APPARATUS FOR AND METHOD OF MANUFACTURING

PHOTOSENSITIVE LAMINATED BODY

Technical Field

The present invention relates to an apparatus for and a method of manufacturing a photosensitive laminated body by providing an elongate photosensitive web which comprises a support, a photosensitive material layer disposed on the support, and a protective film disposed on the photosensitive material layer, peeling the protective film off the photosensitive material layer, and applying masking tapes to the exposed photosensitive material layer at predetermined spaced intervals.

Background Art

Substrates for liquid crystal panels , substrates for printed wiring boards, and substrates for PDP panels, for example, have a photosensitive sheet (photosensitive web) having a photosensitive material (photosensitive resin) layer and applied to substrate surfaces. The photosensitive sheet comprises a photosensitive material layer and a protective film that are successively deposited on a flexible plastic support.

An applying apparatus for applying such a photosensitive sheet usually operates to feed substrates

such as glass substrates, resin substrates, or the like at spaced intervals, peel off the protective film from the photosensitive sheet, and thereafter apply the photosensitive material layer to the substrates. For example, Japanese Patent No. 3314418 discloses a process of bonding a dry film. According to the disclosed process, as shown in FIG. 32 of the accompanying drawings, a dry film 1 is wound around a supply drum 2. The dry film 1 comprises a protective film Ia and a base film Ib that are bonded to each other by an adhesive layer Ic.

When the dry film 1 is unreeled from the supply drum 2, the protective film Ia is peeled off, leaving the adhesive layer Ic exposed, and wound around a protective film takeup drum 3. A plurality of masking tapes 6 are applied at spaced intervals to the exposed surface of the adhesive layer Ic by a tape applicator 5 that is movable back and forth by a cylinder 4.

Then, the adhesive layer Ic on the base film Ib is thermally compressed against the surfaces of printed wiring boards 7 by a heating roller 8 while the printed wiring boards 7 are being successively fed along. The masking tapes 6 on the adhesive layer Ic that is bonded to the printed wiring boards 7 are positioned across gaps between the printed wiring boards 7. After the adhesive layer Ic is thermally compressed against the printed wiring boards 7, a cooling fan 9 applies cooling air to the base film Ib, the adhesive layer Ic, and

the printed wiring boards 7, stabilizing the bonded state of the assembly. Thereafter, the base film Ib is wound around a base film takeup drum 10. At this time, the masking tapes 6 and the portions of the adhesive layer Ic which are interposed between the masking tapes 6 and the base film Ib remain attached to the base film Ib, and are also wound around the base film takeup drum 10.

According to the disclosed conventional process, a conveyor frame (not shown) for gripping and feeding the printed wiring boards 7 is fed at a speed which is the same as the speed at which the dry film 1 is delivered, and the cylinder 4 operates in synchronism with the delivery of the printed wiring boards 7 to the conveyor frame . As a result , each of the masking tapes 6 extends across the upper surfaces of confronting edges of two adjacent printed wiring boards 7.

However, the lengths of the base film Ib and the adhesive layer Ic may possibly be changed due to the heat of the heating roller 8. If the lengths of the base film Ib and the adhesive layer Ic are changed, then the masking tapes 6 applied to the adhesive layer Ic are positioned out of alignment with the gaps between the printed wiring boards 7.

The conventional arrangement shown in FIG. 32 does not have a structure for adjusting the relative positions of the masking tapes 6 and the printed wiring boards 7. Consequently, the masking tapes 6 and the printed wiring

boards 7 cannot be relatively positioned with high accuracy, and hence a high-quality applying process is not performed.

Disclosure of Invention It is an object of the present invention to provide an apparatus for and a method of manufacturing a high-quality photosensitive laminated body efficiently by positioning masking tapes and substrates highly accurately with respect to an elongate photosensitive web with a simple process and arrangement -

According to the present invention, there is provided an apparatus for manufacturing a photosensitive laminated body, comprising a web reel-out mechanism for reeling out an elongate photosensitive web comprising a support, a photosensitive material layer disposed on the support, and a protective film disposed on the photosensitive material layer, a peeling mechanism for continuously peeling the protective film off from the elongate photosensitive web, a masking tape applying mechanism for applying masking tapes to the photosensitive material layer exposed on a surface of the elongate photosensitive web, at spaced intervals in a reel-out direction in which the elongate photosensitive web is reeled out, a substrate feed mechanism for feeding a substrate which has been heated to a predetermined temperature to an applying position, an applying mechanism for positioning the masking tape between the substrates and applying the photosensitive material layer to the substrate

in the applying position, thereby to produce an applied substrate, a detecting mechanism for positionally detecting the masking tape applied to the elongate photosensitive web, and a control mechanism for adjusting relative positions of the masking tape and the substrate in the applied position based on detected information from the detecting mechanism.

Preferably, the detecting mechanism comprises a sensor disposed upstream of and closely to the applying position, for directly detecting the masking tape. The detecting mechanism is thus capable of directly detecting the position of the masking tape in the vicinity of the applying position. Preferably, the detecting mechanism electrically tracks the masking tape from the masking tape applying mechanism. The detecting mechanism thus constructed allows the relative positions of the masking tape and the substrate to be adjusted highly accurately according to a simple control process.

Preferably, the apparatus further comprises a tension control mechanism disposed between the peeling mechanism and the applying mechanism, for applying tension to the elongate photosensitive web. The tension control mechanism makes it possible to adjust stretching of the elongate photosensitive web for easily adjusting the position of the masking tape to the applying position. Preferably, the apparatus further comprises a cutting mechanism disposed downstream of the applying mechanism, for cutting off the support, which is elongate, between the

applied substrates, and a support peeling mechanism disposed downstream of the cutting mechanism, for peeling the support together with the masking tape off from the applied substrate, thereby to produce a photosensitive laminated body.

Preferably, the apparatus further comprises a support peeling mechanism disposed downstream of the applying mechanism, for continuously peeling the support, which is elongate, together with the masking tape off from the applied substrate, thereby to produce a photosensitive laminated body. Therefore, since the support and the masking tape do not need to be cut off, dust and dirt particles such as severed pieces are not produced from the support and the masking tape. The applying mechanism preferably comprises a pair of rubber rollers which can be heated to a predetermined temperature, and a roller clamp unit for moving one of the rubber rollers back and forth, the roller clamp unit comprising a cylinder for applying a clamping pressure to the one of the rubber rollers, and a cam actuatable by an actuator for moving the cylinder back and forth.

