JP4124022B2

JP4124022B2 - Bonding apparatus and bonding method

Info

Publication number: JP4124022B2
Application number: JP2003138119A
Authority: JP
Inventors: 賢二竹政; 宏道板橋
Original assignee: Sony Corp
Current assignee: Sony Corp
Priority date: 2003-01-23
Filing date: 2003-05-16
Publication date: 2008-07-23
Anticipated expiration: 2023-05-16
Also published as: JP2004276579A

Description

【０００１】
【発明の属する技術分野】
本発明は、例えばタッチパネルやフラットディスプレイ、円盤状記録メディア等の製造工程等において、薄物シートやそれに類似するものを樹脂・ガラス製の基板に貼り合せる貼り合わせ装置および貼り合わせ方法に関する。
【０００２】
【従来の技術】
フラットディスプレイやタッチパネルの製造工程において、接着剤が塗布されたシートやフィルム、偏光板等をプラスチックやガラス等の基板に貼り付ける機会は多くあり、それを実現する設備も数多く存在している。
【０００３】
例えば、液晶セルを偏光板に貼り付ける装置としては以下の特許文献１に示すような装置が用いられていた。
【０００４】
【特許文献１】
特開平６−１０２５０５号公報。
【０００５】
図１４は特許文献１に開示されている貼り合わせ方法の一例を示している。まず図１４（ａ）において、一端が回動自在に軸支された上部ステージ１の他端にはローラ２が回転可能に配設され、該上部ステージ１の保持面（このときは上向きとなっている）に第１の部材３を載置するとともに、下部ステージ４の保持面に第２の部材５を載置し、それら第１および第２の部材３、５をバキュームによって吸引保持する。
【０００６】
次に図１４（ｂ）に示すように、上部ステージ１のローラ側端を回転させて、第１の部材３の貼り合わせ開始端をローラ２によって第２の部材５に接着させる。
【０００７】
そして図１４（ｃ）に示すように下部ステージ４を図示矢印方向に移動させて、ローラ２によって第１の部材３と第２の部材５の貼り合わせを行っている。
【０００８】
【発明が解決しようとする課題】
しかしながら前記図１４の貼り合わせ方法では、貼り合せ開始時（図１４（ｂ））において、前記ローラ２が上方より突き当てられることにより、貼り合せ後のワーク（第１、第２の部材３、５）に目視確認が可能な「押し跡」が発生してしまう（特に貼り合せ開始部）場合が確認されている。この「押し跡」が品質に悪影響を与え、歩留まりの低下を招いている。
【０００９】
そこでこの「押し跡」問題を解消する方法としては、貼り合せる2つの対象物を同期させながら貼り合せ機構部に挿入する方法が挙げられる。
【００１０】
すなわち例えば図１５（ａ）〜（ｃ）に示すように、ローラ２は移動させずに固定とし、該ローラ２の近傍に第１の部材３を保持した上部ステージ１１と第２の部材５を保持した下部ステージ４を、各保持面が所定の角度をもって対向するように配設し、上部ステージ１１および下部ステージ４を例えばサーボモータによって速度制御しながら図示矢印方向に移動させ、第１および第２の部材３、５を同一速度で同時に下部ステージ４とローラ２間の隙間に挿入し貼り合わせることが考えられる。
【００１１】
しかし前記のようにサーボモータを使用することは、貼り合わせ装置のコストアップと大型化を招き、前記上部および下部ステージ１１、４の移動速度の調整や、前記第１および第２の部材３、５の貼り合わせ開始位置の調整等、制御の煩雑さが生じてしまう。
【００１２】
本発明は上記の点に鑑みてなされたものでその目的は、サーボモータ等の高額な機器および特別な制御を用いずに、押し跡の発生を防止して良好に貼り合わせを行うことができる貼り合わせ装置および貼り合わせ方法を提供することにある。
【００１３】
【課題を解決するための手段】
本発明では、前記第１と第２の部材を同一速度で移動させ、前記第１と第２の部材の貼り合わせ開始端を、同時に固定ローラの外径部と前記下部ステージとで形成される隙間に挿入する機構と、前記第１と第２の部材の貼り合わせ開始の位置を自在に調整できる機構を、例えばエアーシリンダを使用したメカ機構のみで貼り合わせ機に取り入れるように構成した。
【００１４】
すなわち、本発明の貼り合わせ装置は、少なくともいずれか一方に接着剤が塗布された第１および第２の部材を貼り合わせる貼り合わせ装置であって、弾性を有するとともに所定径を有した回転可能な筒体と、前記筒体の回転中心軸と平行であって、該筒体の外周表面の所定部位に存在する第１の軸平行線と、該第１の軸平行線に直交する第１の直交線とで形成される第１の平面上に、第１の部材を保持する第１の保持手段と、前記筒体の外周表面から所定距離離間し、前記第１の軸平行線と平行であり、且つ前記第１の平面の、前記筒体と反対側の面に対向して存在する第２の軸平行線と、該第２の軸平行線に直交し且つ前記第１の平面に対して所定角度を有した第２の直交線とで形成される第２の平面上に、第２の部材を保持する第２の保持手段と、前記第１の保持手段を、前記第１の平面のうち、第１の軸平行線を境とする一方側の平面領域で、前記第１の直交線に沿って第１の速度で移動させる第１の移動手段と、前記第２の保持手段を、前記第２の平面のうち、第２の軸平行線を境とする一方側の平面から他方側の平面に、前記第２の直交線に沿って、前記第１の速度よりも遅い第２の速度で移動させる第２の移動手段と、前記第１の部材および第２の部材の各端部が、前記第１の軸平行線と第２の軸平行線との間に形成される隙間に挿入される位置で、前記第１の保持手段の移動を停止させる第１の移動停止手段とを備え、前記第１の部材および第２の部材を、前記隙間内で貼り合わせることを特徴としている。
【００１５】
また前記第１の移動停止手段は、前記第１の保持手段の移動停止位置を任意に設定変更できるように構成されていることを特徴としている。
【００１６】
また前記第１の保持手段には、該第１の保持手段の移動時に前記第２の保持手段に当接する当接片が設けられ前記第１の移動手段の移動推力は前記第２の移動手段の移動推力よりも小さく設定されていることを特徴としている。
【００１７】
また前記所定角度を任意に設定する角度設定手段を備えたことを特徴としている。
【００１８】
また前記第１の移動停止手段は、前記筒体と前記第１の保持手段の間に配設されたストッパを有し、前記第１の保持手段の前記筒体側端部には、前記ストッパに当接する当接部と、該当接部から所定距離前記筒体側に延設された延長保持面とが形成されていることを特徴としている。
【００１９】
また前記第１の保持手段は所定の吸引力によって第１の部材を保持することを特徴としている。
【００２０】
また前記第１の保持手段は、その保持面に多孔質材を有していることを特徴としている。
【００２１】
また前記隙間の間隔を調整する隙間調整手段を備えたことを特徴としている。
【００２２】
また前記隙間の間隔は、前記第１の部材および第２の部材の合計厚みと同一か又はそれ以下に形成されていることを特徴としている。
【００２３】
また前記第１の保持手段を前記第１の平面位置以外の位置に移動させる基体を備えたことを特徴としている。
【００２４】
また前記第１の移動手段は第１のエアーシリンダを備え、前記第２の移動手段は第２のエアーシリンダを備えていることを特徴としている。
【００２５】
また前記第１の部材はプラスチックの板材、シートもしくはフィルムであり、前記第２の部材は金属、プラスチックもしくはガラスの基板であることを特徴としている。
【００２６】
また、前記第１の部材の貼り合わせ終端部を受ける接触面を有し、前記第２の保持手段に一体的に保持されるとともに、前記第２の部材の貼り合わせ終端部側の前記第１の部材に対向する部位であって、前記第２の部材から所定距離隔てた部位に配設された受け機構と、前記受け機構の前記隙間に対向する側の先端位置が、前記隙間近傍の所定位置まで移動したときに前記受け機構の移動を停止させる第２の移動停止手段とを備えたことを特徴としている。
【００２７】
また前記第２の移動停止手段は、前記受け機構の移動停止位置を任意に設定変更できるように構成されていることを特徴としている。
【００２８】
また前記受け機構の接触面は、前記第１の部材の貼り合わせ終端部と線接触できる傾斜面に形成されていることを特徴としている。
【００２９】
また前記受け機構の接触面は、接着剤の転写を抑制する表面処理が施されていることを特徴としている。
【００３０】
また本発明の貼り合わせ方法は、少なくともいずれか一方に接着剤が塗布された第１および第２の部材を貼り合わせる貼り合わせ方法であって、弾性を有するとともに所定径を有した回転可能な筒体と、前記筒体の回転中心軸と平行であって、該筒体の外周表面の所定部位に存在する第１の軸平行線と、該第１の軸平行線に直交する第１の直交線とで形成される第１の平面上に、第１の部材を保持する第１の保持手段と、前記筒体の外周表面から所定距離離間し、前記第１の軸平行線と平行であり、且つ前記第１の平面の、前記筒体と反対側の面に対向して存在する第２の軸平行線と、該第２の軸平行線に直交し且つ前記第１の平面に対して所定角度を有した第２の直交線とで形成される第２の平面上に、第２の部材を保持する第２の保持手段と、前記第１の保持手段を、前記第１の平面のうち、第１の軸平行線を境とする一方側の平面領域で、前記第１の直交線に沿って移動させる第１の移動手段と、前記第２の保持手段を、前記第２の平面のうち、第２の軸平行線を境とする一方側の平面から他方側の平面に、前記第２の直交線に沿って移動させる第２の移動手段と、前記第１の保持手段に設けられ、該第１の保持手段の移動時に前記第２の保持手段に当接する当接片とを備え、
前記第１の部材が保持された第１の保持手段を、前記第１の平面の前記一方側の平面であって前記第１の軸平行線から所定距離隔てた開始位置に配設し、前記第２の部材が保持された第２の保持手段を、前記第２の平面の前記一方側の平面であって前記第２の軸平行線から所定距離隔て、且つ前記当接片に当接しない開始位置に配設する第１の工程と、前記第１の保持手段を第１の移動速度且つ第１の移動推力で前記開始位置から第１の軸平行線側に移動させて、前記当接片を第２の保持手段に当接させる第２の工程と、前記第２の工程終了後に、前記第１の保持手段に対する前記第１の移動推力を維持したまま、前記第１の速度よりも遅い第２の速度、且つ前記第１の移動推力よりも大きい第２の移動推力で前記第２の保持手段を第２の軸平行線側に移動させて、前記第１の部材および第２の部材の各端部を前記第１の軸平行線と第２の軸平行線との間に形成される隙間に挿入する第３の工程と、前記第３の工程終了後に、前記第２の保持手段を前記第２の速度且つ第２の移動推力で前記第２の平面の他方側の平面に移動させ、前記第１の部材および第２の部材を、前記隙間内で貼り合わせる第４の工程とを実行することを特徴としている。
【００３１】
また前記第１の工程は、前記開始位置以外の位置で第１の部材を保持した後、前記開始位置に配設する工程を含んでいることを特徴としている。
【００３２】
【発明の実施の形態】
以下、図面を参照しながら本発明の一実施形態例を説明する。図１において２０は、例えば水平に配設された装置本体のベース板であり、該ベース板２０から所定距離隔てた上方には、弾性を有し回転可能に軸支されたローラ２１（本発明の筒体）が配設されている。
【００３３】
このローラ２１の所定距離上方には、該ローラ２１の回転中心軸と平行に回転軸２２が設けられている。この回転軸２２には、図１に示す第１の位置と図２に示す第２の位置との間で回転可能なステージ２３（本発明の基体）の一端が軸支されている。
【００３４】
このステージ２３の一方の面（図１では上方の面）には、本発明の第１の移動手段としての、第１のエアーシリンダ２４ａ、リニアガイド２５ａ、シリンダジョイント２６ａを介して可動部２３ａ（本発明の第１の保持手段）が、前記ローラ２１の回転中心軸と直交する方向に移動可能に配設され、さらに回転軸２２側端には所定長さを有した可動部ストッパ２７（本発明の第１の移動停止手段）が立設されている。
【００３５】
この可動部ストッパ２７の設置位置は、ローラ２１の回転中心軸に直交する方向に調整自在に構成されている。
【００３６】
前記可動部２３ａの一方の面（図１では上方の面）は、例えば通気性のある多孔質材から成るワークＡ保持面２３ｈとして形成され、該ワークＡ保持面２３ｈには例えば偏光板から成るワークＡ（本発明の第１の部材）が載置されて、例えばバキューム（真空引き）の吸引力によって吸着保持されるように構成されている。
【００３７】
尚前記ワークＡ保持面２３ｈには、図示省略しているが、ワークＡと略同一形状の掘り込みがなされており、前記ワークＡは、該掘り込みの直交する２辺により決められる位置に手動にて載置された後、バキュームにて吸着保持されるものである。
【００３８】
前記可動部２３ａの、可動部ストッパ２７に近い側の端部は、該可動部ストッパ２７に当接する当接部２３ｓと、該当接部２３ｓよりも可動部ストッパ２７側に延設された延長保持面２３ｈｈが形成されている。
【００３９】
可動部２３ａの可動部ストッパ２７と反対側の端部には、所定長さの位置決めユニット２８（本発明の当接片）が立設されている。
【００４０】
前記ベース板２０のローラ２１側の面には、該ローラ２１の回転中心軸に直交する方向に移動可能にステージ３３（本発明の第２の保持手段）が配設されている。
【００４１】
尚ステージ３３は、本発明の第２の移動手段としての例えば第２のエアーシリンダ、リニアガイド、シリンダジョイントによって移動するように構成されているが、それらは図示省略している。
【００４２】
ステージ３３のローラ２１側の面はワークＢ保持面３３ｈとして形成され、該ワークＢ保持面３３ｈには例えばタッチパネルのガラス製基板から成るワークＢ（本発明の第２の部材）が載置されて、例えばバキューム（真空引き）の吸引力によって吸着保持されるように構成されている。
【００４３】
尚前記ワークＢ保持面３３ｈには、図示省略しているが、ワークＢと略同一形状の掘り込みがなされており、前記ワークＢは、該掘り込みの直交する２辺により決められる位置に手動にて載置された後、バキュームにて吸着保持されるものである。
【００４４】
ステージ３３の前記ローラ２１と反対側の端部には、カムフォロア（ベアリング）３７が設けられている。
【００４５】
ベース板２０の、前記ローラ２１側の面であって前記カムフォロア３７に近い部位には、所定高さのステージストッパ３８（本発明の角度設定手段）が立設されている。
【００４６】
このステージストッパ３８とステージ２３は、該ステージ２３を図２のように回転させたとき、ステージストッパ３８の先端がステージ２３の可動部２３ａ側の面に当接してステージ２３を図２に示す第２の位置に停止させ得る位置関係に配設されている。
【００４７】
本実施形態例における第１の位置とは、図１に示すように、可動部２３ａのワークＡ保持面２３ｈにワークＡを手動で載置できるように、該ワークＡ保持面２３ｈを上方に向かせた位置である（例えば水平）。
【００４８】
また本実施形態例における第２の位置とは、図２に示すように、ステージ２３のワークＡ保持面２３ｈを、ステージ３３のワークＢ保持面３３ｈに対して所定角度をもって対向させた位置である。
【００４９】
すなわち図２において、可動部２３ａのワークＡ保持面２３ｈは、前記ローラ２１の外周表面であって回転中心軸と平行な第１の軸平行線Ｌ₁と、該第１の軸平行線Ｌ₁に直交する第１の直交線とで形成される第１の平面のうち、第１の軸平行線Ｌ₁を境として所定距離ステージストッパ３８側に隔てた平面（本発明の開始位置）に配設される。
【００５０】
またステージ３３のワークＢ保持面３３ｈは、前記第１の軸平行線Ｌ₁と平行であって、且つローラ２１の外周表面からベース板２０側に所定距離離間した第２の軸平行線Ｌ₂と、該第２の軸平行線Ｌ₂に直交し且つ前記第１の平面に対して所定角度を有した第２の直交線とで形成される第２の平面のうち、第２の軸平行線Ｌ₂を境として所定距離ステージストッパ３８側に隔てた平面（本発明の開始位置）に配設される。
【００５１】
前記第１の軸平行線Ｌ₁と第２の軸平行線Ｌ₂間の隙間Ｇの間隔は、例えばワークＡとワークＢを合わせた厚みに対し０〜３０μｍ小さく設定されている。
【００５２】
そしてこの隙間Ｇの間隔（すなわちローラ２１のステージ３３に対する高さ）は、例えばローラ２１の両端に取り付けられた図示省略のマイクロヘッド（本発明の隙間調整手段）によって調整される。
【００５３】
また図２における（第２の位置における）ワークＡ保持面２３ｈがワークＢ保持面３３ｈに対向する角度は、ステージストッパ３８にある調整手段（例えば高さ調整手段）によって調整可能となっており、例えば１．５〜３度の範囲に設定される。
【００５４】
またステージ２３および可動部２３ａが図２の第２の位置にセットされたとき、位置決めユニット２８はステージ３３のカムフォロア３７に接触せず、それらの間には所定の隙間が空くよう（互いに接触しないよう）な位置関係に設定されている。
【００５５】
次に上記のように構成された装置の動作を図１〜図５とともに述べる。まずワークＡを保持する前は、ステージ２３の可動部２３ａは図１の第１の位置に示すように、ワークＡ保持面２３ｈを上方に向けている。
【００５６】
この状態でワークＡを、ワークＡ保持面２３ｈの掘り込みにより決定される位置に手動で載置する。そしてステージ３３のワークＢ保持面３３ｈにも前記と同様に掘り込みにより決定される位置にワークＢを載置し、それら各ワークＡ、Ｂをバキュームにより各々吸着保持する。
【００５７】
次にステージ２３を、手動にて、回転軸２２を中心にステージ３３上のステージストッパ３８の先端に当たるまで回転させ、図２の第２の位置にセットする。このとき可動部２３ａの位置決めユニット２８はステージ３３のカムフォロア３７とは接触していない。
【００５８】
次に図示しない外部制御手段によって第１のエアーシリンダ２４ａを動作させて、可動部２３ａを、前記第１の平面に沿って第１の軸平行線Ｌ₁側に、第１の推力且つ第１の移動速度で移動させる。
【００５９】
そして位置決めユニット２８が図３に示すようにステージ３３のカムフォロア３７に接触すると、前記第１の推力はステージ３３を動かすほどの推力に設定されていないため、可動部２３ａは、前記接触した位置で前記第１の推力を維持したまま停止する。
【００６０】
次に図示しない外部制御手段によって第２のエアーシリンダ（図示省略）を動作させて、ステージ３３を前記第２の平面に沿って第２の軸平行線Ｌ₂側に、第２の推力且つ第２の移動速度で移動させる。
【００６１】
すると、前記可動部２３ａは、維持していた前記第１の推力により前記隙間Ｇ方向へ第１の移動速度で移動を再開しようとするが、この時、前記可動部２３ａの第１の移動速度は前記ステージ３３の第２の移動速度より速く、前記第１の推力は前記第２の推力より小さくなるように設定されているため、前記位置決めユニット２８と、前記カムフォロア３７は常に接触した状態で、第２の移動速度で移動することとなり、前記可動部２３ａと前記ステージ３３は、図４に示すように、前記可動部２３ａの当接部２３ｓが可動部ストッパ２７に当接して停止するまで、前記第２の移動速度で共に移動する。
【００６２】
尚、前記第１の移動速度と第２の移動速度は、例えば、前記第１のエアーシリンダと第２のエアーシリンダに供給されるエアーを、スピードコントローラにて調節することにより調整される。
【００６３】
前記可動部２３ａの移動終了位置（当接部２３ｓが可動部ストッパ２７に当接した位置）において、ワークＡとワークＢの貼り合わせ開始端（各ローラ側端部）は、同一速度で同時に前記隙間Ｇへ挿入され、ステージ３３とローラ２１の外周表面にて貼り合わせ開始端から１〜２ｍｍ挟まれ圧着される。
【００６４】
前記ワークＡ，Ｂの貼り合わせ開始端が図４のように圧着された後は、前記可動部２３ａは可動部ストッパ２７で規定された移動終了位置で停止し、ステージ３３のみが図示矢印方向に前記第２の移動速度で移動を続け、ワークＡとワークＢは圧着した状態で隙間Ｇ内に引き込まれていき、図５（ａ）のように順次ローラ２１の回転により圧着され貼り合わせが行われる。
【００６５】
このワークＡとワークＢの貼り合わせ開始端の前記隙間Ｇ内への挿入時および貼り合わせ進行時の速度は前記第２の移動速度で行われ、例えば７５ｍｍ／ｓｅｃ以下の速度に設定される。
【００６６】
またこの時のワークＡを保持するためのバキューム力は、前記ワークＡが前記隙間Ｇ内に引き込まれていく際に、前記可動部２３ａのワークＡ保持面２３ｈから離れることができるバキューム力に調整されている。
【００６７】
前記ステージ２３上の可動部ストッパ２７は、前記可動部２３ａの移動方向に調整自在に設置されているため、前記可動部ストッパ２７の位置により前記可動部２３ａの移動最終位置を調整するだけで、前記ワークＡとワークＢの貼り合わせの開始位置を任意の位置に設定することが可能となる。
【００６８】
貼り合せの終了直前において、前記ワークＡ（偏光板）は図５（ａ）に示す状態になる。理想はローラ２１の直前までワークＡとワークＢ（ガラス基板）が接触しないことであるが、ローラ２１と可動部２３ａが干渉するため、ワークＡの貼り合わせ終端部は隙間Ｇに挿入される前に図５（ｂ）のようにワークＢ上に落下してしまう。
【００６９】
またワークＡの貼り合わせ終端部が隙間Ｇに挿入される前にワークＢ上に落下してしまう他の要因は次のとおりである。
【００７０】
すなわち、貼り合わせ工程が進行するにつれてワークＡ（偏光板）は可動部２３ａのワークＡ保持面２３ｈを移動するため、ワークＡを吸着している面積が減少して行き、吸着力も低下して行く。
【００７１】
ワークＡ、すなわち偏光板はそれ自身が剛性をもっているため、初期形状であるフラットな形状に戻ろうとする弾性復元力が働く。この復元力が吸着力を上回ると前記偏光板は図５（ａ）のように可動部２３ａを離れて落下する。
【００７２】
偏光板（ワークＡ）が落下すると、前記隙間Ｇに挿入される前に偏光板とガラス基板（ワークＢ）が接触してしまう。前記偏光板には接着剤が塗布されているため、図５（ｂ）に示すように、ローラ２１でニップされる前に偏光板（ワークＡ）とガラス基板（ワークＢ）の接着が発生してしまう。
【００７３】
本発明の貼り合わせ装置は、ローラ２１によって空気を押し出しながら貼り合わせを行う構造であるため、ローラ２１でニップする前に偏光板（ワークＡ）とガラス基板（ワークＢ）が接着してしまうと、図５（ｃ）に示すように空気が押し出され難くなり、結果として大きな気泡が偏光板とガラス基板の間に残留してしまう。
【００７４】
このような空気の挟み込み発生によって品質の低下を招く恐れがある。しかしながら前記偏光板の落下を防止するために、単純に可動部２３ａのバキューム力を強くすると、貼り合わせの際に、吸着された偏光板が可動部２３ａのワークＡ保持面２３ｈを滑らなくなり、貼り合わせ位置がずれる等の不具合が発生する。
【００７５】
そこで本実施形態例では次のような対策を講じた。前記可動部２３ａの拡大図である図５（ａ），（ｂ）において、可動部２３ａはワークＡを真空引きにより吸着している。真空引きをするために、通常は可動部２３ａに吸着用の孔を適切な数量あけている。しかし本実施形態例の可動部２３ａはこのような吸着用の孔をあけてはおらず、通気性がある多孔質材を採用している。
【００７６】
前記吸着用孔の場合、孔部分でのみの吸着となるが、本実施形態例の多孔質材は吸着用孔とは異なり、表面部全体がワークを吸着するという特徴を持っている。
【００７７】
この多孔質材を可動部２３ａの先端部、すなわち図５（ｄ）に示す延長保持面２３ｈｈまで使用し、可動部先端をローラ２１から逃げられるような加工を施す（ローラ２１の円筒形状に合わせるように、当接部２３ｓから延長保持面２３ｈｈ先端にかけてを傾斜面２３_Rとする）ことで、理論上、ローラ２１と可動部２３ａが接触しないように設ける隙間部分だけしか離れていないところまでワークＡの保持が可能となる。
