# US 2009/0260738 A1 · Method for manufacturing optical display device and material roll for use therein

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- Number: US 2009/0260738 A1
- Document ID: US20090260738A1
- Status: Published application
- Kind: A1
- Application number: 12/423,095
- Filed: 2009-04-14
- Published: 2009-10-22
- Earliest claimed: 2008-04-16
- Assignees: Nitto Denko Corporation
- Inventors: Kazuo KITADA; Takuya NAKAZONO; Satoru KOSHIO; Tomokazu YURA
- Web page: https://patentgrep.com/patent/US20090260738A1

## CPC

- B32B 38/04: Punching, slitting or perforating
- B32B 2037/268: {Release layers}
- B32B 2457/202: LCD, i.e. liquid crystal displays
- G02B 5/3025: {Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state (G02B5/3008, G02B5/3016 take precedence)}
- G02F 1/133528: {Polarisers}
- Y10T 156/1056: Perforating lamina
- Y10T 156/1057: Subsequent to assembly of laminae
- Y10T 156/1062: Prior to assembly
- Y10T 156/1084: of continuous or running length bonded web
- Y10T 156/1085: One web only
- Y10T 428/1476: Release layer
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- G02B: OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02F: OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

The invention provides a method for manufacturing an optical display device including an optical display unit and an optical film that includes a polarizing plate and is bonded to the optical display unit. The method comprises the steps of: unwinding and feeding a long sheet material from a roll of the long sheet material, wherein the long sheet material includes the optical film, a pressure-sensitive adhesive layer and a release film laminated in this order and has undergone a slitting process in a direction parallel or at a constant angle to an absorption axis of the polarizing plate so that it has a width corresponding to a short or long side of the optical display unit; inspecting the optical film of the fed long sheet material to detect a defect; cutting a part of the long sheet material other than the release film into a length corresponding to a long or short side of the optical display unit, while separating the detected defect; bonding a non-defective cut piece of the optical film to a surface of the optical display unit; and rejecting a defect-containing part of the optical film.

## Claims

### Claim 1

A method for manufacturing an optical display device including an optical display unit and an optical film that includes a polarizing plate and is bonded to the optical display unit, comprising the steps of:
unwinding and feeding a long sheet material from a roll of the long sheet material, wherein the long sheet material includes the optical film, a pressure-sensitive adhesive layer and a release film laminated in this order and has undergone a slitting process in a direction parallel or at a constant angle to an absorption axis of the polarizing plate so that it has a width corresponding to a short or long side of the optical display unit;
inspecting the optical film of the fed long sheet material to detect a defect;
cutting a part of the long sheet material other than the release film into a length corresponding to a long or short side of the optical display unit, while separating the detected defect;
bonding a non-defective cut piece of the optical film to a surface of the optical display unit; and
rejecting a defect-containing part of the optical film.

### Claim 2

A method for manufacturing an optical display device including an optical display unit and an optical film that includes a polarizing plate and is bonded to the optical display unit, comprising the steps of:
unwinding and feeding a long sheet material from a roll of the long sheet material, wherein the long sheet material includes the optical film, a pressure-sensitive adhesive layer and a release film laminated in this order, has defect information indentifying a defect position and has undergone a slitting process in a direction parallel or at a constant angle to an absorption axis of the polarizing plate so that it has a width corresponding to a short or long side of the optical display unit;
cutting a part of the long sheet material other than the release film into a length corresponding to a long or short side of the optical display unit, while separating the defect based on the defect information;
bonding a non-defective cut piece of the optical film to a surface of the optical display unit; and
rejecting a defect-containing part of the optical film.

### Claim 3 (depends on 1, 2)

The method according to claim 1 or 2, comprising the step of providing a roll of the long sheet material having undergone the slitting process so that it has a width corresponding to the short side of the optical display unit and another roll of the long sheet material having undergone the slitting process so that it has a width corresponding to the long side of the optical display unit, wherein the long sheet material having a width corresponding to the short side is cut into a length corresponding to the long side, and the long sheet material having a width corresponding to the long side is cut into a length corresponding to the short side.

### Claim 4 (depends on 1, 2)

The method according to any one of claim 1 or 2, wherein the optical display unit is a VA or IPS mode liquid crystal panel.

### Claim 5

A material roll for use in the process of cutting it into a specific-length piece to be bonded to a surface of an optical display unit, comprising:
a roll of a long sheet material including an optical film, a pressure-sensitive adhesive layer and a release film laminated in this order, wherein the optical film includes a polarizing plate, and having undergone a slitting process in a direction parallel or at a constant angle to an absorption axis of the polarizing plate so that it has a width corresponding to a short or long side of the optical display unit.

### Claim 6 (depends on 5)

The material roll according to claim 5, wherein the optical display unit for use in bonding is a VA or IPS mode liquid crystal panel.