Preferably, the apparatus further comprises a preheating unit disposed upstream of and closely to the applying mechanism, for preheating the elongate photosensitive web to a predetermined temperature.

Preferably, the masking tape applying mechanism comprises a movable unit which is positionally adjustable in

the reel-out direction, and the control mechanism controls the movable unit to adjust positions in which the masking tapes are applied to the photosensitive material layer by the masking tape applying mechanism. The masking tape applying mechanism thus constructed allows the applied position of the masking tape to be adjusted well through a simple control process and arrangement.

According to the present invention, there is also provided a method of manufacturing a photosensitive laminated body, comprising the steps of reeling out an elongate photosensitive web comprising a support, a photosensitive material layer disposed on the support, and a protective film disposed on the photosensitive material layer, continuously peeling the protective film off from the elongate photosensitive web which has been reeled out, applying masking tapes to the photosensitive material layer exposed on a surface of the elongate photosensitive web, at spaced intervals in a reel-out direction in which the elongate photosensitive web is reeled out, positionally detecting the masking tape applied to the elongate photosensitive web, feeding a substrate which has been heated to a predetermined temperature to an applying position, adjusting relative positions of the masking tape and the substrate in the applied position based on detected information of the masking tape, and positioning the masking tape between substrates and applying the photosensitive material layer to the substrate in the applying position.

thereby to produce an applied substrate.

Brief Description of Drawings

FIG. 1 is a schematic side elevational view of a manufacturing apparatus according to a first embodiment of the present invention,-

FIG. 2 is an enlarged fragmentary cross-sectional view of an elongate photosensitive web used in the manufacturing apparatus ; FIG. 3 is an enlarged fragmentary cross-sectional view showing the elongate photosensitive web with a masking tape applied thereto;

FIG. 4 is a perspective view of a masking tape applying mechanism of the manufacturing apparatus; FIG. 5 is a side elevational view of the masking tape applying mechanism;

FIG. 6 is a front elevational view of an applying mechanism of the manufacturing apparatus ;

FIG. 7 is a fragmentary cross-sectional view of a pass-through region of the manufacturing apparatus;

FIG. 8 is a schematic view of a portion of the manufacturing apparatus, showing an initial state thereof;

FIG. 9 is an enlarged fragmentary side elevational view showing the manner in which a protective film is peeled off the elongate photosensitive web;

FIG. 10 is a schematic view of a portion of the manufacturing apparatus, showing the manner in which a glass

substrate enters between rubber rollers;

FIG. 11 is a schematic view of a portion of the manufacturing apparatus, showing the manner in which the rubber rollers start to rotate; FIG. 12 is a schematic view of a portion of the manufacturing apparatus , showing its operation upon completion of a lamination process on a first glass substrate;

FIG. 13 is a schematic view of a portion of the manufacturing apparatus, showing the manner in which the rubber rollers and substrate feed rollers rotate;

FIG. 14 is a fragmentary cross-sectional view of glass substrates to which a photosensitive resin layer is transferred; FIG. 15 is a schematic view of a portion of the manufacturing apparatus, showing the manner in which the substrate feed rollers are spaced from an end of an applied substrate;

FIG. 16 is a schematic view of a portion of the manufacturing apparatus, showing the manner in which elongate photosensitive webs are severed between applied substrates ;

FIG. 17 is a schematic view of a portion of the manufacturing apparatus, showing a stopped state thereof; FIG. 18 is a schematic view of a portion of the manufacturing apparatus , showing a finished state thereof ; FIG. 19 is a schematic view of a portion of the

manufacturing apparatus, showing the manner in which the photosensitive web has its leading end set in position,-

FIG. 20 is a plan view showing the manner in which the photosensitive resin layer leads the glass substrate; FIG. 21 is a plan view showing the manner in which the photosensitive resin layer lags the glass substrate;

FIG. 22 is a perspective view of a masking tape applying mechanism of a manufacturing apparatus according to a second embodiment of the present invention; FIG. 23 is a side elevational view of the masking tape applying mechanism;

FIG. 24 is a schematic side elevational view of a manufacturing apparatus according to a third embodiment of the present invention; FIG. 25 is a plan view showing the manner in which a photosensitive resin layer having a prescribed length is applied to a glass substrate;

FIG. 26 is a plan view showing the manner in which a photosensitive resin layer longer than a prescribed length is applied to a glass substrate;

FIG. 27 is a plan view showing the manner in which a photosensitive resin layer shorter than a prescribed length is applied to a glass substrate;

FIG. 28 is a schematic side elevational view of a manufacturing apparatus according to a fourth embodiment of the present invention;

FIG. 29 is an enlarged cross-sectional view of a pre-

peeler of the manufacturing apparatus;

FIG. 30 is an enlarged cross-sectional view showing the manner in which the pre-peeler operates;

FIG. 31 is a view illustrative of the manner in which the position of a photosensitive resin layer applied to a glass substrate is detected; and

FIG. 32 is a schematic sectional elevational view illustrative of a conventional process of bonding a dry film.

Best Mode for Carrying Out the Invention

FIG. 1 shows in schematic side elevation an apparatus 20 for manufacturing a photosensitive laminated body according to a first embodiment of the present invention. The manufacturing apparatus 20 operates to thermally transfer a photosensitive resin layer 28 (described later) of an elongate photosensitive web 22 to glass substrates 24 in a process of manufacturing color filters for use with liquid crystal panels, PDPs, or organic EL panels. FIG. 2 shows in cross section the photosensitive web 22 that is employed in the manufacturing apparatus 20. The photosensitive web 22 comprises a laminated assembly of a flexible base film (support) 26, a photosensitive resin layer (photosensitive material layer) 28 disposed on the flexible base film 26, and a protective film 30 disposed on the photosensitive resin layer 28.