【００７８】
すなわち、貼り合わせ終了間際までワークＡを吸着保持することができ、図５（ｂ）の状態を極力抑制することが可能となる。
【００７９】
次にワークＡの貼り合わせ終端部が前記ローラ２１にニップされる前にワークＢ上に落下してしまうのを防止した本発明の他の実施形態例を図６〜図１３とともに説明する。
【００８０】
本実施形態例では、貼り合わせの最終段階において、偏光板（第１の部材）が自身の弾性復元力によって偏光板吸着部（第１の保持手段）から離反し下方に位置するガラス基板（第２の部材）に接触しないように、図６に示すように、前記偏光板の離反した端面を受け止める機構である受け機構、例えば偏光板受け台を設けた。
【００８１】
図６〜図１３において図１〜図４と同一部分は同一符号をもって示している。図６において５０は、図１〜図４と同様に構成されたローラ２１の回転中心軸に直交する方向に、例えば水平に配設されたスライドガイドである。
【００８２】
５３はワークＢ（ガラス基板）を上面にて水平に吸着保持するステージ（基板吸着部；本発明の第２の保持手段）であり、その下面にはステージ支持部材５３ａが固設されている。ステージ支持部材５３ａの端部は、スライドガイド５０上を摺動する摺動部材５４ａに固設されている。
【００８３】
したがってワークＢを吸着保持したステージ５３は、図示省略の第２の移動手段（例えば第２のエアーシリンダ）によってスライドガイド５０に沿って移動することができる。
【００８４】
２３ａは、前記図１〜図４と同様に構成されてワークＡ（偏光板）を摺動可能に吸着保持する可動部（偏光板吸着部）であり、図１〜図４における、回転軸２２、ステージ２３、第１のエアーシリンダ２４ａ、リニアガイド２５ａ、シリンダジョイント２６ａ、可動ストッパ２７、位置決めユニット２８、ステージストッパ３８等は図示省略している。
【００８５】
またワークＡ保持面２３ｈは、図１〜図４の実施形態例と同様に、可動部２３ａを図１の第１の位置から図２の第２の位置（貼り合わせの開始位置）にセットしたときに、ワークＢ保持面５３ｈに対して２〜５°程度の角度をもって対向するように構成されている。
【００８６】
５５ａは、高さ方向一方の端面が、ステージ５３に吸着保持したワークＢの高さより若干高い位置となるように、ワークＢの貼り合わせ終端部側に設けられた受け台支持部材である。
【００８７】
この受け台支持部材５５ａのステージ５３よりも下側部位にはコイルばね５６の一端が固定され、該コイルばね５６の他端はステージ５３の下面の係止部５７に係止されており、これによって受け台支持部材５５ａは、コイルばね５６のばね力によってステージ５３の、ワークＢの貼り合わせ終端部側の側面に密着保持されている。
【００８８】
尚ステージ５３のワークＢ貼り合わせ終端部側の側面には、図１〜図４のカムフォロア３７と同様に、位置決めユニット２８と接触するカムフォロアが設けられている（図示省略）。
【００８９】
受け台支持部材５５ａの高さ方向一方の端面には、下面が受け台支持部材５５ａの幅寸法よりも大きい幅寸法に形成され、ワークＢの貼り合わせ終端部側に所定距離延設された偏光板受け台５５が固設されている。
【００９０】
前記のように、受け台支持部材５５ａの高さ方向一方の端面がワークＢの高さより若干高い位置であるため、受け台支持部材５５ａがステージ５３に密着保持されている状態において、偏光板受け台５５の下面はワークＢに対して若干の隙間を隔てて対向する。
【００９１】
偏光板受け台５５には、可動部２３ａのワークＡ保持面２３ｈから落下するワークＡの貼り合わせ終端部を受ける接触面５５ｂが、幅（厚み）２〜５ｍｍ、角度５０〜７０°の範囲で形成されている。
【００９２】
この接触面５５ｂは、ワークＡ端面との接触が線接触となるように斜面形状に形成され、またワークＡ（偏光板）に塗布された接着剤の転写を防ぐため、例えばトシカル処理や、テフロン(登録商標)処理等が施されている。
【００９３】
受け台支持部材５５ａの高さ方向他端部は、前記スライドガイド５０上を摺動する摺動部材５４ｂに固設されている。したがって、ステージ５３にコイルばね５６によって密着された受け台支持部材５５ａおよび偏光板受け台５５は、ステージ５３の移動とともにスライドガイド５０に沿って移動することができる。
【００９４】
５８は、装置本体に固設され、前記隙間Ｇ近傍で前記受け台支持部材５５ａと当接して該部材５５ａを停止させる偏光板受け台ストッパー（本発明の第２の移動停止手段）である。
【００９５】
前記ストッパー５８は、偏光板受け台５５の隙間Ｇに対向する側の先端が、ステージ５３とともに隙間Ｇ近傍まで移動したときに、隙間Ｇの直前で受け台支持部材５５ａに当接して受け台支持部材５５ａおよび偏光板受け台５５を停止させる位置に設けられている。尚偏光板受け台ストッパー５８の取り付け位置は任意に変更できるように構成されている。
【００９６】
図６〜図１１は、前記のように構成された装置を用いて貼り合わせを行うときの貼り合わせ工程を示している。尚これらの図において、可動部２３ａ（第１の保持手段）を移動させる第１の速度、ステージ５３（第２の保持手段）を移動させる第２の速度、およびそれらの移動推力は、図１〜図４で述べた実施形態例と同様に設定されている。
【００９７】
まず図６は、前記図２の第２の位置のようにワークＡを吸着保持した可動部２３ａを、ワークＢを吸着保持したステージ５３に対して所定角度をもって対向配設させた初期状態を示している。
【００９８】
次に貼り合わせ装置の各部は前記図２〜図４で述べた動作と同様の動作を行う。すなわち、第１のエアーシリンダ２４ａを動作させて可動部２３ａを隙間Ｇ側に移動させ、位置決めユニット２８をステージ５３のカムフォロア（図示省略）に接触させ、その後第２のエアーシリンダ（図示省略）を動作させてステージ５３をスライドガイド５０に沿って隙間Ｇ側に移動させる。
【００９９】
するとステージ５３の移動にともなって、受け台支持部材５５ａ、偏光板受け台５５および可動部２３ａが図７の矢印の方向に移動し、図４に示すように可動部２３ａの当接部２３ｓが可動部ストッパ２７に当接した時点で可動部２３ａの移動が終了する。
【０１００】
前記可動部２３ａの移動終了位置（当接部２３ｓが可動部ストッパ２７に当接した位置）において、ワークＡとワークＢの貼り合わせ開始端（各ローラ側端部）は、同一速度で同時に前記隙間Ｇへ挿入され、図７に示すように、ステージ５３とローラ２１の外周表面にて貼り合わせ開始端から１〜２ｍｍ挟まれ圧着される。
【０１０１】
前記ワークＡ，Ｂの貼り合わせ開始端が図７のように圧着された後は、前記可動部２３ａは可動部ストッパ２７で規定された移動終了位置で停止し、ステージ５３、受け台支持部材５５ａ、偏光板受け台５５が前記移動を続け、ワークＡとワークＢは圧着した状態で隙間Ｇ内に引き込まれていき、図８のように順次ローラ２１の回転により圧着され貼り合わせが行われる。
【０１０２】
図８に示すような貼り合わせ工程途中において、ワークＡ、すなわち偏光板はローラ２１を支点にして可動部２３ａとステージ５３の対向角度分だけ変形している。前記偏光板はそれ自身が剛性を持っているため弾性復元力が働く。
【０１０３】
この弾性復元力の方向は、偏光板吸着部である可動部２３ａから離れる方向、すなわち図８中の矢印のように偏光板が落下する方向に働いている。そのため前記偏光板を吸着している吸着力よりも弾性復元力が大きくなったときに偏光板は可動部２３ａを離れる。
【０１０４】
前記偏光板が可動部２３ａより離れた時に本発明の偏光板受け台５５が設けられていない場合、前述した図５（ｂ）のように偏光板とガラス基板が接着してしまい、図５（ｃ）に示すような気泡残留を誘発する。
【０１０５】
しかし本発明のように偏光板受け台５５が設けられていると、落下した偏光板（ワークＡ）は図９に示すように、偏光板受け台５５の接触面５５ｂによって保持され、ワークＢ、すなわちガラス基板との接触を防止することができ、その結果、図５（ｃ）に示すような気泡の挟み込みを抑制することができる。
【０１０６】
前記偏光板受け台５５は、接触面５５ｂにて偏光板（ワークＡ）の貼り合わせ終端部を保持したままステージ５３と同一速度で隙間Ｇ方向へ移動するが、偏光板受け台５５の隙間Ｇ側の先端が図１０（ａ）のようにローラ２１直前位置まで移動し、受け台支持部材５５ａが偏光板受け台ストッパー５８に当接すると、該受け台支持部材５５ａおよび偏光板受け台５５の移動は停止する。
【０１０７】
そしてその後ステージ５３はコイルばね５のばね力に抗して図示矢印方向への移動が継続され、図１１のようにワークＡ，Ｂの貼り合わせ終端部が隙間Ｇを通過した位置で貼り合わせが完了する。
【０１０８】
前記偏光板受け台ストッパー５８の設置位置は任意に変更可能であり、偏光板受け台５５の停止位置を自由に設定することができる。これにより、偏光板（ワークＡ）の厚みが異なっても貼り合わせ直前まで偏光板の保持が可能である。
【０１０９】
すなわち、前記偏光板が厚い時は、偏光板受け台ストッパー５８を、図１０（ａ）の位置よりもステージ５３進行方向手前位置である図１０（ｂ）の位置に配設し、また逆に前記偏光板が薄い時は、ローラ２１側の位置に配設するものである。
【０１１０】
また前記偏光板を保持する区間を任意設定することができるため、偏光板保持区間の最適条件を設定することが可能である。
【０１１１】
前記偏光板（ワークＡ）とガラス基板（ワークＢ）の貼り合わせにおいては、偏光板側に接着剤が塗布されている。偏光板受け台５５は、この接着面を受けることになるため、繰り返し使用をすると、偏光板に塗布されている接着剤が偏光板受け台５５に転写してしまう。
【０１１２】
そこで本発明では、偏光板受け台５５と偏光板の接触は、図１２に示すように接触面５５ｂを傾斜面に形成することで、偏光板のエッジ部分のみが接触する線接触とした。
【０１１３】
また、この偏光板を受け止める接触面５５ｂには、トシカル処理やテフロン処理等の表面処理を施し、更に接着剤の転写を抑制した。こうした加工や処理をすることによって、偏光板受け台５５の接着剤除去にかける時間を大幅に削減することが可能となる。
【０１１４】
次に本発明の、より具体的な実施形態例を図１３に示す。図１３は本実施形態例における要部のみ、すなわち偏光板（ワークＡ）、ガラス基板（ワークＢ）、可動部２３ａ、ステージ５３、偏光板受け台５５、受け台支持部材５５ａ、接触面５５ｂを示している。
【０１１５】
実施の主要条件は次のとおりである。
【０１１６】
偏光板と、水平に保持されたガラス基板との対向角度：３°
偏光板受け台５５の接触面下面と、ガラス基板との隙間：０．５ｍｍ
偏光板受け台の接触面５５ｂをなす部分の厚み（幅）：３ｍｍ
偏光板受け台の接触面５５ｂの角度：６０°
偏光板受け台の接触面５５ｂの表面処理：トシカル処理
偏光板厚み：０．２５５ｍｍ
貼り合わせスピード：３０ｍｍ／ｓｅｃ
偏光板吸着部（可動部２３ａ）のバキューム力：真空エジェクタに０．４Ｍｐａ圧縮エア供給。
【０１１７】
上記条件にて、貼り合わせを行った結果において、前記ガラス基板と偏光板の貼り合わせ面に残留する気泡の発生頻度は極めて少なくなり、次工程である脱泡工程に費やす時間を大幅に短縮することが可能となった。
【０１１８】
また、前記偏光板の端面（貼り合わせ終端部）の前記接触面５５ｂへの接触が線接触であることと、前記接触面５５ｂに表面処理を施していることにより、前記偏光板に塗布された接着剤が前記接触面５５ｂへ転写することは非常に少なくなった。
【０１１９】
以上のように前記実施形態例の装置によれば、サーボモータ等での特別な制御を施さなくても、ワークＡとワークＢの貼り合わせ開始端を同一速度で同時に、ローラ２１とステージ３３又は５３で形成される隙間Ｇに挿入することが可能となり、貼り合わせ開始端に見られる「押し跡」は１００％防止することができた。
【０１２０】
尚前記実施形態例では、ステージ２３を回転させるための回転軸２２を、ローラ２１の上方位置に回転中心軸と平行に配設していたが、これに限らず、例えば図２の実線で示す構成において、ステージ２３の、ローラ２１の回転中心軸に直交する線に沿ったいずれかの辺に、ステージ２３を回転させるための回転軸を設けるように構成しても良い。
【０１２１】
このように構成した場合は、ローラ２１の回転中心軸をいずれかに延長した延長線側において、可動部２３ａのワークＡ保持面２３ｈを上方に向けた第１の位置でワークＡを可動部２３ａに載置して吸着、保持を行い、その後ステージ２３を回転させて図２の実線で示す第２の位置に装置をセットすることになる。
【０１２２】
またステージ２３の回転軸２２を、図２の実線で示す構成において、ローラ２１の回転中心軸と平行であって、可動部ストッパ２７に近い側の辺ではなく、ステージストッパ３８に近い側の辺に設けても良い。
【０１２３】
このように構成した場合は、前記ステージ２３の回転軸を境とし、ローラ２１とは反対側の領域において可動部２３ａのワークＡ保持面２３ｈを上方に向けた第１の位置でワークＡを可動部２３ａに載置して吸着、保持を行い、その後ステージ２３を回転させて図２の実線で示す第２の位置に装置をセットすることになる。
【０１２４】
尚本発明における第１の部材（ワークＡ）は、プラスチックの板材、シートもしくはフィルムが使用され、前記第２の部材（ワークＢ）は、金属、プラスチックもしくはガラスの基板が使用される。
【０１２５】
また前記第１の移動速度よりも遅い第２の移動速度は、例えば３０ｍｍ／ｓｅｃ〜１００ｍｍ／ｓｅｃ程度が良好な速度範囲である。
【０１２６】
また前記ローラ２１の径は、小さければ小さいほどローラ２１と可動部２３ａを近ずけることができワークＡを貼り合わせ間際まで吸着、保持することができるため、例えばローラ径をφ１０、ゴム硬度を３０に選定するのが好ましい。
【０１２７】
但し、ローラ径をφ１０よりも小さくしてしまうとゴムの肉厚が薄くなるため、ゴム硬度３０という数値に信頼性がなくなる。
【０１２８】
また本発明で使用される第１および第２の部材（ワークＡ、Ｂ）の大きさは、例えば６０ｍｍ×１００ｍｍ以下で適用されるが、大きくすることは特に制限はない。
【０１２９】
また第１の部材として用いるシートは薄くて剛性が小さいもの、第２の部材として用いる基板は硬いもの（弾力がない）が理想である。
【０１３０】
また前記ワークＡ保持面２３ｈ、ワークＢ保持面３３ｈのバキューム穴のパターンは、例えば格子状、千鳥状等に形成される。
【０１３１】
また前記装置本体のベース板２０、スライドガイド５０、ローラ２１、回転軸２２は、図１〜図４、図６〜図１１のように水平に配設するに限らず、所定の角度を有して配設しても良い。
【０１３２】
さらに、本発明の第１、第２の保持手段、第１、第２の移動手段、移動停止手段、角度設定手段、隙間調整手段、基体、受け機構は、前記実施形態例に限らず、同様の作用、効果を奏する他の手段で構成しても良い。
【０１３３】
例えば図６〜図１１においては、受け台支持部材５５ａを、コイルばね５６によってステージ５３に一体的に保持させ、受け台支持部材５５ａが偏光板受け台ストッパー５８に当接することによって該部材５５ａの移動を停止させていたが、これに限らず、ステージ５３と受け台支持部材５５ａの当接部分で両者を連結する連結具を設け、前記偏光板受け台ストッパー５８の設置位置において前記連結具の連結を解くとともに、受け台支持部材５５ａの移動を停止させるストッパーを設けるように構成しても良い。
【０１３４】
また図６〜図１１（偏光板受け台５５を設ける実施形態例）における可動部２３ａを、図５（ｄ）に示すような延長保持面２３ｈｈおよび傾斜面２３Ｒを有した形状に構成しても良い。
【０１３５】
また図６〜図１１の偏光板受け台５５の接触面５５ｂの、ローラ２１の軸方向に沿う長さは、ワークＡ（偏光板）の幅と同一に形成しなくても、貼り合わせ時にワークＡ貼り合わせ終端部が落下しない範囲内で、比較的小さい接触面積の偏光板受け台を所定間隔隔てて複数個ローラ２１の軸方向に沿って並設して構成しても良い。
【０１３６】
尚、本発明の貼り合わせ装置は、タッチパネルのガラス製基板と偏光板の貼り合わせ以外に、液晶ディスプレイの製造工程、高密度円盤状記録ディスク等、ワークの貼り合わせを行う製造工程においても、サーボモータ等での特別な制御を使用せずに適用することが可能である。
【０１３７】
【発明の効果】
（１）以上のように請求項１〜１６に記載の発明によれば、サーボモータ等の高価な機器や特別な制御を施さなくても、簡単な装置構成によって貼り合わせ時の「押し跡」の発生を１００％防止することができる。このためモータコントローラ等を省くことができ、装置の小型化および制御の簡略化を図ることができる。
（２）また請求項２に記載の発明によれば、移動停止手段を設定変更するだけで、第１および第２の部材の貼り合わせ開始端を決めることができ、貼り合わせ開始位置調整が容易となる。
（３）また請求項３に記載の発明によれば、第１の保持手段の当接片が第２の保持手段に当接してから、第１および第２の部材の貼り合わせ開始端が筒体と第２の保持手段の間の隙間に挿入されるまでの間、第１および第２の部材を同一速度（第２の速度）で移動させることができる。
（４）また請求項４に記載の発明によれば、貼り合わせ開始時に前記隙間に挿入される第１の部材と第２の部材のなす角度を任意に設定することができる。
（５）また請求項５に記載の発明によれば、第１の保持手段を筒体側に極力近づけて貼り合わせを行うことができ、延長保持面によって、貼り合わせ終了間際まで第１の部材を保持することができる。これによって、貼り合わせ終了前の部材落下による気泡の発生を防止したり、貼りむらの発生を防止することができる。
（６）また請求項７に記載の発明によれば、吸着用孔を設ける必要はなくなり、第１の保持手段の保持面が下方に向けられた場合でも、第１の部材を貼り合わせ終了時まで確実に保持することが可能となり、貼り合わせ終了前の部材落下による気泡の発生を防止したり、貼りむらの発生を防止することができる。
（７）また請求項８に記載の発明によれば、貼り合わせる第１および第２の部材の厚さに応じて筒体と第２の保持手段の間の隙間の間隔を任意に調整することができる。
（８）また請求項１０に記載の発明によれば、第１の平面位置以外の位置で第１の部材を容易に第１の保持手段の保持面に載置し保持させることができる。
（９）また請求項１１に記載の発明によれば、従来のサーボモータ使用時に比較して５％程度の費用のエアーシリンダを使用して貼り合わせを良好に行うことができ、装置価格が大幅に低廉化するとともに、制御も極めて簡略化される。
（１０）また請求項１３〜１６に記載の発明によれば、第１の部材、例えば偏光板が貼り合わせ工程中に第１の保持手段から外れて落下しても、前記偏光板が第２の部材、例えばガラス基板に接着することがなくなったため、気泡の発生頻度が極めて小さくなった。それにより、次工程である脱泡工程に必要な時間を短縮することができるようになった（１２０分から１０分程度に短縮）。
（１１）また請求項１５、１６に記載の発明によれば、受け機構の接触面を、前記偏光板のエッジしか触れない構造にしたことと、受け機構の接触面にトシカル処理やテフロン処理等の表面処理を施したため、前記偏光板からの接着剤転写はほとんど発生せず、受け機構に必要な清掃等のメンテナンス機会を抑制することが可能となった。
（１２）また請求項１７、１８に記載の発明によれば、簡単な方法によって貼り合わせ時の「押し跡」の発生を１００％防止することができる。また本発明の方法を用いれば、貼り合わせ装置を、高価なサーボモータ等の部品を使用することなく構成することができる。
（１３）また請求項１８に記載の発明によれば、第１の平面位置以外の位置で第１の部材を容易に第１の保持手段の保持面に載置し保持させることができる。
【図面の簡単な説明】
【図１】本発明の貼り合わせ装置の一実施形態例の概略構成図。
【図２】本発明の貼り合わせ装置の一実施形態例を表し、第１の保持手段を第２の位置に回転させた直後を示す構成図。
【図３】本発明の貼り合わせ装置の一実施形態例を表し、当接片が第２の保持手段に当接して第１の保持手段が停止したときの構成図。
【図４】本発明の貼り合わせ装置の一実施形態例を表し、第１の保持手段がストッパに当接して第１の保持手段の移動が停止したときの構成図。
【図５】貼り合わせ装置による貼り合わせ終了直前の様子を示す説明図。
【図６】本発明の他の実施形態例の貼り合わせ工程における、初期状態を示す説明図。
【図７】本発明の他の実施形態例の貼り合わせ工程における、貼り合わせ開始時の状態を示す説明図。
【図８】本発明の他の実施形態例の貼り合わせ工程における、貼り合わせ進行中の状態を示す説明図。
【図９】本発明の他の実施形態例の貼り合わせ工程における、落下した偏光板を受け止めた状態を示す説明図。
【図１０】本発明の他の実施形態例の貼り合わせ工程における、偏光板を受け止めた状態で貼り合わせを行っているときの様子を示す説明図。
【図１１】本発明の他の実施形態例の貼り合わせ工程における、貼り合わせ完了時の様子を示す説明図。
【図１２】本発明の他の実施形態例の要部説明図。
【図１３】本発明の他の実施形態例の要部説明図。
【図１４】従来の貼り合わせ方法の一例を示す説明図。
【図１５】従来の貼り合わせ方法の他の例を示す説明図。
【符号の説明】
２０…ベース板、２１…ローラ、２２…回転軸、２３，３３，５３…ステージ、２３ａ…可動部、２３ｈ…ワークＡ保持面、２３ｈｈ…延長保持面、２３ｓ…当接部、２４ａ…第１のエアーシリンダ、２５ａ…第１のリニアガイド、２６ａ…第１のシリンダジョイント、２７…可動部ストッパ、２８…位置決めユニット、３３ｈ，５３ｈ…ワークＢ保持面、３７…カムフォロア、３８…ステージストッパ、５０…スライドガイド、５４ａ，５４ｂ…摺動部材、５５…偏光板受け台、５５ａ…受け台支持部材、５５ｂ…接触面、５６…コイルばね、５７…係止部、５８…偏光板受け台ストッパー、Ａ，Ｂ…ワーク、Ｇ…隙間、Ｌ₁…第１の軸平行線、Ｌ₂…第２の軸平行線。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a laminating apparatus and a laminating method for laminating a thin sheet or the like to a resin / glass substrate in a manufacturing process of a touch panel, a flat display, a disk-shaped recording medium, and the like.
[0002]
[Prior art]
In the manufacturing process of flat displays and touch panels, there are many opportunities to affix an adhesive-coated sheet, film, polarizing plate or the like to a substrate such as plastic or glass, and there are many facilities for realizing it.
[0003]
For example, as an apparatus for attaching a liquid crystal cell to a polarizing plate, an apparatus as shown in Patent Document 1 below has been used.
[0004]
[Patent Document 1]
JP-A-6-102505.
[0005]
