Information storage/readout device for use in continuously manufacturing system for liquid-crystal display elements, and method and system for producing the same

An information storage/readout device for use in a system for continuously manufacturing liquid-crystal display elements, the system for continuously manufacturing liquid-crystal display elements being configured to work with a roll of a continuous optical film laminate which comprises a continuous polarizing composite film including an adhesive layer and having a width conforming to a long or short side of a liquid-crystal panel formed in a given size, and a continuous carrier film releasably laminated on the adhesive layer, the system for continuously manufacturing liquid-crystal display elements being configured to form a plurality of slits in the continuous optical film laminate fed out from the roll, along a direction perpendicular to a longitudinal direction thereof, to make it possible to sequentially cut a plurality of polarizing sheets each having a given length corresponding to the long or short side of the liquid-crystal panel from the continuous optical film laminate and to laminate the sheets to respective ones of a plurality of the liquid-crystal panels so as to continuously manufacture liquid-crystal display elements, the information storage/readout device comprising:

• an information storage medium which stores therein slitting position information created based on a position of a defect detected by an inspection of a continuous polarizing composite film included in a continuous optical film laminate to indicate defective-polarizing-sheet slitting positions defining a defective or defect-containing polarizing sheet, and normal-polarizing-sheet slitting positions defining a normal or defect-free polarizing sheet, in the continuous inspected optical film laminate;
• and
• a roll of the continuous inspected optical film laminate which is provided with an identification indicia;
• wherein the system for continuously manufacturing liquid-crystal display elements is operable, based on the slitting position information read out from the information storage medium in accordance with reading of the identification means from the continuous inspected optical film laminate, and distance measurement data obtained from a feed distance of the continuous inspected optical film laminate from the roll, to form a plurality of slits in the continuous inspected optical film laminate from a surface opposite to the continuous carrier film to a depth reaching a surface of the continuous carrier film adjacent to the adhesive layer, to make it possible to cut a plurality of the normal polarizing sheets each having a length corresponding to the long or short side of the liquid-crystal panel from the continuous inspected optical film laminate, and to laminate the sheets to respective ones of a plurality of the liquid-crystal panels.

A method for producing an information storage/readout device for use in a system for continuously manufacturing liquid-crystal display elements, the system for continuously manufacturing liquid-crystal display elements being configured to work with a roll of a continuous optical film laminate which comprises a continuous polarizing composite film including an adhesive layer and having a width conforming to a long or short side of a liquid-crystal panel formed in a given size, and a continuous carrier film releasably laminated on the adhesive layer, the system for continuously manufacturing liquid-crystal display elements being configured to form a plurality of slits in the continuous optical film laminate fed out from the roll, along a direction perpendicular to a longitudinal direction thereof, to make it possible to sequentially cut a plurality of polarizing sheets each having a given length corresponding to the long or short side of the liquid-crystal panel from the continuous optical film laminate and to laminate the sheets to respective ones of a plurality of liquid-crystal panels so as to continuously manufacture liquid-crystal display elements, the information storage/readout device comprising an information storage medium which stores therein slitting position information created based on a position of a defect detected by an inspection of a continuous polarizing composite film included in a continuous optical film laminate to indicate defective-polarizing-sheet slitting positions defining a defective or defect-containing polarizing sheet, and normal-polarizing-sheet slitting positions defining a normal or defect-free polarizing sheet, in the continuous inspected optical film laminate, and a roll of the continuous inspected optical film laminate which is provided with an identification indicia, the production method comprising the steps of:

