are disposed between the bonding mechanism 46 and the inter- substrate web cutting mechanism 48.
  • a cooling mechanism 120 is disposed downstream of the inter-substrate web cutting mechanism 48, and a base peeling mechanism 122 is disposed downstream of the cooling mechanism 120.
  • the cooling mechanism 120 supplies cold air onto a bonded substrate 24a, after the photosensitive web 22 has been cut off between the bonded substrate 24a and a subsequent bonded substrate 24a, by the inter-substrate web cutting mechanism 48.
  • the cooling mechanism 120 supplies cold air having a temperature of 10° C at a rate ranging from 1.0 to 2.0 m/min.
  • the cooling mechanism 120 may be dispensed with, and the bonded substrate 24a may be cooled naturally within a photosensitive laminated body storage frame 136, as shall be described later.
  • the base peeling mechanism 122 disposed downstream of the cooling mechanism 120 has a plurality of suction pads 124 for attracting the lower surface of a bonded substrate 24a. While the bonded substrate 24a is attracted under suction by the suction pads 124, the base film 26 and the residual section 30b are peeled off from the bonded substrate 24a by a robot hand 126. Electrically neutralizing air blowers (not shown) , for ejecting electrically neutralizing clean air to four sides of the laminated area of the bonded substrate 24a, are disposed upstream, downstream, and laterally of the suction pads 124. The base film 26 and the residual section 30b may be peeled off from the bonded substrate 24a, while a table for supporting the bonded substrate 24a thereon is oriented vertically, obliquely, or turned upside down for facilitating dust removal.
  • the base peeling mechanism 122 is followed downstream by the photosensitive laminated body storage frame 136, for storing a plurality of photosensitive laminated bodies 130.
  • a photosensitive laminated body 130 which is produced when the base film 26 and the residual section 30b are peeled off from the bonded substrate 24a by the base peeling mechanism 122, is attracted by suction pads 134 provided on a hand 132a of a robot 132. Accordingly, the photosensitive laminated body 130 is taken out from the base peeling mechanism 122, and then placed into the photosensitive laminated body storage frame 136.
  • the photosensitive laminated body storage frame 136 has dust removing fan units (or duct units) 102 disposed on three respective sides , except for a charging slot and a discharging slot portion thereof.
  • the fan units 102 eject electrically neutralizing clean air into the photosensitive laminated body storage frame 136.
  • the web reel-out mechanism 32, the partial cutting mechanism 36, the label bonding mechanism 40, the reservoir mechanism 42, the peeling mechanism 44, the tension control mechanism 76, and the detecting mechanism 47 are disposed above the bonding mechanism 46.
  • the web reel-out mechanism 32, the partial cutting mechanism 36, the label bonding mechanism 40, the reservoir mechanism 42, the peeling mechanism 44, the tension control mechanism 76, and the detecting mechanism 47 may be disposed below the bonding mechanism 46, so as to apply the photosensitive resin layer 29, which is turned upside down, onto a lower surface of the glass substrate 24.
  • the components of the manufacturing apparatus 20 may be arranged in a linear pattern as a whole.
  • the manufacturing apparatus 20 is controlled in its entirety by a lamination process controller 140.
  • the manufacturing apparatus 20 also has a lamination controller 142, a substrate heating controller 144, and a base peeling controller 146, etc., for controlling the different functional components of the manufacturing apparatus 20. These controllers are interconnected by an in-process network.
  • the lamination process controller 140 is connected to the network of a factory, which incorporates the manufacturing apparatus 20 therein, and which performs information processing for production, e.g., production management and mechanism operation management, based on instructional information (condition settings and production information) from a factory CPU (not shown).
  • the lamination controller 142 serves as a process master for controlling the functional components of the manufacturing apparatus 20.
  • the lamination controller 142 operates as a control mechanism for controlling the heating mechanism 45, for example, based on positional information. detected by the detecting mechanism 47, of the partially cut regions 34 of the photosensitive web 22.
  • the base peeling controller 146 controls the base peeling mechanism 122 to peel off the base film 26 from the bonded substrate 24a that is supplied from the bonding mechanism 46, and also to discharge the photosensitive laminated body 130 to a downstream process.
  • the base peeling controller 146 also handles information about the bonded substrate 24a and the photosensitive laminated body 130.
  • the installation space of the manufacturing apparatus 20 is divided by a partition wall 150 into a first clean room 152a and a second clean room 152b.
  • the first clean room 152a houses therein various components ranging from the web reel-out mechanism 32 to the tension control mechanism