FIG. 14 shows an example of a bonding method disclosed in Patent Document 1. First, in FIG. 14A, a roller 2 is rotatably disposed at the other end of the upper stage 1 whose one end is pivotally supported, and the holding surface of the upper stage 1 (in this case, facing upward). And the second member 5 is placed on the holding surface of the lower stage 4, and the first and second members 3 and 5 are sucked and held by vacuum.
[0006]
Next, as shown in FIG. 14B, the roller side end of the upper stage 1 is rotated, and the bonding start end of the first member 3 is adhered to the second member 5 by the roller 2.
[0007]
Then, as shown in FIG. 14C, the lower stage 4 is moved in the direction indicated by the arrow, and the first member 3 and the second member 5 are bonded together by the roller 2.
[0008]
[Problems to be solved by the invention]
However, in the bonding method of FIG. 14, at the start of bonding (FIG. 14 (b)), the roller 2 is abutted from above, so that the workpieces after bonding (first and second members 3, It has been confirmed that “push marks” that can be visually confirmed are generated in 5) (particularly at the bonding start portion). This “push mark” has an adverse effect on quality and leads to a decrease in yield.
[0009]
Therefore, as a method of solving this “push mark” problem, there is a method of inserting two objects to be bonded into the bonding mechanism section while synchronizing them.
[0010]
That is, for example, as shown in FIGS. 15A to 15C, the roller 2 is fixed without being moved, and the upper stage 11 and the second member 5 holding the first member 3 in the vicinity of the roller 2 are provided. The held lower stage 4 is arranged so that the holding surfaces face each other at a predetermined angle, and the upper stage 11 and the lower stage 4 are moved in the direction of the arrow shown in the figure while controlling the speed by a servo motor, for example. It can be considered that the two members 3 and 5 are simultaneously inserted at the same speed into the gap between the lower stage 4 and the roller 2 and bonded together.
[0011]
However, the use of the servo motor as described above increases the cost and size of the bonding apparatus, adjusts the moving speed of the upper and lower stages 11, 4, and the first and second members 3, Thus, complicated control such as adjustment of the bonding start position of 5 occurs.
[0012]
The present invention has been made in view of the above points, and the object thereof is to prevent the occurrence of a press mark and perform good bonding without using expensive equipment such as a servo motor and special control. It is in providing the bonding apparatus and the bonding method.
[0013]
[Means for Solving the Problems]
In the present invention, the first and second members are moved at the same speed, and the bonding start ends of the first and second members are simultaneously formed by the outer diameter portion of the fixed roller and the lower stage. A mechanism that can be inserted into the gap and a mechanism that can freely adjust the position at which the first and second members start to be bonded are configured to be incorporated into the bonding machine only by a mechanical mechanism that uses, for example, an air cylinder.
[0014]
That is, the laminating apparatus of the present invention is a laminating apparatus for laminating at least one of the first and second members coated with an adhesive, and has elasticity and is rotatable with a predetermined diameter. A cylindrical body, a first axis parallel line that is parallel to the central axis of rotation of the cylindrical body and that exists at a predetermined portion of the outer peripheral surface of the cylindrical body, and a first axis that is orthogonal to the first axis parallel line A first holding means for holding a first member on a first plane formed by an orthogonal line and a predetermined distance from the outer peripheral surface of the cylindrical body, and parallel to the first axis parallel line And a second axis parallel line that faces the surface of the first plane opposite to the cylindrical body, and is orthogonal to the second axis parallel line and with respect to the first plane A second member holding the second member on a second plane formed by a second orthogonal line having a predetermined angle A holding means and the first holding means in a plane region on one side of the first plane with the first axis parallel line as a boundary, and a first speed along the first orthogonal line The first moving means and the second holding means are moved from one plane to the other plane of the second plane with the second axis parallel line as a boundary. The second moving means for moving the second member at a second speed that is slower than the first speed, and the end portions of the first member and the second member are arranged on the first axis. First movement stop means for stopping movement of the first holding means at a position inserted in a gap formed between a parallel line and a second axis parallel line, and the first member And the 2nd member is bonded together in the said clearance gap, It is characterized by the above-mentioned.
[0015]
Further, the first movement stop means is configured to be able to arbitrarily set and change the movement stop position of the first holding means.
[0016]
The first holding means is provided with a contact piece that comes into contact with the second holding means when the first holding means is moved, and the moving thrust of the first moving means is the second moving means. It is characterized by being set smaller than the moving thrust of.
[0017]
Further, an angle setting means for arbitrarily setting the predetermined angle is provided.
[0018]
The first movement stop means has a stopper disposed between the cylinder and the first holding means, and the cylinder side end of the first holding means has a stopper on the stopper. An abutting part that abuts and an extended holding surface that extends from the corresponding part to the cylindrical body by a predetermined distance are formed.
[0019]
Further, the first holding means holds the first member with a predetermined suction force.
[0020]
Further, the first holding means has a porous material on its holding surface.
[0021]
Further, a gap adjusting means for adjusting the gap interval is provided.
[0022]
In addition, the gap is formed to be equal to or less than a total thickness of the first member and the second member.
[0023]
The first holding means is provided with a base for moving to a position other than the first planar position.
[0024]
Further, the first moving means includes a first air cylinder, and the second moving means includes a second air cylinder.
[0025]
The first member is a plastic plate, sheet or film, and the second member is a metal, plastic or glass substrate.
[0026]
The first member has a contact surface that receives the bonding end portion of the first member, and is integrally held by the second holding means, and the first member on the bonding end portion side of the second member. A receiving mechanism disposed at a position spaced from the second member by a predetermined distance, and a tip position of the receiving mechanism facing the gap is a predetermined position near the gap. And a second movement stop means for stopping the movement of the receiving mechanism when moved to a position.
[0027]
Further, the second movement stop means is configured to be able to arbitrarily set and change the movement stop position of the receiving mechanism.
[0028]
In addition, the contact surface of the receiving mechanism is formed as an inclined surface that can be brought into line contact with the bonding end portion of the first member.
[0029]
The contact surface of the receiving mechanism is characterized in that a surface treatment for suppressing transfer of the adhesive is performed.
[0030]
The laminating method of the present invention is a laminating method for laminating the first and second members having at least one of which an adhesive is applied, and is a rotatable cylinder having elasticity and a predetermined diameter. A first axis parallel line that is parallel to the rotation center axis of the cylinder, and is present at a predetermined portion of the outer peripheral surface of the cylinder, and a first orthogonal line that is orthogonal to the first axis parallel line A first holding means for holding a first member on a first plane formed by a line, and a predetermined distance from the outer peripheral surface of the cylindrical body, and parallel to the first axis parallel line And a second axis parallel line that faces the surface of the first plane opposite to the cylindrical body, and is orthogonal to the second axis parallel line and with respect to the first plane A second holding hand for holding the second member on a second plane formed by a second orthogonal line having a predetermined angle And a first movement for moving the first holding means along the first orthogonal line in a plane region on one side of the first plane with the first axis parallel line as a boundary. And the second holding means are moved along the second orthogonal line from one of the second planes to a plane on the other side of the second axis parallel line. Second moving means to be provided, and an abutting piece provided on the first holding means and abutting on the second holding means when the first holding means is moved,
The first holding means holding the first member is disposed at a starting position on the one side of the first plane and separated from the first axis parallel line by a predetermined distance, The second holding means holding the second member is a plane on the one side of the second plane, is spaced from the second axis parallel line by a predetermined distance, and does not contact the contact piece. A first step disposed at a start position; and the first holding means is moved from the start position to the first axis parallel line side at a first movement speed and a first movement thrust, and the contact A second step of bringing the piece into contact with the second holding means; and after the completion of the second step, while maintaining the first moving thrust with respect to the first holding means, than the first speed. The second holding means is moved to the second axis at a second speed that is slow and a second movement thrust that is greater than the first movement thrust. The third member is moved to the row line side, and each end of the first member and the second member is inserted into a gap formed between the first axis parallel line and the second axis parallel line. And after the completion of the third step, the second holding means is moved to the plane on the other side of the second plane at the second speed and the second moving thrust, and the first member is moved. And the 4th process of bonding the 2nd member in the said clearance gap is performed, It is characterized by the above-mentioned.