As shown in FIG. 1, the manufacturing apparatus 20 has

a web reel-out mechanism 32 for accommodating a photosensitive web roll 22a in the form of the rolled photosensitive web 22 and reeling out the photosensitive web 22 from the photosensitive web roll 22a, a peeling mechanism 34 for continuously peeling the protective film 30 from the photosensitive web 22, a masking tape applying mechanism 38 for applying masking tapes 36 to the photosensitive resin layer 28 exposed on the surface of the photosensitive web 22, at spaced intervals in a reel-out direction indicated by the arrow A, a substrate feed mechanism 40 for feeding a glass substrate 24 which is heated to a predetermined temperature to an applying position, and an applying mechanism 42 for applying the photosensitive resin layers 28 which have been exposed by peeling off the protective film 30 to the glass substrate 24.

A detecting mechanism 44 for directly detecting masking tapes 36 at the boundary positions of the photosensitive web 22 is disposed upstream of and closely to the applying position in the applying mechanism 42. An inter-substrate web cutting mechanism 48 for cutting the photosensitive web 22 between adjacent glass substrates 24 is disposed downstream of the applying mechanism 42. A web leading end cutting mechanism 48a that is used when the manufacturing apparatus 20 starts to operate, suffers a trouble, or ejects a defective film is disposed upstream of the inter-substrate web cutting mechanism 48.

An applying base 47 for applying the trailing end of a

photosensitive web 22 that has essentially been used up and the leading end of a photosensitive web 22 that is to be newly used is disposed downstream of and closely to the web reel-out mechanism 32. The applying base 47 is followed downstream by a film end position detector 49 for controlling a transverse shift of the photosensitive web 22 due to a winding irregularity of the photosensitive web roll 22a. The film end of the photosensitive web 22 is positionally adjusted by transversely moving the web reel- out mechanism 32. However, the film end of the photosensitive web 22 may be adjusted by a position adjusting mechanism combined with rollers. The web reel-out mechanism 32 may comprise a multi-shaft mechanism including two or three unreeling shafts for supporting the photosensitive web roll 22a and feeding out the photosensitive web 22.

The peeling mechanism 34 has a suction drum 46 for reducing variations of the tension to which the supplied photosensitive web 22 is subjected for thereby stabilizing the tension of the photosensitive web 22 when it is subsequently laminated. The peeling mechanism 34 also has a peeling roller 46a disposed closely to the suction drum 46. The protective film 30 that is peeled off from the photosensitive web 22 at a sharp peel-off angle by the peeling roller 46a is continuously wound by a protective film takeup unit 50.

A tension control mechanism 52 for applying tension to

the photosensitive web 22 is disposed downstream of the peeling mechanism 34. The tension control mechanism 52 has a cylinder 54 that is actuatable to angularly displace a tension dancer 56 to adjust the tension of the photosensitive web 22, which is held in rolling contact with the tension dancer 56. The tension control mechanism 52 may be employed only when necessary, and may be dispensed with.

As shown in FIG. 3, the masking tape applying mechanism 38 applies each masking tape 36 to the photosensitive resin layer 28, from which the protective film 30 has been peeled off, across a substrate interval T. The masking tape 36 comprises a base of polyethylene terephthalate (PET) and an adhesive layer 58 of acrylic resin, silicone, a combination of acrylic resin and silicone, or rubber, which is disposed on one surface of the base which is to be bonded to the photosensitive resin layer 28.

The other surface of the masking tape 36 is free of an adhesive layer, and should preferably be treated with a non- sticky film, e.g., coated with a fluoroplastic film or the like. Desirably, the adhesive layer 58 should have a small thickness and a width smaller than the width of the masking tape 36 to prevent itself from oozing out from the ends of the masking tape 36 in a subsequent laminating process to be described later. It is also desirable that the masking tape 36 should have a width slightly greater than the width of the photosensitive web 22 to be able to remove dirt from a

rubber roller 90a to be described later.

As shown in FIGS. 4 and 5, the masking tape applying mechanism 38 has a masking tape reel-out unit 60 and a masking tape attracting and feeding unit 62. As shown in FIG. 4, masking tapes 36 blanked or cut to predetermined lengths are applied in advance to a release paper strip 64. The masking tape reel-out unit 60 has a rotatable shaft 65 around which the release paper strip 64 is wound as a roll. When the rotatable shaft 65 is rotated in the direction indicated by the arrow, it reels out the release paper strip 64 in the direction indicated by the arrow B. The release paper strip 64 travels from the masking tape reel-out unit 60 transversely across the photosensitive web 22, and is wound around a takeup shaft 66. An elongate attracting base 68 which extends transversely across the photosensitive web 22 is disposed near the photosensitive resin layer 28 of the photosensitive web 22. Guide rollers 70a, 70b are disposed near the respective longitudinal ends of the elongate attracting base 68. The guide rollers 70a, 70b are movable toward and away from the release paper strip 64 that extends transversely across the photosensitive web 22.

As shown in FIGS. 4 and 5, the masking tape attracting and feeding unit 62 has a pair of laterally spaced first linearly movable guides (or linearly movable robots) 72a extending in the feed-out direction, indicated by the arrow Al, of the photosensitive web 22, a pair of first movable

carriages (movable units) 74a movable back and forth along the first linearly movable guides 72a, a pair of laterally spaced second linearly movable guides (or linearly movable robots) 72b extending in the feed-out direction, indicated by the arrow Al, of the photosensitive web 22 and shorter than the first linearly movable guides 72a, and a pair of second movable carriages (movable units) 74b movable back and forth along the second linearly movable guides 72b. The first linearly movable guides 72a are disposed on one side of the photosensitive web 22, and the second linearly movable guides 72b are disposed on the opposite side of the photosensitive web 22.

Linear actuators, e.g., cylinders 76, are mounted respectively on the first movable carriages 74a. The cylinders 76 have respective rods 76a on which an attracting member 78 is mounted. As shown in FIG. 4, the attracting member 78 extends over a distance corresponding to the length of a masking tape 36 in the direction indicated by the arrow B, which extends transversely across the photosensitive web 22.