  • the second clean room 152b houses therein the detecting mechanism 47 along with the other components following the detecting mechanism 47.
  • the first clean room 152a and the second clean room 152b are connected to each other by a through region 154.
  • the photosensitive web 22 is reeled out from the photosensitive web roll 22a in the web reel-out mechanism 32, and is fed to the partial cutting mechanism 36 .
  • the slide base 52 moves transversely across the photosensitive web 22, perpendicularly to the direction (indicated by the arrow A) in which the photosensitive web 22 is fed.
  • the rotary circular blade 54 cuts a desired depth into the partially cut region 34 of the photosensitive web 22, and rotates while moving transversely across the photosensitive web 22. Therefore, a slit, which is cut to the desired depth from the protective film 30, is formed in the partially cut region 34 of the photosensitive web 22 (see FIG. 2).
  • the photosensitive web 22 that has thus been partially cut is fed a distance corresponding to the dimension of the residual section 30b of the protective film 30, in the direction indicated by the arrow A, and then is stopped, whereupon a next partially cut region 34 is formed therein by the rotary circular blade 54.
  • a front peel-off section 30aa and a rear peel-off section 30ab are now provided in the photosensitive web 22, with the residual section 30b being interposed therebetween.
  • the photosensitive web 22 is fed to the label bonding mechanism 40 so as to position a bonding area of the protective film 30 on the support base 59.
  • the label bonding mechanism 40 a predetermined number of adhesive labels 38 are attracted under suction and held by the suction pads 58a through 58e, and are securely bonded to the front peel-off section 30aa and the rear peel-off section 30ab of the protective film 30, across the residual section 3Ot) thereof (see FIG. 3).
  • the photosensitive web 22 with five adhesive labels 38 bonded thereto, for example, is isolated by the reservoir mechanism 42 from variations in tension to which the supplied photosensitive web 22 is subjected, and then is continuously fed to the peeling mechanism 44.
  • the photosensitive web 22 is sandwiched between the suction drum 62 and the peeling roller 64, and the base film 26 of the photosensitive web 22 is attracted to the suction drum 62.
  • the suction drum 62 is rotated, whereupon the protective film 30 is tensioned by the torque motor 68.
  • the protective film 30 is peeled off from the photosensitive web 22, leaving the residual section 30b.
  • the protective film 30 is peeled off at a sharp peel-off angle by the peeling roller 64, and is wound by the protective film takeup shaft 66. It is preferable to apply an electrically neutralizing air flow to the region where the protective film 30 is peeled off.
  • the photosensitive web 22 is adjusted in tension by the tension control mechanism 76. Then, the partially cut regions 34 of the photosensitive web 22 are detected by the photoelectric sensor 82 of the detecting mechanism 47.
  • a laminating process is performed according to an operation sequence shown in FIG. 4.
  • the photosensitive web 22 is fed a predetermined distance toward the bonding mechanism 46 by the film feed roller 118a. Thereafter, the photosensitive web 22 is fed a predetermined distance toward the bonding mechanism 46 by the substrate feed rollers 118b, which grip a bonded substrate 24a, based on the detected information of the partially cut regions 34.
  • the contact prevention roller 116 waits above the photosensitive web 22, while the rubber roller 110b is disposed below the photosensitive web 22.
  • the heating temperatures inside the heating furnaces 90 are set to values depending • on the lamination temperature in the bonding mechanism 46.
  • the robot 104 grips a glass substrate 24 stored in the substrate storage frame 100, and introduces the gripped glass substrate 24 into the receiver 88.
  • the glass substrate 24 is fed by the feed rollers 86 of the feed mechanism 84 successively from the receiver 88 to the heating furnaces 90 in the tact feed mode.
  • the heating furnace 90 at the downstream end of the heating mechanism 45 in the direction indicated by the arrow C, the glass substrate 24 is stopped accurately in a given stop position.
  • the glass substrate 24 is temporarily positioned between the rubber rollers 110a, 110b, in alignment with the bonded region of the photosensitive resin layer 29 of the photosensitive web 22 (see FIG. 5). Then, the roller clamp unit 114 is operated to lift the backup roller 112b and the rubber roller 110b, in order to clamp the glass substrate 24 under a predetermined pressure between the rubber rollers 110a, 110b. The rubber roller 110a is rotated so as to transfer, i.e., laminate, the photosensitive resin layer 29, which is melted by heat, onto the glass substrate 24.
  • the photosensitive resin layer 29 is laminated onto the glass substrate 24 under conditions such that the photosensitive resin layer 29 is fed at a speed in the range from 1.0 m/min. to 10.0 m/min., the rubber rollers 110a, 110b have a temperature ranging from 80° C to 140 0 C, and a hardness ranging from 40 to 90, and the applied pressure (linear pressure) from the rubber rollers 110a, 110b ranges from 50 N/cm to 400 N/cm.