[0031]
Further, the first step includes a step of holding the first member at a position other than the start position and then disposing the first member at the start position.
[0032]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, an embodiment of the present invention will be described with reference to the drawings. In FIG. 1, reference numeral 20 denotes a base plate of the apparatus main body disposed horizontally, for example. Above the base plate 20 at a predetermined distance, a roller 21 that is elastically supported and rotatably supported (the present invention). Are provided).
[0033]
A rotation shaft 22 is provided above the roller 21 by a predetermined distance in parallel with the rotation center axis of the roller 21. One end of a stage 23 (base of the present invention) that can rotate between the first position shown in FIG. 1 and the second position shown in FIG. 2 is pivotally supported on the rotary shaft 22.
[0034]
On one surface of the stage 23 (upper surface in FIG. 1), a movable portion 23a (a first air cylinder 24a, a linear guide 25a, and a cylinder joint 26a serving as a first moving means of the present invention is provided. The first holding means of the present invention is disposed so as to be movable in a direction orthogonal to the rotation center axis of the roller 21, and further, a movable portion stopper 27 (main book) having a predetermined length at the end of the rotation shaft 22. The first movement stop means of the invention is provided upright.
[0035]
The installation position of the movable portion stopper 27 is configured to be adjustable in a direction orthogonal to the rotation center axis of the roller 21.
[0036]
One surface (upper surface in FIG. 1) of the movable portion 23a is formed as a work A holding surface 23h made of, for example, a porous material having air permeability, and the work A holding surface 23h is made of, for example, a polarizing plate. The workpiece A (first member of the present invention) is placed and is configured to be sucked and held by, for example, a vacuum (evacuation) suction force.
[0037]
Although not shown in the drawing, the workpiece A holding surface 23h is dug in substantially the same shape as the workpiece A, and the workpiece A is manually positioned at a position determined by two orthogonal sides of the dug. After being placed at, it is sucked and held by vacuum.
[0038]
An end portion of the movable portion 23a closer to the movable portion stopper 27 has an abutting portion 23s that abuts the movable portion stopper 27, and an extended holding extending from the corresponding contact portion 23s to the movable portion stopper 27 side. A surface 23hh is formed.
[0039]
A positioning unit 28 (contact piece of the present invention) having a predetermined length is provided upright at the end of the movable portion 23a opposite to the movable portion stopper 27.
[0040]
A stage 33 (second holding means of the present invention) is disposed on the surface of the base plate 20 on the roller 21 side so as to be movable in a direction perpendicular to the rotation center axis of the roller 21.
[0041]
The stage 33 is configured to move by, for example, a second air cylinder, a linear guide, and a cylinder joint as the second moving means of the present invention, but these are not shown.
[0042]
The surface on the roller 21 side of the stage 33 is formed as a work B holding surface 33h, and a work B (second member of the present invention) made of, for example, a glass substrate of a touch panel is placed on the work B holding surface 33h. For example, it is configured to be sucked and held by a suction force of vacuum (evacuation).
[0043]
Although not shown in the drawing, the workpiece B holding surface 33h is dug in substantially the same shape as the workpiece B, and the workpiece B is manually positioned at a position determined by two orthogonal sides of the dug. After being placed at, it is sucked and held by vacuum.
[0044]
A cam follower (bearing) 37 is provided at the end of the stage 33 opposite to the roller 21.
[0045]
A stage stopper 38 (an angle setting means of the present invention) having a predetermined height is erected on a portion of the base plate 20 on the roller 21 side and close to the cam follower 37.
[0046]
When the stage stopper 38 and the stage 23 are rotated as shown in FIG. 2, the tip of the stage stopper 38 comes into contact with the surface of the stage 23 on the movable portion 23a side, and the stage 23 is shown in FIG. It is arranged in a positional relationship that can be stopped at position 2.
[0047]
As shown in FIG. 1, the first position in this embodiment refers to the workpiece A holding surface 23 h facing upward so that the workpiece A can be manually placed on the workpiece A holding surface 23 h of the movable portion 23 a. It is a squeezed position (for example, horizontal).
[0048]
Further, the second position in this embodiment is a position where the work A holding surface 23h of the stage 23 is opposed to the work B holding surface 33h of the stage 33 at a predetermined angle, as shown in FIG. .
[0049]
That is, in FIG. 2, the work A holding surface 23 h of the movable portion 23 a is a first axis parallel line L that is the outer peripheral surface of the roller 21 and is parallel to the rotation center axis. ₁ And the first axis parallel line L ₁ 1st axis parallel line L among the 1st planes formed with the 1st perpendicular line orthogonal to ₁ Is disposed on a plane (starting position of the present invention) separated from the stage stopper 38 by a predetermined distance.
[0050]
Further, the work B holding surface 33h of the stage 33 has a first axis parallel line L. ₁ And a second axis parallel line L which is parallel to the outer peripheral surface of the roller 21 and spaced apart from the outer peripheral surface of the roller 21 by a predetermined distance. ₂ And the second axis parallel line L ₂ Of the second plane formed by a second orthogonal line orthogonal to the first plane and having a predetermined angle with respect to the first plane. ₂ Is disposed on a plane (starting position of the present invention) separated from the stage stopper 38 by a predetermined distance.
[0051]
The first axis parallel line L ₁ And second axis parallel line L ₂ For example, the gap G is set smaller by 0 to 30 μm than the total thickness of the workpiece A and the workpiece B.
[0052]
The gap G (ie, the height of the roller 21 with respect to the stage 33) is adjusted by, for example, a micro head (not shown) that is attached to both ends of the roller 21 (not shown).
[0053]
The angle at which the workpiece A holding surface 23h (in the second position) in FIG. 2 faces the workpiece B holding surface 33h can be adjusted by adjusting means (for example, height adjusting means) in the stage stopper 38. For example, it is set in the range of 1.5 to 3 degrees.
[0054]
When the stage 23 and the movable part 23a are set at the second position in FIG. 2, the positioning unit 28 does not contact the cam follower 37 of the stage 33, and a predetermined gap is not formed between them (not contact each other). Like)).
[0055]
Next, the operation of the apparatus configured as described above will be described with reference to FIGS. First, before the workpiece A is held, the movable portion 23a of the stage 23 has the workpiece A holding surface 23h facing upward as shown in the first position in FIG.
[0056]
In this state, the workpiece A is manually placed at a position determined by digging the workpiece A holding surface 23h. The workpiece B is placed on the workpiece B holding surface 33h of the stage 33 at a position determined by digging in the same manner as described above, and each of the workpieces A and B is sucked and held by vacuum.
[0057]
Next, the stage 23 is manually rotated about the rotating shaft 22 until it contacts the tip of the stage stopper 38 on the stage 33, and is set at the second position in FIG. At this time, the positioning unit 28 of the movable portion 23 a is not in contact with the cam follower 37 of the stage 33.
[0058]
Next, the first air cylinder 24a is operated by an external control means (not shown), and the movable portion 23a is moved along the first plane along the first axis parallel line L. ₁ To the side with a first thrust and a first moving speed.
[0059]
When the positioning unit 28 comes into contact with the cam follower 37 of the stage 33 as shown in FIG. 3, the first thrust is not set so as to move the stage 33. Therefore, the movable portion 23a is in the contacted position. Stop while maintaining the first thrust.
[0060]
Next, the second air cylinder (not shown) is operated by an external control means (not shown), and the stage 33 is moved along the second plane to the second axis parallel line L. ₂ To the side with a second thrust and a second moving speed.
[0061]
Then, the movable part 23a tries to resume movement at the first movement speed in the gap G direction by the maintained first thrust, but at this time, the first movement speed of the movable part 23a Is set so that it is faster than the second moving speed of the stage 33 and the first thrust is smaller than the second thrust, so that the positioning unit 28 and the cam follower 37 are always in contact with each other. As shown in FIG. 4, the movable portion 23a and the stage 33 are moved at the second moving speed until the contact portion 23s of the movable portion 23a contacts the movable portion stopper 27 and stops. And move together at the second moving speed.
[0062]
The first moving speed and the second moving speed are adjusted, for example, by adjusting the air supplied to the first air cylinder and the second air cylinder with a speed controller.
[0063]
At the movement end position of the movable part 23a (position where the contact part 23s contacts the movable part stopper 27), the bonding start ends (each roller side end part) of the work A and the work B are simultaneously at the same speed. It is inserted into the gap G, and is clamped between the stage 33 and the outer peripheral surface of the roller 21 by 1 to 2 mm from the bonding start end.
[0064]