• laminating a continuous protective film on at least one of opposite surfaces of a continuous polarizer to form an continuous polarizing composite film on which the adhesive layer is not yet formed;
• inspecting the continuous polarizing composite film to detect any defect existing in the continuous polarizing composite film on which the adhesive layer is not yet formed;
• creating, based on the position of the defect in the continuous polarizing composite film on which the adhesive layer is not yet formed, the slitting position information indicative of the normal polarizing sheet-slitting positions and the defective polarizing sheet-slitting positions defining respective ones of the normal polarizing sheet and the defective polarizing sheet in a direction perpendicular to a longitudinal direction of the continuous polarizing composite film on which the adhesive layer is not yet formed;
• releasably laminating a continuous carrier film to the continuous inspected polarizing composite film on which the adhesive layer is not yet formed through an adhesive layer to form the continuous inspected optical film laminate;
• storing the slitting position information in a storage medium to thereby provide the information storage medium, in a manner usable by the system continuously manufacturing to, during feeding of the continuous inspected optical film laminate, form a plurality of slits in the continuous inspected optical film laminate along a direction perpendicular to the longitudinal direction from a surface opposite to the continuous carrier film to a depth reaching a surface of the continuous carrier film adjacent to the adhesive layer so as to make it possible to cut the normal polarizing sheet and the defective polarizing composite film from the continuous inspected optical film laminate individually;
• creating the identification means in association with the slitting position information and providing the identification indicia on the continuous inspected optical film laminate;
• and
• winding the continuous inspected optical film laminate provided with the identification indicia, into a roll to provide the roll of the continuous optical film laminate.

A method for producing an information storage/readout device for use in a system for continuously manufacturing liquid-crystal display elements, the system for continuously manufacturing liquid-crystal display elements being configured to work with a roll of a continuous optical film laminate which comprises a continuous polarizing composite film including an adhesive layer and having a width conforming to a long or short side of a liquid-crystal panel formed in a given size, and a continuous carrier film releasably laminated on the adhesive layer, the system for continuously manufacturing liquid-crystal display elements being configured to form a plurality of slits in the continuous optical film laminate fed out from the roll, along a direction perpendicular to a longitudinal direction thereof, to make it possible to sequentially cut a plurality of polarizing sheets each having a given length corresponding to the long or short side of the liquid-crystal panel from the continuous optical film laminate and to laminate the sheets to respective ones of a plurality of the liquid-crystal panels so as to continuously manufacture liquid-crystal display elements, the information storage/readout device comprising an information storage medium which stores therein slitting position information created based on the position of a defect detected by an inspection of a continuous polarizing composite film included in a continuous optical film laminate to indicate defective-polarizing-sheet slitting positions defining a defective or defect-containing polarizing sheet, and normal-polarizing-sheet slitting positions defining a normal or defect-free polarizing sheet, in the continuous inspected optical film laminate, and a roll of the continuous inspected optical film laminate which is provided with an identification indicia, the method comprising the steps of:

• preparing a roll of a continuous provisional optical film laminate which comprises a continuous polarizing composite film formed with an adhesive layer, and a continuous provisional carrier film releasably laminated on the adhesive layer;
• peeling the continuous provisional carrier film while feeding the continuous provisional optical film laminate out from the roll, to have adhesive layer on the continuous polarizing composite film exposed;
• inspecting a surface and inside of the continuous polarizing composite film having the exposed adhesive layer to detect a defect contained in the continuous polarizing composite film including adhesive layer;
• creating, based on a position of the defect in the continuous polarizing composite film including adhesive layer, the slitting position information indicative of the normal polarizing sheet-slitting positions and the defective polarizing sheet-slitting positions defining respective ones of the normal polarizing sheet and the defective polarizing sheet in a direction perpendicular to a longitudinal direction of the continuous polarizing composite film including adhesive layer;
• releasably laminating a continuous carrier film on the exposed adhesive layer of the continuous inspected polarizing composite film to form the continuous inspected optical film laminate;
• storing the slitting position information in a storage medium to thereby form the information storage medium, in a manner usable by the continuous manufacturing system to, during feeding of the continuous inspected optical film laminate, form a plurality of slits in the continuous inspected optical film laminate along a direction perpendicular to the longitudinal direction from a surface opposite to the continuous carrier film to a depth reaching a surface of the continuous carrier film adjacent to the adhesive layer so as to make it possible to cut the normal polarizing sheet and the defective polarizing composite film from the continuous inspected optical film laminate individually;
• creating the identification indicia in association with the slitting position information and providing the identification means on the continuous inspected optical film laminate;
• and
• winding the continuous inspected optical film laminate provided with the identification means, into a roll to serve as the roll of the continuous optical film laminate.