  • the rubber roller 110a is stopped from rotating.
  • the angular position at which the rubber roller 110a is stopped from rotating is referred to as a bonding termination angular position.
  • the bonded substrate 24a, with the photosensitive web 22 laminated on the glass substrate 24, is clamped by the substrate feed rollers 118b.
  • the rubber roller 110b is retracted away from the rubber roller 110a, thereby unclamping the photosensitive web 22.
  • the lamination of one unit length of photosensitive web 22 is now finished (time tl in FIG. 4).
  • a glass substrate 24, which is heated to the predetermined temperature by the heating mechanism 45, is fed and positioned between the rubber rollers 110a, 110b.
  • the photosensitive web 22 is held in contact with the rubber roller 110a and is fed slightly thereby.
  • the rubber roller 110a starts rotating at a low speed.
  • the photosensitive web 22 that is held in contact with the rubber roller 110a is fed a predetermined distance in the direction indicated by the arrow C, until a time T3.
  • the substrate feed rollers 118b are rotating at a low speed in synchronism with the rubber roller 110a, to slightly feed the bonded substrate 24a in the direction indicated by the arrow C.
  • next laminating cycle is initiated.
  • a time T5 elapses, a next bonded substrate 24a is produced.
  • the photosensitive web 22 is fed slightly by the rubber roller 110a.
  • the laminating process is suspended continuously for a certain period of time, e.g., 90 seconds, or more.
  • the laminating process is suspended when the photosensitive web roll 22a in the web reel-out mechanism 32 is to be replaced with a new photosensitive web roll 22a.
  • the trailing end of the last bonded substrate 24a is positioned near the rubber roller 110a, and tends to be adversely- affected by radiant heat from the rubber roller 110a.
  • a photosensitive web 22, which has been partially cut to a predetermined length corresponding to the length of a next glass substrate 24 upstream of the rubber roller 110a, is also susceptible to the radiant heat from the rubber roller 110a.
  • the position where partially cut regions are to be formed is changed, so as to reduce any length of the photosensitive web 22 that will have to be discarded.
  • the photosensitive web 22 is continuously fed without stoppage, and as shown in FIG. 7, partially cut regions 34c for stoppage are formed at a position forward of partially cut regions 34b, which are next to preceding partially cut regions 34a that have already been produced by the partial cutting mechanism 36.
  • the partially cut regions 34a and the partially cut regions 34c are spaced from each other by a distance L3.
  • the distance L3 is smaller than a distance L2 between the partially cut regions 34a and the partially cut regions 34b, and greater than a distance within which the photosensitive web 22 would be thermally affected by the rubber roller 110a, which acts as a heating roller.
  • the distance L3 1/2 x the distance L2.
  • the photosensitive web 22, with partially cut regions 34 formed therein immediately in front of a region 22b extending between the partially cut regions 34a and the partially cut regions 34c for stoppage, is applied to and laminated onto the glass substrate 24 progressively from the trailing end of the bonded substrate 24a which has been laminated initially (see times TnI - Tn4 in Fig. 4).
  • the region 22b reaches a position immediately before the bonding mechanism 46, as shown in FIG. 8, the rubber roller 110b is spaced from the rubber roller 110a. While the glass substrate 24 is not being fed between the rubber rollers 110a, 110b, the rubber roller 110a is rotated (times Tn5 - Tn6 in FIG. 4).
  • the rubber roller 110a is rotated through a certain angular range, and the substrate feed roller 118b is rotated in synchronism with the rubber roller 110a. Therefore, the bonded substrate 24a produced immediately prior to the region 22b is moved a certain distance in the direction indicated by the arrow C.
  • a substantially central portion of the region 22b is disposed on the outer circumferential surface of the rubber roller 110a, and the distance h between the trailing end of the bonded substrate 24a and the rubber roller 110a reaches a predetermined distance, whereupon the rubber roller 110a and the substrate feed roller 118b stop rotating (time Tn6 in FIG. 4).
  • the trailing end of the bonded substrate 24a is not exposed for a prolonged period of time to radiant heat from the rubber roller 110a.
  • the photosensitive resin layer 29 is kept in good quality. According to a simple process, the bonded substrate 24a is thus prevented from being thermally affected by the rubber roller 110a when it is held at rest. The bonded substrate 24a is prevented from becoming defective, and thus bonded substrates can be produced efficiently and effectively with high quality.
  • the partially cut regions 34c for stoppage are formed in the photosensitive web 22, wherein the partially cut regions 34c are spaced from the partially cut regions 34a by a distance L3, which is smaller than the distance L2 between the partially cut regions 34a, 34b.