After the bonding start ends of the workpieces A and B are crimped as shown in FIG. 4, the movable portion 23a stops at the movement end position defined by the movable portion stopper 27, and only the stage 33 is in the direction indicated by the arrow. The movement is continued at the second moving speed, and the workpiece A and the workpiece B are drawn into the gap G in a crimped state, and are sequentially crimped by the rotation of the roller 21 as shown in FIG. Is called.
[0065]
The speed at the time of inserting the workpiece A and workpiece B into the gap G at the start of bonding and the progress of the bonding is performed at the second moving speed, and is set to a speed of 75 mm / sec or less, for example.
[0066]
Further, the vacuum force for holding the workpiece A at this time is adjusted to a vacuum force that can be separated from the workpiece A holding surface 23h of the movable portion 23a when the workpiece A is drawn into the gap G. Has been.
[0067]
Since the movable portion stopper 27 on the stage 23 is installed so as to be adjustable in the moving direction of the movable portion 23a, only the final movement position of the movable portion 23a is adjusted by the position of the movable portion stopper 27. It is possible to set the start position for bonding the workpiece A and the workpiece B to an arbitrary position.
[0068]
Immediately before the end of bonding, the workpiece A (polarizing plate) is in the state shown in FIG. Ideally, the workpiece A and the workpiece B (glass substrate) do not contact until immediately before the roller 21, but the roller 21 and the movable portion 23a interfere with each other, so that the bonding end portion of the workpiece A is not inserted into the gap G. As shown in FIG. 5B, it falls on the workpiece B.
[0069]
Further, other factors that cause the workpiece A to fall onto the workpiece B before it is inserted into the gap G are as follows.
[0070]
That is, since the work A (polarizing plate) moves on the work A holding surface 23h of the movable portion 23a as the bonding process proceeds, the area where the work A is adsorbed decreases and the adsorbing force also decreases. .
[0071]
Since the workpiece A, that is, the polarizing plate itself has rigidity, an elastic restoring force is exerted to return to the flat shape which is the initial shape. When the restoring force exceeds the attracting force, the polarizing plate falls off the movable part 23a as shown in FIG.
[0072]
When the polarizing plate (work A) falls, the polarizing plate and the glass substrate (work B) come into contact before being inserted into the gap G. Since an adhesive is applied to the polarizing plate, the polarizing plate (work A) and the glass substrate (work B) are bonded before being nipped by the roller 21, as shown in FIG. 5B. End up.
[0073]
Since the laminating apparatus of the present invention has a structure in which the laminating is performed while extruding air by the roller 21, if the polarizing plate (work A) and the glass substrate (work B) are bonded before nipping by the roller 21. As shown in FIG. 5C, the air is hardly pushed out, and as a result, large bubbles remain between the polarizing plate and the glass substrate.
[0074]
Such air entrapment may cause a deterioration in quality. However, if the vacuum force of the movable portion 23a is simply increased in order to prevent the polarizing plate from falling, the adsorbed polarizing plate does not slide on the workpiece A holding surface 23h of the movable portion 23a during bonding, and is stuck. Problems such as misalignment occur.
[0075]
Therefore, the following measures are taken in this embodiment. In FIGS. 5A and 5B, which are enlarged views of the movable portion 23a, the movable portion 23a sucks the workpiece A by evacuation. In order to evacuate, an appropriate number of holes for suction are usually formed in the movable portion 23a. However, the movable portion 23a of the present embodiment does not have such an adsorption hole, and employs a porous material having air permeability.
[0076]
In the case of the suction hole, the suction is performed only at the hole portion. However, unlike the suction hole, the porous material of the present embodiment has a feature that the entire surface portion sucks the workpiece.
[0077]
The porous material is used up to the tip of the movable portion 23a, that is, the extended holding surface 23hh shown in FIG. 5D, and is processed so that the tip of the movable portion can escape from the roller 21 (according to the cylindrical shape of the roller 21). As described above, the inclined surface 23 extends from the contact portion 23s to the tip of the extended holding surface 23hh. _R Theoretically, the workpiece A can be held up to a place where only the gap portion provided so that the roller 21 and the movable portion 23a are not in contact with each other is separated.
[0078]
That is, the workpiece A can be adsorbed and held until just before the end of bonding, and the state of FIG. 5B can be suppressed as much as possible.
[0079]
Next, another embodiment of the present invention will be described with reference to FIGS. 6 to 13 in which the bonding end portion of the workpiece A is prevented from dropping onto the workpiece B before being nipped by the roller 21. FIG.
[0080]
In the present embodiment example, at the final stage of bonding, the polarizing plate (first member) is separated from the polarizing plate adsorbing portion (first holding means) by its own elastic restoring force and is positioned below the glass substrate (first As shown in FIG. 6, a receiving mechanism that is a mechanism for receiving the separated end face of the polarizing plate, for example, a polarizing plate pedestal, is provided so as not to contact the second member.
[0081]
6 to 13, the same parts as those in FIGS. 1 to 4 are denoted by the same reference numerals. In FIG. 6, reference numeral 50 denotes a slide guide disposed horizontally, for example, in a direction orthogonal to the rotation center axis of the roller 21 configured in the same manner as in FIGS.
[0082]
Reference numeral 53 denotes a stage (substrate adsorption portion; second holding means of the present invention) that horizontally adsorbs and holds the work B (glass substrate) on the upper surface, and a stage support member 53a is fixed on the lower surface thereof. An end portion of the stage support member 53a is fixed to a sliding member 54a that slides on the slide guide 50.
[0083]
Accordingly, the stage 53 that holds the workpiece B by suction can be moved along the slide guide 50 by a second moving means (not shown) (for example, a second air cylinder).
[0084]
Reference numeral 23a denotes a movable portion (polarizing plate adsorbing portion) configured similarly to FIGS. 1 to 4 to slidably adsorb and hold the workpiece A (polarizing plate). The rotating shaft 22 in FIGS. The stage 23, the first air cylinder 24a, the linear guide 25a, the cylinder joint 26a, the movable stopper 27, the positioning unit 28, the stage stopper 38, etc. are not shown.
[0085]
The work A holding surface 23h has the movable portion 23a set from the first position in FIG. 1 to the second position in FIG. 2 (lamination start position) as in the embodiment of FIGS. Sometimes, it is configured to face the workpiece B holding surface 53h with an angle of about 2 to 5 °.
[0086]
Reference numeral 55 a denotes a cradle support member provided on the bonding end portion side of the work B so that one end face in the height direction is slightly higher than the height of the work B sucked and held on the stage 53.
[0087]
One end of a coil spring 56 is fixed to the lower portion of the cradle support member 55a from the stage 53, and the other end of the coil spring 56 is locked to a locking portion 57 on the lower surface of the stage 53. Thus, the cradle support member 55a is held in close contact with the side surface of the stage 53 on the side of the bonding terminal portion of the workpiece B by the spring force of the coil spring 56.
[0088]
A cam follower that comes into contact with the positioning unit 28 is provided on the side surface of the stage 53 on the workpiece B bonding end portion side (not shown) in the same manner as the cam follower 37 in FIGS.
[0089]
Polarized light whose bottom surface is formed to have a width dimension larger than the width dimension of the cradle support member 55a on one end face in the height direction of the cradle support member 55a, and is extended by a predetermined distance on the bonding terminal side of the workpiece B. A plate receiving base 55 is fixed.
[0090]
As described above, since one end surface in the height direction of the cradle support member 55a is a position slightly higher than the height of the workpiece B, the cradle support member 55a is held in close contact with the stage 53. The lower surface of the base 55 faces the work B with a slight gap therebetween.
[0091]
On the polarizing plate receiving base 55, a contact surface 55b that receives the bonding end portion of the workpiece A falling from the workpiece A holding surface 23h of the movable portion 23a has a width (thickness) of 2 to 5 mm and an angle of 50 to 70 °. Is formed.
[0092]
The contact surface 55b is formed in a slope shape so that the contact with the end surface of the work A is a line contact, and in order to prevent the transfer of the adhesive applied to the work A (polarizing plate), for example, tossal treatment or Teflon (Registered trademark) processing etc. are performed.
[0093]
The other end in the height direction of the cradle support member 55a is fixed to a slide member 54b that slides on the slide guide 50. Therefore, the cradle support member 55 a and the polarizing plate pedestal 55 that are in close contact with the stage 53 by the coil spring 56 can move along the slide guide 50 as the stage 53 moves.
[0094]
Reference numeral 58 denotes a polarizing plate cradle stopper (second movement stopping means of the present invention) that is fixed to the apparatus main body and stops in contact with the cradle support member 55a in the vicinity of the gap G.
[0095]
The stopper 58 comes into contact with the cradle support member 55a immediately before the gap G when the tip of the polarizing plate pedestal 55 facing the gap G moves together with the stage 53 to the vicinity of the gap G. It is provided at a position where the member 55a and the polarizing plate receiving base 55 are stopped. The mounting position of the polarizing plate cradle stopper 58 can be arbitrarily changed.