The attracting member 78 is movable selectively to a first position Sl and a second position S2 by the first movable carriages 74a (see FIG. 5). The first position Sl is a position where the attracting member 78 receives a masking tape 36 from the masking tape reel-out unit 60. The second position S2 is a position where the masking tape 36 attracted by the attracting member 78 is applied to the

photosensitive web 22.

Linear actuators, e.g., cylinders 80, are mounted respectively on the second movable carriages 74b. The cylinders 80 have respective rods 80a on which an applying back base 79 is mounted. The applying back base 79 can be placed in a position aligned with the second position S2 of the attracting member 78.

As shown in FIGS. 1 and 5, the detecting mechanism 44 comprises a photoelectric sensor 82 such as a laser beam sensor, a photosensor, or the like. The photoelectric sensor 82 directly detects a change in the intensity of light passing through the photosensitive web 22 when a masking tape 36 blocks the passing light. The photoelectric sensor 82 produces a boundary position signal when it detects such a change in the intensity of the passing light. The photoelectric sensor 82 is positioned in confronting relation to a backup roller 83 with the photosensitive web 22 traveling therebetween in rolling contact with the backup roller 83. The detecting mechanism 44 may comprise a contactless displacement meter for detecting a masking tape thickness on the photosensitive web 22, or an image inspecting means such as a CCD camera or the like, etc. rather than the photoelectric sensor 82. Positional data of masking tapes 36 that are detected by the detecting mechanism 44 can be statistically processed into a graph to give a warning in the event that the applied

masking tapes 36 are positionally deviated or displaced off proper positions.

As shown in FIG. 1, the substrate feed mechanism 40 has a plurality of substrate heating units (e.g., heaters) 84 disposed for sandwiching and heating glass substrates 24, and a feeder 86 for feeding glass substrates 24 in the direction indicated by the arrow C. The temperatures of the glass substrates 24 in the substrate heating units 84 are monitored at all times. When the monitored temperature of a glass substrate 24 becomes abnormal, the feeder 86 is inactivated and a warning is issued, and abnormality information is sent to reject and discharge the abnormal glass substrate 24 in a subsequent process, and is also used for quality control and production management . The feeder 86 has an air-floated plate (not shown) for floating and feeding glass substrates 24 in the direction indicated by the arrow C. Instead, the feeder 86 may comprise a roller conveyor for feeding glass substrates 24.

The temperatures of the glass substrates 24 should preferably be measured in the substrate heating units 84 or immediately prior to the applying position according to a contact process (using a thermocouple, for example) or a non-contact process.

A substrate storage frame 81 for storing a plurality of glass substrates 24 is disposed upstream of the substrate heating units 84. The glass substrates 24 stored in the substrate storage frame 81 are attracted one by one by

suction pads 89 mounted on a hand 85a of a robot 85, taken out from the substrate storage frame 81, and inserted into the substrate heating units 84.

Downstream of the substrate heating units 84, there are disposed a stopper 87 for abutting against the leading end of a glass substrate 24 and holding the glass substrate 24, and a position sensor 88 for detecting the position of the leading end of the glass substrate 24. The position sensor 88 detects the position of the leading end of the glass substrate 24 on its way toward the applying position. After the position sensor 88 has detected the position of the leading end of the glass substrate 24, the glass substrate 24 is fed a predetermined distance and is positioned between rubber rollers 90a, 90b of the applying mechanism 42. Preferably, a plurality of position sensors 88 are disposed at spaced intervals along the feed path for monitoring the times at which a glass substrate 24 reaches the respective positions of the position sensors 88, thereby to check a delay due to a slippage of the glass substrate 24 when the glass substrate 24 starts to be fed. In FIG. 1, glass substrates 24 are heated by the substrate heating units while the glass substrates 24 are being fed. However, glass substrates 24 may be heated in a batch-heating oven and fed by a robot . The applying mechanism 42 has a pair of vertically spaced laminating rubber rollers 90a, 90b that can be heated to a predetermined temperature. The applying mechanism 42

also has a pair of backup rollers 92a, 92b held in rolling contact with the rubber rollers 90a, 90b, respectively. The backup roller 92b is pressed against the rubber roller 90b by a roller clamp unit 93. As shown in FIG. 6, the roller clamp unit 93 has a drive motor 103 having a drive shaft coupled to a speed reducer 103a which has a drive shaft 103b coaxially connected to a ball screw 104. A nut 105 is threaded over the ball screw 104 and fixed to a slide base 106. Tapered cams 107a, 107b are fixedly mounted on respective opposite ends of the slide base 106 in the transverse direction of the photosensitive web 22, which is indicated by the arrow B. The tapered cams 107a, 107b are progressively higher in the direction indicated by the arrow Bl. Rollers 108a, 108b are placed in rolling contact with the respective tapered cams 107a, 107b and rotatably held on the respective lower ends of pressing cylinders 94a, 94b.

As shown in FIG. 1, a contact prevention roller 96 is movably disposed near the rubber roller 90a for preventing the photosensitive web 22 from contacting the rubber roller 90a. A preheating unit 97 for preheating the photosensitive web 22 to a predetermined temperature is disposed upstream of and closely to the applying mechanism 42. The preheating unit 97 comprises a heating means such as an infrared bar heater or the like.

Glass substrates 24 are fed from the applying mechanism 42 through the inter-substrate web cutting

mechanism 48 along a feed path 98 which extends in the direction indicated by the arrow C. The feed path 98 comprises an array of rollers including film feed rollers 100 and substrate feed rollers 102 with the web leading end cutting mechanism 48a interposed therebetween. The distance between the rubber rollers 90a, 90b and the substrate feed rollers 102 is equal to or less than the length of one glass substrate 24.

In the manufacturing apparatus 20, the web reel-out mechanism 32, the peeling mechanism 34, the tension control mechanism 52, the masking tape applying mechanism 38, and the detecting mechanisms 44 are disposed above the applying mechanism 42. Conversely, the web reel-out mechanism 32, the peeling mechanism 34, the tension control mechanism 52, the masking tape applying mechanism 38, and the detecting mechanisms 44 may be disposed below the applying mechanism 42, so that the photosensitive web 22 may be vertically inverted, and the photosensitive resin layer 28 may be joined to the lower surfaces of glass substrates 24. Alternatively, all the mechanisms of the manufacturing apparatus 20 may be linearly arrayed.