  • the region 22b, which extends between the partially cut regions 34a and the partially cut regions 34c for stoppage is placed in contact with the outer circumferential surface of the rubber roller 110a, the rubber roller 110a is stopped from rotating.
  • the range in which the photosensitive web 22 is thermally affected by the rubber roller 110a is reduced from one unit length (corresponding to the distance L2) to be laminated of the photosensitive web 22 to a shorter length (corresponding to the distance L3), which is about one half the one unit length. Consequently, the portion of the photosensitive web 22 which could be rendered defective by radiant heat is limited within one unit length to be laminated of the photosensitive web 22, and the yield of the photosensitive web 22 is effectively prevented from being lowered.
  • the rubber roller 110a is rotated to feed the region 22b of the photosensitive web 22, which is judged as having been thermally affected by the rubber roller 110a, over a distance corresponding to one half of one unit length of the photosensitive web 22, in the direction indicated by the arrow C. After the possibly defective region 22b has been fed downstream from the bonding position, lamination of the next unit length of the photosensitive web 22 onto a next glass substrate 24 is initiated.
  • the region 22b i.e., the possibly defective portion of the photosensitive web 22, which is judged as being thermally affected by the rubber roller 110a in contact therewith or in the vicinity thereof, is not laminated onto the glass substrate 24.
  • defective bonded substrates 24a are prevented from being produced.
  • the bonded substrate 24a which comprises the glass substrate 24 with the photosensitive web 22 bonded thereto, is fed a certain distance in the direction indicated by the arrow C, is cooled by the cooling mechanism 120, and then is delivered to the base peeling mechanism 122.
  • the base peeling mechanism 122 while the bonded substrate 24a is attracted by the suction pads 124, the base film 26 and the residual section 30b are peeled off by the robot hand 126, thereby producing the photosensitive laminated body 130.
  • a method of applying an elongate web according to a second embodiment of the present invention shall be described below with reference to FIG. 9.
  • the method of applying the elongate web according to the second embodiment may also be carried out using the manufacturing apparatus 20 shown in FIG. 1.
  • the trailing end of the bonded substrate 24a which is closest to the rubber roller 110a, is spaced a predetermined distance in the direction indicated by the arrow C.
  • the contact prevention roller 116 is displaced downwardly in order to bring the photosensitive web 22 out of contact with the rubber roller 110a.
  • the suction drum 62 is fixed against rotation by a brake (not shown) , and the cylinder 78 of the tension control mechanism 76 is actuated in order to move the tension pickup roller 80 in synchronism with the contact prevention roller 116.
  • the photosensitive web 22 when the photosensitive web 22 is spaced away from the rubber roller 110a by the contact prevention roller 116, the photosensitive web 22 extends through a path of constant length.
  • a method of applying an elongate web according to a third embodiment of the present invention shall be described below with reference to FIG. 10. The method of applying an elongate web according to the third embodiment may also be carried out using the manufacturing apparatus 20 shown in FIG. 1.
  • the rubber roller HOa is continuously rotated.
  • a region 22c of the photosensitive web 22, which lies between the partially cut regions 34 and the partially cut regions 34a has a substantially central area thereof positioned on the outer circumferential surface of the rubber roller HOa, the rubber roller HOa is stopped from rotating.
  • the area of the photosensitive web 22 that is thermally affected by the rubber roller HOa is reduced from two unit lengths thereof, which has heretofore been laminated, to one unit length of the photosensitive web 22. As a result, the yield of the photosensitive web 22 is effectively prevented from being lowered.
  • the rotation of the rubber roller HOa may simply be controlled to hold the substantially central area of the region 22c between the partially cut regions 34, 34a on the outer circumferential surface of the rubber roller HOa, it is possible to produce high-quality bonded substrates 24a efficiently and economically, through a simple control process .
  • the methods of applying the elongate web have been described as being carried out by the manufacturing apparatus 20, which thermally transfers the photosensitive resin layer 29 of the single elongate photosensitive web 22 onto the glass substrate 24.
  • the present invention is not solely limited to this application.
  • the methods according to the present invention may also be carried out by a manufacturing apparatus, which thermally transfers photosensitive resin layers of two parallel single elongate photosensitive webs onto the same glass substrate.

