Method and system for manufacturing optical display device

A method for manufacturing an optical display device in which optical films are bonded to an optical display unit, comprising:

• a first bonding step of drawing a long sheet material having a first optical film out from a first roll on which the long sheet material is wound up, cutting at least the first optical film into a predetermined length and, while feeding the long sheet material having the first optical film cut, bonding the first optical film cut onto one surface of the optical display unit that is successively fed;
• a second bonding step of drawing a long sheet material having a second optical film out from a second roll on which the long sheet material is wound up, cutting at least the second optical film into a predetermined length and, while feeding the long sheet material having the second optical film cut, bonding the second optical film cut onto the other surface of the optical display unit that is successively fed;
• a first roll exchanging step of exchanging a first roll of a previous category for a first roll of a latter category and joining the first optical films of the previous category and the latter category at the time of exchanging categories;
• and
• a second roll exchanging step of exchanging a second roll of a previous category for a second roll of a latter category and joining the second optical films of the previous category and the latter category at the time of exchanging categories,
• wherein the first bonding step or the second bonding step is stopped and the first roll exchanging step or the second roll exchanging step corresponding thereto is performed when the number X of remaining sheets of the optical display units of the previous category prior to bonding becomes substantially equal to the number N1 or substantially equal to the number N2 at the time of exchanging categories,
• assuming that the number of optical display units that are bonded substantially in correspondence with the first optical films that are present from a joining position of the first optical film to a bonding position of the first optical film is N1, and
• that the number of optical display units that are bonded substantially in correspondence with the second optical films that are present from a joining position of the second optical film to a bonding position of the second optical film is N2.

A method for manufacturing an optical display device in which optical films are bonded to an optical display unit, comprising:

• a first bonding step of drawing a long sheet material having a first optical film out from a first roll on which the long sheet material is wound up, cutting at least the first optical film into a predetermined length and, while feeding the long sheet material having the first optical film cut, bonding the first optical film cut onto one surface of the optical display unit that is successively fed;
• a second bonding step of drawing a long sheet material having a second optical film out from a second roll on which the long sheet material is wound up, cutting at least the second optical film into a predetermined length and, while feeding the long sheet material having the second optical film cut, bonding the second optical film cut onto the other surface of the optical display unit that is successively fed;
• a first roll exchanging step of exchanging a first roll of a previous category for a first roll of a latter category and joining the first optical films of the previous category and the latter category at the time of exchanging categories;
• and
• a second roll exchanging step of exchanging a second roll of a previous category for a second roll of a latter category and joining the second optical films of the previous category and the latter category at the time of exchanging categories, wherein,
• when N1 is larger than N2, the first bonding step and the second bonding step are stopped and the first roll exchanging step is performed when the number X of remaining sheets of the optical display units of the previous category prior to bonding becomes substantially equal to the number N1;
• the first bonding step and the second bonding step are started again;
• and the first bonding step and the second bonding step are stopped and the second roll exchanging step is performed when the number X of remaining sheets of the optical display units of the previous category prior to bonding becomes substantially equal to the number N2 at the time of exchanging categories, and
• when N1 is smaller than N2, the first bonding step and the second bonding step are stopped and the second roll exchanging step is performed when the number X of remaining sheets of the optical display units of the previous category prior to bonding becomes substantially equal to the number N2;
• the first bonding step and the second bonding step are started again;
• and the first bonding step and the second bonding step are stopped and the first roll exchanging step is performed when the number X of remaining sheets of the optical display units of the previous category prior to bonding becomes substantially equal to the number N1 at the time of exchanging categories, and
• when N1 is substantially equal to N2, the first bonding step and the second bonding step are stopped and the first roll exchanging step and the second roll exchanging step are performed when the number X of remaining sheets of the optical display units of the previous category prior to bonding becomes substantially equal to the number N1 or substantially equal to the number N2 at the time of exchanging categories,
• assuming that the number of optical display units that are bonded substantially in correspondence with the first optical films that are present from a joining position of the first optical film to a bonding position of the first optical film is N1, and
• that the number of optical display units that are bonded substantially in correspondence with the second optical films that are present from a joining position of the second optical film to a bonding position of the second optical film is N2.

A system for manufacturing an optical display device in which an optical film is bonded to an optical display unit, comprising:

• an optical display unit feeding apparatus that successively feeds optical display units;
• an optical film feeding apparatus that draws a long sheet material having an optical film out from a roll on which the long sheet material is wound up, cuts at least the optical film into a predetermined length, and feeds the long sheet material having the optical film cut;
• a bonding apparatus that bonds the optical film cut fed from the optical film feeding apparatus onto a surface of the optical display unit fed from the optical display unit feeding apparatus;
• and
• a controller that operates or stops each of the apparatuses, wherein
• the optical film feeding apparatus has a roll exchanging section for exchanging a roll of a previous category for a roll of a latter category and joining the optical films of the previous category and the latter category at the time of exchanging categories,
• the optical display unit feeding apparatus has a counting section that counts the number of feeding of the optical display units, and
• the controller stores the number N of optical display units that are bonded substantially in correspondence with the optical films that are present from a joining position of the optical film to a bonding position of the optical film, and stops each of the apparatuses when the number X of remaining sheets of the optical display units of the previous category prior to bonding becomes substantially equal to the number N at the time of exchanging categories based on information from the counting section.