[0096]
6 to 11 show a bonding process when bonding is performed using the apparatus configured as described above. In these drawings, the first speed for moving the movable portion 23a (first holding means), the second speed for moving the stage 53 (second holding means), and their moving thrust are shown in FIG. -It is set similarly to the embodiment described in FIG.
[0097]
First, FIG. 6 shows an initial state in which the movable portion 23a holding and holding the workpiece A is disposed opposite to the stage 53 holding and holding the workpiece B at a predetermined angle as shown in the second position of FIG. ing.
[0098]
Next, each part of the bonding apparatus performs the same operation as the operation described in FIGS. That is, the first air cylinder 24a is operated to move the movable portion 23a to the gap G side, the positioning unit 28 is brought into contact with the cam follower (not shown) of the stage 53, and then the second air cylinder (not shown) is moved. The stage 53 is moved to the gap G side along the slide guide 50 by operating.
[0099]
Then, as the stage 53 moves, the cradle support member 55a, the polarizing plate pedestal 55, and the movable portion 23a move in the direction of the arrow in FIG. 7, and the contact portion 23s of the movable portion 23a moves as shown in FIG. The movement of the movable part 23a is completed when it comes into contact with the movable part stopper 27.
[0100]
At the movement end position of the movable part 23a (position where the contact part 23s contacts the movable part stopper 27), the bonding start ends (each roller side end part) of the work A and the work B are simultaneously at the same speed. As shown in FIG. 7, it is inserted into the gap G, and is clamped by 1 to 2 mm from the bonding start end on the outer peripheral surface of the stage 53 and the roller 21.
[0101]
After the bonding start ends of the workpieces A and B are crimped as shown in FIG. 7, the movable portion 23a stops at the movement end position defined by the movable portion stopper 27, and the stage 53 and the cradle support member 55a. Then, the polarizing plate pedestal 55 continues to move, and the workpiece A and the workpiece B are drawn into the gap G in a pressure-bonded state, and are sequentially pressed and bonded together by the rotation of the roller 21 as shown in FIG.
[0102]
In the middle of the bonding process as shown in FIG. 8, the workpiece A, that is, the polarizing plate is deformed by the opposite angle between the movable portion 23 a and the stage 53 with the roller 21 as a fulcrum. Since the polarizing plate itself has rigidity, an elastic restoring force works.
[0103]
The direction of this elastic restoring force works in a direction away from the movable portion 23a which is a polarizing plate adsorption portion, that is, a direction in which the polarizing plate falls as indicated by an arrow in FIG. Therefore, when the elastic restoring force becomes larger than the attracting force attracting the polarizing plate, the polarizing plate leaves the movable portion 23a.
[0104]
When the polarizing plate pedestal 55 of the present invention is not provided when the polarizing plate is separated from the movable portion 23a, the polarizing plate and the glass substrate are bonded as shown in FIG. c) Residual bubbles are induced as shown in c).
[0105]
However, when the polarizing plate support 55 is provided as in the present invention, the dropped polarizing plate (work A) is held by the contact surface 55b of the polarizing plate support 55 as shown in FIG. That is, the contact with the glass substrate can be prevented, and as a result, the entrapment of bubbles as shown in FIG. 5C can be suppressed.
[0106]
The polarizing plate pedestal 55 moves in the direction of the gap G at the same speed as the stage 53 while holding the bonding end of the polarizing plate (work A) at the contact surface 55b. When the tip on the side moves to the position immediately before the roller 21 as shown in FIG. 10A and the cradle support member 55a comes into contact with the polarizing plate cradle stopper 58, the cradle support member 55a and the polarizing plate cradle base 55 are The movement stops.
[0107]
After that, the stage 53 continues to move in the direction indicated by the arrow against the spring force of the coil spring 5, and the bonding is performed at the position where the bonding end portions of the workpieces A and B have passed through the gap G as shown in FIG. Complete.
[0108]
The installation position of the polarizing plate support stopper 58 can be arbitrarily changed, and the stop position of the polarizing plate support 55 can be freely set. Thereby, even if the thickness of the polarizing plate (work A) is different, the polarizing plate can be held until just before the bonding.
[0109]
That is, when the polarizing plate is thick, the polarizing plate pedestal stopper 58 is disposed at the position of FIG. 10B, which is a position before the position of FIG. When the polarizing plate is thin, it is disposed at a position on the roller 21 side.
[0110]
Further, since the section for holding the polarizing plate can be arbitrarily set, it is possible to set the optimum conditions for the polarizing plate holding section.
[0111]
In bonding the polarizing plate (work A) and the glass substrate (work B), an adhesive is applied to the polarizing plate side. Since the polarizing plate receiving base 55 receives this adhesive surface, the adhesive applied to the polarizing plate is transferred to the polarizing plate receiving base 55 when repeatedly used.
[0112]
Therefore, in the present invention, the contact between the polarizing plate receiving base 55 and the polarizing plate is a line contact in which only the edge portion of the polarizing plate is in contact by forming the contact surface 55b on the inclined surface as shown in FIG.
[0113]
Further, the contact surface 55b for receiving the polarizing plate was subjected to a surface treatment such as a toric treatment or a Teflon treatment to further suppress the transfer of the adhesive. By performing such processing and processing, it is possible to significantly reduce the time taken to remove the adhesive on the polarizing plate receiving base 55.
[0114]
Next, a more specific embodiment of the present invention is shown in FIG. FIG. 13 shows only main parts in this embodiment, that is, a polarizing plate (work A), a glass substrate (work B), a movable portion 23a, a stage 53, a polarizing plate pedestal 55, a pedestal support member 55a, and a contact surface 55b. Show.
[0115]
The main conditions for implementation are as follows.
[0116]
Opposing angle between polarizing plate and horizontally held glass substrate: 3 °
Gap between the lower surface of the polarizing plate pedestal 55 and the glass substrate: 0.5 mm
Thickness (width) of the portion forming the contact surface 55b of the polarizing plate cradle: 3 mm
Angle of contact surface 55b of polarizing plate cradle: 60 °
Surface treatment of the contact surface 55b of the polarizing plate cradle: tocical treatment
Polarizing plate thickness: 0.255 mm
Bonding speed: 30mm / sec
Vacuum force of polarizing plate adsorption part (movable part 23a): 0.4 Mpa compressed air is supplied to the vacuum ejector.
[0117]
As a result of bonding under the above conditions, the occurrence frequency of bubbles remaining on the bonding surface of the glass substrate and the polarizing plate is extremely reduced, and the time spent for the defoaming process, which is the next process, is greatly reduced. It became possible.
[0118]
Moreover, the contact with the contact surface 55b of the end face (bonding terminal portion) of the polarizing plate was a line contact, and the contact surface 55b was subjected to a surface treatment, so that it was applied to the polarizing plate. The transfer of the adhesive onto the contact surface 55b is very little.
[0119]
As described above, according to the apparatus of the above-described embodiment, the roller 21 and the stage 33 or the bonding start end of the workpiece A and the workpiece B can be simultaneously made at the same speed without special control by a servo motor or the like. It was possible to insert into the gap G formed by 53, and “push marks” seen at the bonding start end could be prevented 100%.
[0120]
In the above-described embodiment, the rotation shaft 22 for rotating the stage 23 is disposed above the roller 21 in parallel with the rotation center axis. However, the present invention is not limited to this, and is shown by a solid line in FIG. In the configuration, a rotation axis for rotating the stage 23 may be provided on any side of the stage 23 along a line orthogonal to the rotation center axis of the roller 21.
[0121]
In the case of such a configuration, the workpiece A is moved to the movable portion 23a at the first position with the workpiece A holding surface 23h of the movable portion 23a facing upward on the extension line side where the rotation center axis of the roller 21 is extended to somewhere. Then, suction and holding are performed, and then the stage 23 is rotated to set the apparatus at the second position indicated by the solid line in FIG.
[0122]
Further, in the configuration shown by the solid line in FIG. 2, the rotation axis 22 of the stage 23 is parallel to the rotation center axis of the roller 21 and is not the side near the movable portion stopper 27 but the side near the stage stopper 38. May be provided.
[0123]
In this case, the workpiece A is movable at the first position with the workpiece A holding surface 23h of the movable portion 23a facing upward in a region opposite to the roller 21 with the rotation axis of the stage 23 as a boundary. The device is placed on the portion 23a for suction and holding, and then the stage 23 is rotated to set the apparatus at the second position indicated by the solid line in FIG.
[0124]
In the present invention, the first member (work A) is a plastic plate, sheet or film, and the second member (work B) is a metal, plastic or glass substrate.
[0125]
In addition, the second moving speed that is slower than the first moving speed is, for example, about 30 mm / sec to 100 mm / sec, which is a good speed range.
[0126]
Further, the smaller the diameter of the roller 21 is, the closer the roller 21 and the movable part 23a can be, and the work A can be adsorbed and held until just pasting. For example, the roller diameter is φ10 and the rubber hardness is increased. It is preferable to select 30.