Landscapes

  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Materials For Photolithography (AREA)

Abstract

A rubber roller (110a) is pressed against a photosensitive web (22) and rotated to thermally compress the photosensitive web (22) against a glass substrate (24), thereby producing a bonded substrate (24a). If it is judged that the rubber roller (110a) will be stopped against rotation for a predetermined period of time, then the rubber roller (110a) is rotated a predetermined angle. Thus, the trailing end of the bonded substrate (24a) that is closest to the rubber roller (110a) becomes spaced a desired distance from. the rubber roller (110a), and hence is prevented from being adversely affected by radiant heat from the rubber roller (110a).
PCT/JP2007/052664 2006-03-28 2007-02-08 Method of applying elongate web WO2007122843A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP2006088144A JP4698462B2 (ja) 2006-03-28 2006-03-28 長尺状ウエブの貼り付け方法
JP2006-088144 2006-03-28

Publications (2)

Publication Number Publication Date
WO2007122843A1 true WO2007122843A1 (fr) 2007-11-01
WO2007122843A8 WO2007122843A8 (fr) 2007-12-27

Family

ID=38169431

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/JP2007/052664 WO2007122843A1 (fr) 2006-03-28 2007-02-08 Method of applying elongate web

Country Status (5)

Country Link
JP (1) JP4698462B2 (fr)
KR (1) KR20080106518A (fr)
CN (1) CN101405140A (fr)
TW (1) TW200744826A (fr)
WO (1) WO2007122843A1 (fr)

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP6205212B2 (ja) * 2013-08-30 2017-09-27 日東電工株式会社 フィルム積層体の製造方法及びフィルム積層体の製造設備
CN105197659A (zh) * 2015-08-26 2015-12-30 蚌埠市高德机械自动化科技有限公司 一种滤清器滤芯板的自动烫布机
KR101668439B1 (ko) * 2015-11-10 2016-10-21 임재균 전자기 유도가열 구조를 갖는 라미네이터
KR102124281B1 (ko) * 2019-11-11 2020-06-17 김선학 복합원단 제조장치 및 그에 의해 제조된 복합원단