A system for producing an information storage/readout device for use in a system for continuously manufacturing liquid-crystal display elements, the system for continuously manufacturing liquid-crystal display elements being configured to work with a roll of a continuous optical film laminate which comprises a continuous polarizing composite film including an adhesive layer and having a width conforming to a long or short side of a liquid-crystal panel formed in a given size, and a continuous carrier film releasably laminated on the adhesive layer, the system for continuously manufacturing liquid-crystal display elements being configured to form a plurality of slits in the continuous optical film laminate fed out from the roll, along a direction perpendicular to a longitudinal direction thereof, to make it possible to sequentially cut a plurality of polarizing sheets each having a given length corresponding to the long or short side of the liquid-crystal panel from the continuous optical film laminate and to laminate the sheets to respective ones of a plurality of the liquid-crystal panels so as to continuously manufacture liquid-crystal display elements, the information storage/readout device comprising an information storage medium which stores therein slitting position information created based on the position of a defect detected by an inspection of a continuous polarizing composite film included in a continuous optical film laminate to indicate defective-polarizing-sheet slitting positions defining a defective or defect-containing polarizing sheet, and normal-polarizing-sheet slitting positions defining a normal or defect-free polarizing sheet, in the continuous inspected optical film laminate, and a roll of the continuous inspected optical film laminate which is provided with an identification indicia, the system for producing an information storage/readout device comprising:

• a polarizing composite film forming unit adapted to laminate a continuous protective film on at least one of opposite surfaces of a continuous polarizer to form an continuous polarizing composite film on which the adhesive layer is not yet formed;
• an inspection unit adapted to inspect the continuous polarizing composite film which the adhesive layer is not yet formed to detect a defect contained in the continuous polarizing composite film on which the adhesive layer is not yet formed;
• slitting position information creating means adapted to, based on the position of the defect in the continuous polarizing composite film on which the adhesive layer is not yet formed, create the slitting position information indicative of the normal polarizing sheet-slitting positions and the defective polarizing sheet-slitting positions defining respective ones of the normal polarizing sheet and the defective polarizing sheet in a direction perpendicular to a longitudinal direction of the continuous polarizing composite film on which the adhesive layer is not yet formed;
• a continuous inspected optical film laminate forming unit adapted to releasably laminate a continuous carrier film to the continuous inspected polarizing composite film on which the adhesive layer is not yet formed through an adhesive layer to form the continuous inspected optical film laminate;
• an information storage medium forming unit adapted to store the slitting position information in a storage medium to thereby form the information storage medium, in a manner usable by the system for continuously manufacturing liquid-crystal display elements to, during feeding of the continuous inspected optical film laminate, form a plurality of slits in the continuous inspected optical film laminate along a direction perpendicular to the longitudinal direction from a surface opposite to the continuous carrier film to a depth reaching a surface of the continuous carrier film adjacent to the adhesive layer so as to make it possible to cut the normal polarizing sheet and the defective polarizing composite film from the continuous inspected optical film laminate individually;
• an identification providing unit adapted to create the identification indicia in association with the slitting position information and provide the identification indicia on the continuous inspected optical film laminate;
• a taking up unit adapted to wind the continuous inspected optical film laminate provided with the identification indicia, into a roll to provide the roll of the continuous optical film laminate;
• and
• a control unit adapted control respective operations of at least the polarizing composite film forming unit, the inspection unit, the slitting position information creating means, the continuous inspected optical film laminate forming unit, the information storage medium forming unit, the identification providing unit and the taking up unit, in an inter-related manner.