As shown in FIG. 1, the manufacturing apparatus 20 is controlled in its entirety by a lamination process controller 110. The manufacturing apparatus 20 also has a lamination controller 112, a substrate heating controller 114, etc. for controlling the different functional components of the manufacturing apparatus 20. These

controllers are interconnected by an in-process network. The lamination process controller 110 is connected to the network of a factory which incorporates the manufacturing apparatus 20, and performs information processing for production, e.g., production management and mechanism operation management, based on instruction information (condition settings and production information) from a factory CPU (not shown).

The substrate heating controller 114 controls the substrate heating units 84 to receive glass substrates 24 from an upstream process and heat the received glass substrates 24 to a desired temperature, controls the feeder 86 to feed the heated glass substrates 24 to the applying mechanism 42, and also controls the handling of information about the glass substrates 24.

The lamination controller 112 serves as process master for controlling the functional components of the manufacturing apparatus 20. The lamination controller 112 operates as a control mechanism for controlling the substrate feed mechanism 40 and the masking tape applying mechanism 38, for example, based on the positional information, detected by the detecting mechanism 44, of the masking tapes 36 on the photosensitive web 22.

The installation space of the manufacturing apparatus 20 is divided into a first clean room 122a and a second clean room 122b by a partition wall 120. The first clean room 122a houses therein the web feed-out mechanism 32, the

peeling mechanism 34, and the masking tape applying mechanism 38. The second clean room 122b houses therein the detecting mechanism 44 and the other components following the detecting mechanism 44. The first clean room 122a and the second clean room 122b are connected to each other by a pass-through region 124.

As shown in FIG. 7, the pass-through region 124 has a deduster 125 disposed in the first clean room 122a and an air sealer 126 disposed in the second clean room 122b. The deduster 125 has a pair of suction nozzles 127a disposed in confronting relation to respective opposite surfaces of the photosensitive web 22, and a pair of ejection nozzles 128 disposed respectively in the suction nozzles 127a. The ejection nozzles 128 eject air to the photosensitive web 22 to remove dust particles from the photosensitive web 22, and the suction nozzles 127a draw the ejected air and the removed dust particles.

The air sealer 126 has a pair of suction nozzles 127b disposed in confronting relation to respective opposite surfaces of the photosensitive web 22. The suction nozzles 127b draw air to seal the pass-through region 124. The positions of the deduster 125 and the air sealer 126 may be switched, or a plurality of dedusters 125 and a plurality of air sealers 126 may be combined with each other. Only the suction nozzle 127a, without the ejection nozzle 128, may be disposed in confronting relation to the side of the photosensitive web 22 where the photosensitive resin layer

28 is exposed.

In the manufacturing apparatus 20, the partition wall 120 prevents heated air from the applying mechanism 42 from thermally affecting the photosensitive web 22, e.g., from wrinkling, deforming, thermally shrinking, or stretching the photosensitive web 22. The partition wall 120 separates an upper area of the manufacturing apparatus 20, i.e., the first clean room 122a, where dust particles are liable to occur and fall, from a lower area of the manufacturing apparatus 20, i.e., the second clean room 122b, thereby keeping the applying mechanism 42 clean.

It is desirable to keep the pressure in the second clean room 122b higher than the pressure in the first clean room 122a, thereby preventing dust particles from flowing from the first clean room 122a into the second clean room 122b. An air supply (not shown) for supplying a downward flow of clean air is disposed in an upper portion of the second clean room 122b.

Operation of the manufacturing apparatus 20 for carrying out a manufacturing method according to the present invention will be described below.

Initially for positioning the leading end of the photosensitive web 22 in place, the photosensitive web 22 is unreeled from the photosensitive web roll 22a accommodated in the web reel-out mechanism 32. The photosensitive web 22 is delivered through the peeling mechanism 34, the masking tape applying mechanism 38, and the applying mechanism 42 to

the film feed rollers 100, which grip the leading end of the photosensitive web 22.

When a masking tape 36 is detected by the photosensitive sensor 82, the film feed rollers 100 are rotated based on a detected signal from the photosensitive sensor 82. The photosensitive web 22 is now fed a predetermined distance to the applying position by the film feed rollers 100, positioning the masking tape 36 at the applying position. Alternatively, a masking tape may be detected downstream of the applying position, and the photosensitive web 22 may be stopped at a predetermined position.

As shown in FIG. 8, the contact prevention roller 96 is lowered to prevent the photosensitive web 22 from contacting the rubber roller 90a. A glass substrate 24 is waiting immediately prior to the applying position. The photosensitive web 22 is now in an initial state of the manufacturing apparatus 20.

Operation of the functional components of the manufacturing apparatus 20 in a lamination mode will be described below.

As shown in FIG. 1, the photosensitive web 22 is unreeled from the web reel-out mechanism 32 and continuously fed to the peeling mechanism 34. In the peeling mechanism 34, as shown in FIG. 9, the base film 26 of the photosensitive web 22 is attracted to the suction drum 46, and the protective film 30 is continuously peeled off from

the photosensitive web 22. The protective film 30 is peeled off at a sharp peel-off angle by the peeling roller 46a and wound by the protective film takeup unit 50 (see FIG. 1).

At this time, inasmuch as the photosensitive web 22 is firmly held by the suction drum 46, shocks produced when the protective film 30 is peeled off from the photosensitive web 22 are not transferred to the photosensitive web 22 downstream of the suction drum 46. Consequently, such shocks are not transferred to the applying mechanism 42, and hence laminated sections of glass substrates 24 are effectively prevented from developing a striped defective region .

After the protective film 30 has been peeled off from the base film 26 by the peeling mechanism 34, the photosensitive web 22 is adjusted in tension by the tension control mechanism 52, and then fed to the masking tape applying mechanism 38.

In the masking tape applying mechanism 38, as shown in FIG. 5, the first movable carriages 74a are placed in the first position Sl as indicated by the two-dot-and-dash lines. In the first position Sl, the release paper strip 64 unreeled from the masking tape reel-out unit 60 is attracted to the attracting base 68. The cylinders 76 operate to displace the attracting member 78 in the direction indicated by the arrow Dl to a position where the attracting member 78 attracts a masking tape 36 applied to the release paper strip 64.