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0550811A1 (fr) * 1992-01-10 1993-07-14 Somar Corporation Appareil pour la lamination humide
US5728252A (en) * 1995-09-19 1998-03-17 Polaroid Corporation Method and apparatus for laminating image-bearing media
US5807461A (en) * 1996-05-09 1998-09-15 Fargo Electronics, Inc. Lamination technique
US6264296B1 (en) * 1997-05-06 2001-07-24 Fargo Electronics, Inc. Ink jet identification card printer with lamination station
US6986376B1 (en) * 2004-11-24 2006-01-17 Gmp Co., Ltd. Device for actuation of rollers using a feed tray in a laminator

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR20010024542A (ko) * 1997-10-24 2001-03-26 파고 일렉트로닉스 인코포레이티드 적층 스테이션을 구비하는 ｉｄ 카드 잉크젯 프린터
JP3701221B2 (ja) * 2001-08-27 2005-09-28 株式会社 日立インダストリイズ フィルムラミネート方法とその装置
JP4006534B2 (ja) * 2003-02-19 2007-11-14 株式会社日立プラントテクノロジー フィルム貼付方法及びその装置

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0550811A1 (fr) * 1992-01-10 1993-07-14 Somar Corporation Appareil pour la lamination humide
US5728252A (en) * 1995-09-19 1998-03-17 Polaroid Corporation Method and apparatus for laminating image-bearing media
US5807461A (en) * 1996-05-09 1998-09-15 Fargo Electronics, Inc. Lamination technique
US6264296B1 (en) * 1997-05-06 2001-07-24 Fargo Electronics, Inc. Ink jet identification card printer with lamination station
US6986376B1 (en) * 2004-11-24 2006-01-17 Gmp Co., Ltd. Device for actuation of rollers using a feed tray in a laminator

Also Published As

Publication number Publication date
KR20080106518A (ko) 2008-12-08
TW200744826A (en) 2007-12-16
CN101405140A (zh) 2009-04-08
JP2007261046A (ja) 2007-10-11
WO2007122843A8 (fr) 2007-12-27
JP4698462B2 (ja) 2011-06-08

Similar Documents

Publication Publication Date Title
WO2006129870A2 (fr) Procede et appareil permettant de decouper partiellement un film stratifie
WO2007122892A1 (fr) Procédé et dispositif de découpe partielle d'une pellicule laminée
WO2007034762A1 (fr) Dispositif et procédé de décollement de corps stratifié
US20090044900A1 (en) Method of and apparatus for laminated substrate assembly
US20090075225A1 (en) Heating apparatus and heating method
WO2007034991A1 (fr) Procede d'application de bande
JP2007320678A (ja) 外層体の剥離方法及び剥離装置
CN101272911B (zh) 制备感光层压体的装置和方法
WO2007122843A1 (fr) Method of applying elongate web
JP2008110488A (ja) 感光性ウエブの剥離装置及び剥離方法
US20090078365A1 (en) Apparatus for and method of manufacturing photosensitive laminated body
EP1771772B1 (fr) Appareil et procede pour la fabrication d'un corps stratifie photodensible
US20090050261A1 (en) Apparatus for and Method of Manufacturing Photosensitive Laminated Body
JP4774243B2 (ja) 感光性積層体の製造装置及び製造方法
JP2011140232A (ja) 感光性積層体の製造装置及び製造方法
TWI338619B (en) Apparatus for and method of manufacturing photosensitive laminated body
JP4881585B2 (ja) 感光性積層体の製造装置及び製造方法
CN100528560C (zh) 用于制造感光层叠体的装置和方法
WO2006098497A1 (fr) Dispositif et procede permettant de fabriquer un corps lamine photosensible
TWI356766B (en) Apparatus for and method of manufacturing photosen

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 07708395

Country of ref document: EP

Kind code of ref document: A1

WWE Wipo information: entry into national phase

Ref document number: 1020087019920

Country of ref document: KR

WWE Wipo information: entry into national phase

Ref document number: 200780009444.X

Country of ref document: CN

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 07708395

Country of ref document: EP

Kind code of ref document: A1

点击 这是indexloc提供的php浏览器服务，不要输入任何密码和下载