[0127]
However, if the roller diameter is made smaller than φ10, the thickness of the rubber becomes thin, so the numerical value of rubber hardness 30 is not reliable.
[0128]
Moreover, although the magnitude | size of the 1st and 2nd member (work A, B) used by this invention is applied by 60 mm x 100 mm or less, there is no restriction | limiting in particular to enlarge.
[0129]
Ideally, the sheet used as the first member is thin and has low rigidity, and the substrate used as the second member is hard (no elasticity).
[0130]
The vacuum hole pattern of the workpiece A holding surface 23h and the workpiece B holding surface 33h is formed in a lattice shape, a staggered shape, or the like, for example.
[0131]
Further, the base plate 20, the slide guide 50, the roller 21, and the rotating shaft 22 of the apparatus main body are not limited to being horizontally disposed as shown in FIGS. 1 to 4 and 6 to 11, but have a predetermined angle. May be arranged.
[0132]
Further, the first and second holding means, the first and second moving means, the movement stopping means, the angle setting means, the gap adjusting means, the base body, and the receiving mechanism of the present invention are not limited to the above-described embodiment, and You may comprise by the other means which show | plays this effect | action and effect.
[0133]
For example, in FIGS. 6 to 11, the cradle support member 55 a is integrally held on the stage 53 by the coil spring 56, and the cradle support member 55 a comes into contact with the polarizing plate cradle stopper 58 so that the member 55 a Although the movement is stopped, the present invention is not limited to this, and a connecting tool for connecting the stage 53 and the receiving base support member 55a is provided at the contact position between the stage 53 and the receiving base support member 55a. A stopper that stops the movement of the cradle support member 55a while disengaging the connection may be provided.
[0134]
Further, the movable portion 23a in FIGS. 6 to 11 (embodiment example in which the polarizing plate receiving base 55 is provided) may be configured to have the extended holding surface 23hh and the inclined surface 23R as shown in FIG. 5D. good.
[0135]
Further, the length of the contact surface 55b of the polarizing plate receiving base 55 of FIGS. 6 to 11 along the axial direction of the roller 21 does not have to be the same as the width of the workpiece A (polarizing plate). A polarizing plate base having a relatively small contact area may be arranged in parallel along the axial direction of the roller 21 at a predetermined interval within a range in which the A bonding end portion does not fall.
[0136]
The bonding apparatus of the present invention is not limited to the bonding of the glass substrate of the touch panel and the polarizing plate, but also in the manufacturing process of bonding a workpiece such as a liquid crystal display manufacturing process or a high-density disk-shaped recording disk. It is possible to apply without using special control with a motor or the like.
[0137]
【The invention's effect】
(1) As described above, according to the inventions described in claims 1 to 16, “push marks” at the time of bonding can be achieved with a simple apparatus configuration without performing expensive equipment such as a servo motor or special control. 100% can be prevented. For this reason, a motor controller or the like can be omitted, and the apparatus can be downsized and the control can be simplified.
(2) According to the invention described in claim 2, it is possible to determine the bonding start ends of the first and second members only by changing the setting of the movement stop means, and the bonding start position adjustment is easy. It becomes.
(3) According to the invention described in claim 3, after the contact piece of the first holding means comes into contact with the second holding means, the bonding start ends of the first and second members are cylinders. The first and second members can be moved at the same speed (second speed) until they are inserted into the gap between the body and the second holding means.
(4) According to the invention described in claim 4, the angle formed by the first member and the second member inserted into the gap at the start of bonding can be arbitrarily set.
(5) According to the invention described in claim 5, the first holding means can be bonded as close as possible to the cylindrical body side, and the first member can be attached to the end of the bonding by the extended holding surface. Can be held. Thereby, generation | occurrence | production of the bubble by the member fall before completion | finish of bonding can be prevented, or generation | occurrence | production of nonuniformity can be prevented.
(6) According to the invention described in claim 7, it is not necessary to provide a suction hole, and even when the holding surface of the first holding means is directed downward, the first member is attached at the end of bonding. Can be reliably held, and generation of bubbles due to dropping of members before the end of bonding can be prevented, and occurrence of uneven bonding can be prevented.
(7) According to the invention described in claim 8, the gap between the cylindrical body and the second holding means is arbitrarily adjusted according to the thicknesses of the first and second members to be bonded together. Can do.
(8) According to the invention described in claim 10, the first member can be easily placed and held on the holding surface of the first holding means at a position other than the first plane position.
(9) According to the invention described in claim 11, it is possible to perform the bonding well by using an air cylinder having a cost of about 5% as compared with the case of using a conventional servo motor, and the apparatus price is greatly increased. In addition, the control is greatly simplified.
(10) Further, according to the invention described in claims 13 to 16, even if the first member, for example, the polarizing plate falls off the first holding means during the bonding step, the polarizing plate is the second. Since there is no longer any adhesion to such a member, for example, a glass substrate, the frequency of occurrence of bubbles is extremely low. As a result, the time required for the defoaming step, which is the next step, can be shortened (from 120 minutes to about 10 minutes).
(11) According to the inventions described in claims 15 and 16, the contact surface of the receiving mechanism is structured so that only the edge of the polarizing plate can be touched, and the contact surface of the receiving mechanism is treated with a toxical treatment or a Teflon treatment. As a result of the surface treatment, almost no adhesive transfer from the polarizing plate occurred, and maintenance opportunities such as cleaning necessary for the receiving mechanism could be suppressed.
(12) According to the inventions of claims 17 and 18, the occurrence of “push marks” at the time of bonding can be prevented 100% by a simple method. Moreover, if the method of this invention is used, a bonding apparatus can be comprised, without using components, such as an expensive servomotor.
(13) According to the invention described in claim 18, the first member can be easily placed and held on the holding surface of the first holding means at a position other than the first plane position.
[Brief description of the drawings]
FIG. 1 is a schematic configuration diagram of an embodiment of a bonding apparatus according to the present invention.
FIG. 2 is a configuration diagram showing an embodiment of a bonding apparatus according to the present invention and showing a state immediately after the first holding means is rotated to the second position.
FIG. 3 is a configuration diagram illustrating an embodiment of a bonding apparatus according to the present invention when a contact piece comes into contact with a second holding unit and the first holding unit stops.
FIG. 4 is a configuration diagram illustrating an embodiment of a bonding apparatus according to the present invention when the first holding unit comes into contact with the stopper and the movement of the first holding unit is stopped.
FIG. 5 is an explanatory diagram showing a state immediately before the end of bonding by the bonding apparatus.
FIG. 6 is an explanatory view showing an initial state in a bonding step according to another embodiment of the present invention.
FIG. 7 is an explanatory diagram showing a state at the start of bonding in a bonding step according to another embodiment of the present invention.
FIG. 8 is an explanatory diagram showing a state in which the bonding is in progress in the bonding process of another embodiment of the present invention.
FIG. 9 is an explanatory view showing a state where a dropped polarizing plate is received in a bonding step according to another embodiment of the present invention.
FIG. 10 is an explanatory diagram showing a state when bonding is performed in a state where a polarizing plate is received in a bonding step of another embodiment of the present invention.
FIG. 11 is an explanatory diagram showing a state at the time of completion of bonding in a bonding process according to another embodiment of the present invention.
FIG. 12 is an explanatory diagram of a main part of another embodiment of the present invention.
FIG. 13 is an explanatory diagram of a main part of another embodiment of the present invention.
FIG. 14 is an explanatory diagram showing an example of a conventional bonding method.
FIG. 15 is an explanatory view showing another example of a conventional bonding method.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 20 ... Base plate, 21 ... Roller, 22 ... Rotating shaft, 23, 33, 53 ... Stage, 23a ... Movable part, 23h ... Work A holding surface, 23hh ... Extension holding surface, 23s ... Contact part, 24a ... 1st Air cylinder, 25a ... first linear guide, 26a ... first cylinder joint, 27 ... movable part stopper, 28 ... positioning unit, 33h, 53h ... work B holding surface, 37 ... cam follower, 38 ... stage stopper, 50 ... Slide guide, 54a, 54b ... Sliding member, 55 ... Polarizer cradle, 55a ... Pad support member, 55b ... Contact surface, 56 ... Coil spring, 57 ... Locking portion, 58 ... Polarizer cradle stopper, A, B ... work, G ... gap, L ₁ ... first axis parallel line, L ₂ ... second axis parallel line.