With the attracting member 78 attracting the masking tape 36, the cylinders 76 operate to move the attracting member 78 away from the attracting base 68 in the direction indicated by the arrow D2. Thereafter, the first movable carriages 74a are displaced from the first position Sl to the second position S2. In the second position S2, the attracting member 78 faces the applying back base 79, and while the first movable carriages 74a and the second movable carriages 74b are moving synchronously in the direction indicated by the arrow Al, the cylinders 76, 80 are actuated. The attracting member 78 and the applying back base 79 grip the photosensitive web 22 and apply the masking tape 36 to the photosensitive resin layer 28 while the attracting member 78 and the applying back base 79 moves in synchronization with the photosensitive web 22 in the direction indicated by the arrow Al .

After the attracting member 78 and the applying back base 79 have moved in unison with the photosensitive web 22 in the direction indicated by the arrow Al , the attracting member 78 and the applying back base 79 are spaced from the photosensitive web 22 by the cylinders 76, 80, and thereafter are displaced in the direction indicated by the arrow A2. The attracting member 78 is placed in the first position Sl, and the applying back base 79 is placed in the second position S2.

In the masking tape reel-out unit 60, as shown in FIG. 4, after the masking tape 36 is released from the release

paper strip 64, the guide rollers 70a, 70b are moved forward, displacing the release paper strip 64 off the attracting base 68. The release paper strip 64 is reeled out from the rotatable shaft 65 and wound around the takeup shaft 66, bringing a next new masking tape 36 applied to the release paper strip 64 over the attracting base 68. Then, the rotatable shaft 65 and the takeup shaft 66 are stopped against rotation, and the guide rollers 70a, 70b are retracted to allow the release paper strip 64 to be attracted and held by the attracting base 68.

As described above, when the release paper strip 64 is reeled out from the rotatable shaft 65, the release paper strip 64 is kept out of sliding contact with the attracting base 68 by the guide rollers 70a, 70b. Consequently, the release paper strip 64 is prevented from being unduly damaged and from producing worn-off particles. Instead of moving the guide rollers 70a, 70b, the attracting base 68 may be moved into and out of contact with the release paper strip 64. The photosensitive web 22 with the masking tape 36 applied to a predetermined area of the photosensitive resin layer 28 is then fed to the detecting mechanism 44. In the detecting mechanism 44, the photosensitive sensor 82 detects a boundary edge of the masking tape 36. Based on the detected positional information of the masking tape 36, the film feed rollers 100 are rotated to feed the photosensitive web 22 a predetermined distance to the applying mechanism

42. At this time, the contact prevention roller 96 is waiting above the photosensitive web 22 and the rubber roller 90b is disposed below the photosensitive web 22. As shown in FIG. 10, the first glass substrate 24 which is preheated, is fed to the applying position by the substrate feed mechanism 40. The glass substrate 24 is tentatively positioned between the rubber rollers 90a, 90b in alignment with the area of the photosensitive web 22 where a masking tape 36 is applied to the photosensitive resin layer 28.

Then, as shown in FIG. 6, the ball screw 104 is rotated in a certain direction by the speed reducer 103a coupled to the drive motor 103, moving the slide base 106 in the direction indicated by the arrow B2 in unison with the nut 105 threaded over the ball screw 104. Therefore, the tapered cams 107a, 107b have their cam surfaces in contact with the rollers 108a, 108b raised, displacing the rollers 108a, 108b upwardly. The pressing cylinders 94a, 94b are elevated, lifting the backup roller 92b and the rubber roller 90b to sandwich the glass substrate 24 under a predetermined pressing pressure between the rubber rollers 90a, 90b. At this time, the pressing pressure is adjusted by the pressure of air supplied to the pressing cylinders 94a, 94b. The rubber roller 90a is rotated to transfer, i.e., laminate, the photosensitive resin layer 28, which is melted with heat, to the glass substrate 24.

The photosensitive resin layer 28 is laminated onto

the glass substrate 24 under such conditions that the photosensitive resin layer 28 is fed at a speed in the range from 1.0 m/min. to 10 m/min., the rubber rollers 90a, 90b have a temperature ranging from 80° C to 140 ⁰ C, and a hardness in the range from 40 to 90, and apply a pressure (linear pressure) ranging from 50 N/cm to 400 N/cm.

As shown in FIG. 11, when the leading end of the glass substrate 24 reaches a position near the film feed rollers 100, the film feed rollers 100 are moved away from the glass substrate 24. When the leading end of the photosensitive web 22 which projects forwardly of the glass substrate 24 in the direction indicated by the arrow C reaches a predetermined position with respect to the web leading end cutting mechanism 48a, the web leading end cutting mechanism 48a is actuated to cut off the leading end of the photosensitive web 22. After having cut off the leading end of the photosensitive web 22, the web leading end cutting mechanism 48a returns to its standby position, and will not be used while the manufacturing apparatus 20 is in normal operation.

As shown in FIG. 12, when the photosensitive web 22 has been laminated onto the glass substrate 24 up to its trailing end by the rubber rollers 90a, 90b, the rubber roller 90a is stopped against rotation, and the glass substrate 24 with the laminated photosensitive web 22 (also referred to as "applied substrate 24a") is clamped by the substrate feed rollers 102.

The rubber roller 90b is retracted away from the rubber roller 90a, unclamping the applied substrate 24a. Specifically, as shown in FIG. 6, the speed reducer 103a coupled to the drive motor 103 is reversed, causing the ball screw 104 and the nut 105 to move the slide base 106 in the direction indicated by the arrow Bl. Therefore, the tapered cams 107a, 107b have their cam surfaces in contact with the rollers 108a, 108b lowered, displacing the pressing cylinders 94a, 94b downwardly. The backup roller 92b and the rubber roller 90b are lowered, unclamping the applied substrate 24a.