A system for producing an information storage/readout device for use in a system for continuously manufacturing liquid-crystal display elements, the system for continuously manufacturing liquid-crystal display elements being configured to work with a roll of a continuous optical film laminate which comprises a continuous polarizing composite film including an adhesive layer and having a width conforming to a long or short side of a liquid-crystal panel formed in a given size, and a continuous carrier film releasably laminated on the adhesive layer, the system for continuously manufacturing liquid-crystal display elements being configured to form a plurality of slits in the continuous optical film laminate fed out from the roll, along a direction perpendicular to a longitudinal direction thereof, to make it possible to sequentially cut a plurality of polarizing sheets each having a given length corresponding to the long or short side of the liquid-crystal panel from the continuous optical film laminate and to laminate the sheets to respective ones of a plurality of the liquid-crystal panels so as to continuously manufacture liquid-crystal display elements, the information storage/readout device comprising an information storage medium which stores therein slitting position information created based on a position of a defect detected by an inspection of a continuous polarizing composite film included in a continuous optical film laminate to indicate defective-polarizing-sheet slitting positions defining a defective or defect-containing polarizing sheet, and normal-polarizing-sheet slitting positions defining a normal or defect-free polarizing sheet, in the continuous inspected optical film laminate, and a roll of the continuous inspected optical film laminate which is provided with an identification indicia, the system for producing an information storage/readout device comprising:

• a provisional optical film laminate feed unit configured to work with a roll of a continuous provisional optical film laminate which comprises a continuous polarizing composite film formed with an adhesive layer, and a continuous provisional carrier film releasably laminated on the adhesive layer, and adapted to feed the continuous provisional optical film laminate out from the roll;
• a provisional carrier film peeling unit adapted to peel the continuous provisional carrier film from the continuous provisional optical film laminate being fed out from the roll, to have the adhesive layer on the continuous polarizing composite film exposed;
• an inspection unit adapted to inspect a surface and inside of the continuous polarizing composite film having the exposed adhesive layer to detect any defect contained in the continuous polarizing composite film including adhesive layer;
• slitting position information creating means adapted to, based on the position of the defect in the continuous polarizing composite film having the adhesive layer, create the slitting position information indicative of the normal polarizing sheet-slitting positions and the defective polarizing sheet-slitting positions defining respective ones of the normal polarizing sheet and the defective polarizing sheet in a direction perpendicular to a longitudinal direction of the continuous polarizing composite film having the adhesive layer;
• a continuous inspected optical film laminate forming unit adapted to releasably laminate a continuous carrier film on the exposed adhesive layer of the continuous inspected polarizing composite film to form the continuous inspected optical film laminate;
• an information storage medium forming unit adapted to store the slitting position information in a storage medium to form the information storage medium, in a manner usable by the system for continuously manufacturing liquid-crystal display elements to, during feeding of the continuous inspected optical film laminate, form a plurality of slits in the continuous inspected optical film laminate along a direction perpendicular to the longitudinal direction from a surface opposite to the continuous carrier film to a depth reaching a surface of the continuous carrier film adjacent to the adhesive layer so as to make it possible to cut the normal polarizing sheet and the defective polarizing composite film from the continuous inspected optical film laminate individually;
• an identification providing unit adapted to create the identification indicia in association with the slitting position information and provide the identification indicia on the continuous inspected optical film laminate;
• a taking up unit adapted to wind the continuous inspected optical film laminate provided with the identification indicia, into a roll to provide the roll of the continuous optical film laminate;
• and
• a control unit adapted control respective operations of at least the provisional optical film laminate feed unit, the provisional carrier film peeling unit, the inspection apparatus, the slitting position information creating means, the continuous inspected optical film laminate forming unit, the information storage medium forming unit, the identification providing unit and the taking up unit, in an inter-related manner.