Claims

A laminating apparatus for laminating at least one of the first and second members coated with an adhesive,
A rotatable cylinder having elasticity and a predetermined diameter;
A first axis parallel line that is parallel to the central axis of rotation of the cylinder and is present at a predetermined portion of the outer peripheral surface of the cylinder, and a first orthogonal line that is orthogonal to the first axis parallel line A first holding means for holding the first member on the first plane to be formed;
A second axis that is separated from the outer peripheral surface of the cylinder by a predetermined distance, is parallel to the first axis parallel line, and faces the surface of the first plane opposite to the cylinder. A second member is disposed on a second plane formed by a parallel line and a second orthogonal line orthogonal to the second axis parallel line and having a predetermined angle with respect to the first plane. Second holding means for holding;
The first holding means is moved at a first speed along the first orthogonal line in a plane region on one side of the first plane with the first axis parallel line as a boundary. One moving means;
The second holding means is configured such that, in the second plane, the first plane extending from the one side plane with the second axis parallel line as a boundary along the second orthogonal line from the one side plane to the other side plane. Second moving means for moving at a second speed slower than the speed of
Each end of the first member and the second member is inserted into a gap formed between the first axis parallel line and the second axis parallel line, and the first holding is performed. And a first movement stop means for stopping the movement of the means, and bonding the first member and the second member within the gap.

The bonding apparatus according to claim 1, wherein the first movement stop unit is configured to arbitrarily change a movement stop position of the first holding unit.

The first holding means is provided with a contact piece that comes into contact with the second holding means when the first holding means is moved, and the moving thrust of the first moving means is the second moving means. The bonding apparatus according to claim 1, wherein the bonding apparatus is set to be smaller than the moving thrust.

The bonding apparatus according to claim 1, further comprising an angle setting unit configured to arbitrarily set the predetermined angle.

The first movement stop means has a stopper disposed between the cylinder and the first holding means, and the cylinder side end of the first holding means is in contact with the stopper. The bonding apparatus according to claim 1, wherein an abutting portion that comes into contact with and an extended holding surface that extends from the corresponding contacting portion to the cylindrical body by a predetermined distance are formed.

The bonding apparatus according to claim 1, wherein the first holding unit holds the first member with a predetermined suction force.

The bonding apparatus according to claim 1, wherein the first holding unit has a porous material on a holding surface thereof.

The bonding apparatus according to claim 1, further comprising a gap adjusting unit that adjusts an interval of the gap.

The bonding apparatus according to claim 1, wherein an interval of the gap is formed to be equal to or less than a total thickness of the first member and the second member.

The bonding apparatus according to claim 1, further comprising a base that moves the first holding unit to a position other than the first planar position.

The bonding apparatus according to claim 1, wherein the first moving unit includes a first air cylinder, and the second moving unit includes a second air cylinder.

2. The bonding apparatus according to claim 1, wherein the first member is a plastic plate, a sheet, or a film, and the second member is a metal, plastic, or glass substrate.

The first member on the side of the bonding end portion of the second member has a contact surface for receiving the bonding end portion of the first member and is integrally held by the second holding means. A receiving mechanism disposed at a portion that is a predetermined distance from the second member;
2. A second movement stop means for stopping the movement of the receiving mechanism when a tip position of the receiving mechanism facing the gap moves to a predetermined position in the vicinity of the gap. Item 2. A bonding apparatus according to Item 1.

The bonding apparatus according to claim 13, wherein the second movement stop means is configured to be able to arbitrarily set and change the movement stop position of the receiving mechanism.

The bonding apparatus according to claim 13, wherein the contact surface of the receiving mechanism is formed on an inclined surface that can be in line contact with the bonding end portion of the first member.

The bonding apparatus according to claim 13, wherein the contact surface of the receiving mechanism is subjected to a surface treatment that suppresses transfer of the adhesive.

A laminating method for laminating the first and second members having an adhesive applied to at least one of them,
A rotatable cylinder having elasticity and a predetermined diameter;
A first axis parallel line that is parallel to the central axis of rotation of the cylinder and is present at a predetermined portion of the outer peripheral surface of the cylinder, and a first orthogonal line that is orthogonal to the first axis parallel line A first holding means for holding the first member on the first plane to be formed;
A second axis that is separated from the outer peripheral surface of the cylinder by a predetermined distance, is parallel to the first axis parallel line, and faces the surface of the first plane opposite to the cylinder. A second member is disposed on a second plane formed by a parallel line and a second orthogonal line orthogonal to the second axis parallel line and having a predetermined angle with respect to the first plane. Second holding means for holding;
A first moving means for moving the first holding means along the first orthogonal line in a plane area on one side of the first plane with the first axis parallel line as a boundary; ,
Second moving the second holding means along the second orthogonal line from one of the second planes to a plane on the other side of the second axis parallel line. Means of transportation,
A contact piece that is provided on the first holding means and contacts the second holding means when the first holding means moves;
The first holding means holding the first member is disposed at a starting position on the one side of the first plane and separated from the first axis parallel line by a predetermined distance, The second holding means holding the second member is a plane on the one side of the second plane, is spaced from the second axis parallel line by a predetermined distance, and does not contact the contact piece. A first step disposed at a starting position;
The first holding means is moved from the start position to the first axis parallel line side at the first moving speed and the first moving thrust, and the abutting piece comes into contact with the second holding means. Two steps;
After completion of the second step, a second speed slower than the first speed and larger than the first movement thrust while maintaining the first movement thrust with respect to the first holding means. The second holding means is moved to the second axis parallel line side by a movement thrust of 2, and each end portion of the first member and the second member is moved to the first axis parallel line and the second axis. A third step of inserting into a gap formed between the axial parallel lines;
After completion of the third step, the second holding means is moved to the other plane of the second plane at the second speed and with the second moving thrust, and the first member and the second member are moved. A bonding method comprising: performing a fourth step of bonding the members in the gap.

The bonding method according to claim 17, wherein the first step includes a step of holding the first member at a position other than the start position and then disposing the first member at the start position.