The substrate feed rollers 102 then start rotating to feed the applied substrate 24a a predetermined distance in the direction indicated by the arrow C. The position 22b of the photosensitive web 22 which is to be brought between two adjacent glass substrates 24 is now displaced to a position beneath the rubber roller 90a. A next glass substrate 24 is fed toward the applied position by the substrate feed mechanism 40. When the leading end of the next glass substrate 24 is positioned between the rubber rollers 90a, 90b, the rubber roller 90b is lifted, clamping the next glass substrate 24 and the photosensitive web 22 between the rubber rollers 90a, 90b. The rubber rollers 90a, 90b and the substrate feed rollers 102 are rotated to start laminating the photosensitive web 22 onto the glass substrate 24 and feed the applied substrate 24a in the direction indicated by the arrow C (see FIG. 13).

At this time, as shown in FIG. 14, the applied substrate 24a has opposite ends covered with respective masking tapes 36. Therefore, when the photosensitive resin layer 28 is transferred to the glass substrate 24, the photosensitive resin layer 28 is transferred to form a frame.

As shown in FIG. 15, when the trailing end of the first applied substrate 24a reaches the substrate feed rollers 102, the upper one of the substrate feed rollers 102 is lifted to unclamp the first applied substrate 24a, and the lower one of the substrate feed rollers 102 and the other rollers of the feed path 98 are continuously rotated to feed the applied substrate 24a. When the trailing end of the next, i.e., second applied substrate 24a reaches a position near the rubber rollers 90a, 90b, the rubber rollers 90a, 90b and the substrate feed rollers 102 are stopped against rotation.

The upper one of the substrate feed rollers 102 is lowered to clamp the second applied substrate 24a, and the rubber roller 90b is lowered to unclamp the second applied substrate 24a. Then, the substrate feed rollers 102 are rotated to feed the second applied substrate 24a. The position 22b of the photosensitive web 22 which is to be brought between two adjacent glass substrates 24 is now displaced to the position beneath the rubber roller 90a, and the photosensitive web 22 is repeatedly laminated onto third and subsequent glass substrates 24.

As shown in FIG. 16, when the position between two adjacent applied substrates 24a reaches a position corresponding to the inter-substrate web cutting mechanism 48, the inter-substrate web cutting mechanism 48 severs the photosensitive web 22 between the applied substrates 24a, i.e., intermediate through the masking tape 36, while moving in the direction indicated by the arrow C at the same speed as the applied substrates 24a. Thereafter, the inter- substrate web cutting mechanism 48 returns to a standby position, and the base film 26 and the masking tape 36 are peeled off from the leading applied substrate 24a, thereby manufacturing a photosensitive laminated body 116 (see FIG.

1).

When the laminating process is temporarily stopped, as shown in FIG. 17, the film feed rollers 100 and the rubber roller 90b are brought into unclamping positions, and the contact prevention roller 96 is lowered to prevent the photosensitive web 22 from contacting the rubber roller 90a. When the manufacturing apparatus 20 is to be shut off, the substrate feed rollers 102 are rotated to feed the applied substrate 24a in the direction indicated by the arrow C, and the web leading end cutting mechanism 48a clamps the photosensitive web 22. While the film feed rollers 100 in rotation are clamping the photosensitive web 22, the web leading end cutting mechanism 48a travels transversely across the photosensitive web 22, cutting off the photosensitive web 22.

Consequently, as shown in FIG. 18, the photosensitive web 22 passes between the rubber rollers 90a, 90b and is sandwiched by the film feed rollers 100, and is supported away from the rubber roller 90a by the contact prevention roller 96 which is lowered. The web leading end cutting mechanism 48a unclamps the applied substrate 24a and is placed in its standby position.

When the inter-substrate web cutting mechanism 48 and the web leading end cutting mechanism 48a cut off the photosensitive web 22, they move in synchronism with the photosensitive web 22 in the direction indicated by the arrow C. However, the inter-substrate web cutting mechanism 48 and the web leading end cutting mechanism 48a may move only transversely across the photosensitive web 22 to cut off the photosensitive web 22. The photosensitive web 22 may be cut off by a Thomson blade while it is held at rest , or may be cut off by a rotary blade while it is in motion.

When the manufacturing apparatus 20 operates in its initial state, as shown in FIG. 19, the contact prevention roller 96 is disposed in the lower position and the rubber roller 90b is spaced away from the rubber roller 90a. Then, the film feed rollers 100 are rotated to discharge the photosensitive web 22 into a web disposal container (not shown). At this time, the photosensitive web 22 is severed into a certain length by the web leading end cutting mechanism 48a.

When the detecting mechanism 44 detects a masking tape

36, the photosensitive web 22 is fed a predetermined length from the detected position. Specifically, when the contact prevention roller 96 is elevated, the photosensitive web 22 is fed until the masking tape 36 reaches a position where the photosensitive web 22 is to be laminated by the rubber rollers 90a, 90b. The leading end of the photosensitive web 22 is now positioned in place.

In the first embodiment, a masking tape 36 on the photosensitive web 22 is directly detected by the detecting mechanism 44 upwardly of and closely to the applying mechanism 42. The distance from the detecting mechanism 44 to the position where the masking tape 36 is stopped by the rubber rollers 90a, 90b needs to be smaller than the shortest length of the photosensitive web 22 to be laminated. This is because the information of the detected masking tape 36 is used for a next laminating process through feedback.

The detecting mechanism 44 performs two measuring processes as described below. According to the first measuring process, the rubber rollers 90a, 90b clamp the glass substrate 24, and the number of pulses generated by an encoder combined with a drive motor (not shown) for rotating the rubber rollers 90a, 90b, as representing the distance by which the glass substrate 24 is fed from the start of rotation of the rubber rollers 90a, 90b, is compared with the preset number of pulses generated when the masking tape 36 is to be detected by the detecting mechanism 44, thereby

measuring the position of the masking tape 36. If the masking tape 36 is detected before the preset number of pulses is reached, then the masking tape 36 is judged as being displaced forwardly of a predetermined position on the glass substrate 24 by a distance indicated by the difference between the numbers of pulses. Conversely, if the masking tape 36 is detected after the preset number of pulses is reached, then the masking tape 36 is judged as being displaced rearwardly of a predetermined position on the glass substrate 24.