A system for manufacturing an optical display device in which optical films are bonded to an optical display unit, comprising:

• an optical display unit feeding apparatus that successively feeds optical display units;
• a first optical film feeding apparatus that draws a long sheet material having a first optical film out from a first roll on which the long sheet material is wound up, cuts at least the first optical film into a predetermined length, and feeds the long sheet material having the first optical film cut;
• a first bonding apparatus that bonds the first optical film cut fed from the first optical film feeding apparatus onto one surface of the optical display unit fed from the optical display unit feeding apparatus;
• a feeder that carries and feeds the optical display unit after the first optical film is bonded;
• a second optical film feeding apparatus that draws a long sheet material having a second optical film out from a second roll on which the long sheet material is wound up, cuts at least the second optical film into a predetermined length, and feeds the long sheet material having the second optical film cut;
• a second bonding apparatus that bonds the second optical film cut fed from the second optical film feeding apparatus onto the other surface of the optical display unit fed from the feeder;
• and
• a controller that operates or stops each of the apparatuses, wherein
• the first optical film feeding apparatus has a first roll exchanging section for exchanging a first roll of a previous category for a first roll of a latter category and joining the first optical films of the previous category and the latter category at the time of exchanging categories,
• the second optical film feeding apparatus has a second roll exchanging section for exchanging a second roll of a previous category for a second roll of a latter category and joining the second optical films of the previous category and the latter category at the time of exchanging categories,
• the optical display unit feeding apparatus has a counting section that counts the number of feeding of the optical display units,
• the controller stores the number N1 of optical display units that are bonded substantially in correspondence with the first optical films that are present from a joining position of the first optical film to a bonding position of the first optical film, and stores the number N2 of optical display units that are bonded substantially in correspondence with the second optical films that are present from a joining position of the second optical film to a bonding position of the second optical film, and
• the controller stops each of the apparatuses when the number X of remaining sheets of the optical display units of the previous category prior to bonding becomes substantially equal to the number N1 or the number N2 at the time of exchanging categories based on information from the counting section.

A system for manufacturing an optical display device in which optical films are bonded to an optical display unit, comprising:

• an optical display unit feeding apparatus that successively feeds optical display units;
• a first optical film feeding apparatus that draws a long sheet material having a first optical film out from a first roll on which the long sheet material is wound up, cuts at least the first optical film into a predetermined length, and feeds the long sheet material having the first optical film cut;
• a first bonding apparatus that bonds the first optical film cut fed from the first optical film feeding apparatus onto one surface of the optical display unit fed from the optical display unit feeding apparatus;
• a feeder that carries and feeds the optical display unit after the first optical film is bonded;
• a second optical film feeding apparatus that draws a long sheet material having a second optical film out from a second roll on which the long sheet material is wound up, cuts at least the second optical film into a predetermined length, and feeds the long sheet material having the second optical film cut;
• a second bonding apparatus that bonds the second optical film cut fed from the second optical film feeding apparatus onto the other surface of the optical display unit fed from the feeder;
• and
• a controller that operates or stops each of the apparatuses, wherein
• the first optical film feeding apparatus has a first roll exchanging section for exchanging a first roll of a previous category for a first roll of a latter category and joining the first optical films of the previous category and the latter category at the time of exchanging categories,
• the second optical film feeding apparatus has a second roll exchanging section for exchanging a second roll of a previous category for a second roll of a latter category and joining the second optical films of the previous category and the latter category at the time of exchanging categories,
• the optical display unit feeding apparatus has a counting section that counts the number of feeding of the optical display units,
• the controller stores the number N1 of optical display units that are bonded substantially in correspondence with the first optical films that are present from a joining position of the first optical film to a bonding position of the first optical film, and stores the number N2 of optical display units that are bonded substantially in correspondence with the second optical films that are present from a joining position of the second optical film to a bonding position of the second optical film, and
• the controller stops each of the apparatuses when the number X of remaining sheets of the optical display units of the previous category prior to bonding becomes substantially equal to the number N1 or the number N2, whichever is larger, and after operating each of the apparatuses, stops each of the apparatus when the number X of remaining sheets of the optical display units prior to bonding becomes substantially equal to the number N1 or the number N2, whichever is smaller, at the time of exchanging categories based on information from the counting section.