According to the second measuring process , the number of pulses generated by an encoder combined with a drive motor (not shown) for rotating the rubber rollers 90a, 90b is measured from the detection of a masking tape 36 to the detection of a next masking tape 36, thereby measuring the laminated length H of the photosensitive web 22. The preset number of pulses corresponding to the laminated length H under normal conditions of the photosensitive web 22 is compared with the actually measured number of pulses. If the actually measured number of pulses is greater than the preset number of pulses, then the photosensitive web 22 is judged as being stretched due to heat or the like by a distance indicated by the difference between the numbers of pulses. Conversely, if the actually measured number of pulses is smaller than the preset number of pulses, then the photosensitive web 22 is judged as being shorter than usual. If the leading end of the photosensitive resin layer

28 is detected as being displaced (advanced) with respect to an applied range Pl - P2 of the glass substrate 24 according to the first measuring process, as shown in FIG. 20, then the relative position of the glass substrate 24 and the masking tape 36 on the photosensitive web 22 is adjusted.

Specifically, if the masking tape 36 detected by the photoelectric sensor 82 is detected as being advanced from a predetermined position, then as shown in FIG. 12, the substrate feed rollers 102 feed an unapplied portion of the photosensitive web 22 after being laminated by a distance represented by the difference between the preset distance and the advanced distance. As a result, the masking tape 36 is positionally adjusted and tentatively placed in a predetermined position between the rubber rollers 90a, 90b. Thereafter, the glass substrate 24 is delivered under normal delivery control between the rubber rollers 90a, 90b, and the photosensitive resin layer 28 is applied at a normal position to the glass substrate 24, i.e., in the applied range Pl - P2 of the glass substrate 24. If the position of the masking tape 36 detected by the photoelectric sensor 82 is detected as being delayed from the joined range Pl - P2 of the glass substrate 24 as shown in FIG. 21, then the substrate feed rollers 102 feed the unapplied portion of the photosensitive web 22 after being laminated by a distance represented by the sum of the preset distance and the delayed distance.

Rather than adjusting the distance that the applied

substrate 24a is fed by the substrate feed rollers 102, the substrate feed mechanism 40 may be controlled to adjust the position at which the glass substrate 24 is to be stopped, by the advanced or delayed distance. Furthermore, the second position S2 for the first and second movable carriages 74a, 74b of the masking tape applying mechanism 38 may be adjusted to adjust the position of the masking tape 36.

The distance between the masking tapes 36 detected by the photoelectric sensor 82, i.e., the length H of the photosensitive resin layer 28 to be applied to the glass substrate 24, is measured according to the second measuring process. If the length H is greater than the joined range Pl - P2, then the length between the masking tapes 36 is reduced by the difference between the length H and the joined range Pl - P2. If the length H is smaller than the joined range Pl - P2, then the length between the masking tapes 36 is increased by the difference between the length H and the joined range Pl - P2. In this manner, the applied length of the photosensitive resin layer 28 is adjusted to a predetermined length.

It is also possible to change the amount of stretch of the photosensitive web 22 by adjusting the tension of the photosensitive web 22 with the tension dancer 56 of the tension control mechanism 52.

Consequently, the masking tape 36 on the photosensitive web 22 can be positioned highly accurately

with respect to the applying position, allowing the photosensitive resin layer 28 of the photosensitive web 22 to be applied accurately to a desired area of the glass substrate 24. It is thus possible to efficiently manufacture a high-quality photosensitive laminated body 116 with a simple process and arrangement.

After the protective film 30 has continuously been peeled off from the photosensitive web 22, a masking tape 36 is applied to the photosensitive resin layer 28 which is exposed on the surface of the photosensitive web 22.

Therefore, since the photosensitive web 22 is not partly cut or perforated or otherwise processed to leave portions of the protective film 30 on the photosensitive web 22, no dust and dirt particles are produced from the photosensitive web 22. The applied substrates 24a are thus reliably prevented from being smeared. It is possible to manufacture high- quality applied substrates 24a efficiently and economically.

FIG. 22 shows in perspective a masking tape applying mechanism 130 of a manufacturing apparatus according to a second embodiment of the present invention, and FIG. 23 shows in side elevation the masking tape applying mechanism 130 shown in FIG. 22. Those parts of the masking tape applying mechanism 130 which are identical to those according to the first embodiment are denoted by identical reference characters, and will not be described in detail below.

The masking tape applying mechanism 130 has a label

reel-out unit 134 including a tape roll 132 which comprises a rolled release paper strip 64 with masking tapes 36 applied thereto, the label reel-out unit 134 being movable by a moving unit 133 back and forth in the direction indicated by the arrow A. The label reel-out unit 134 has a rotatable shaft 138 disposed axially in the tape roll 132 and rotatable by a motor 136. When the rotatable shaft 138 rotates, the release paper strip 64 with masking tapes 36 applied thereto is unreeled from the tape roll 132. The release paper strip 64 with masking tapes 36 applied thereto is fed horizontally by being guided by a plurality of guide rollers 140, and then folded back through a sharp angle by a folding member 142. After masking tapes 36 are released from the release paper strip 64, the release paper strip 64 is guided by a plurality of guide rollers 144 and wound around a takeup shaft 146 which is rotated by a motor 148.

The folding member 142 is positioned below a label attracting and feeding unit 150. The label attracting and feeding unit 150 has a rail 152 extending horizontally in the direction indicated by the arrow B and a self-propelled moving base 154 movably mounted on the rail 152 for back- and-forth movement along the rail 152.

The moving base 154 supports cylinders 156a, 156b extending downwardly and having respective downwardly extending rods 158a, 158b with respective suction pads 160a, 160b mounted on lower ends thereof. The suction pads 160a,

160b are spaced from each other in the direction indicated by the arrow B by a distance corresponding to the longitudinal length of each masking tape 36.

The moving base 154 also supports cylinders 162a, 162b extending downwardly and positioned inwardly of the cylinders 156a, 156b. The cylinders 162a, 162b have respective downwardly extending rods 164a, 164b with a horizontal presser bar 166 supported on lower ends thereof. The presser bar 166 has an attracting capability. A downwardly extending cutter 168 is mounted on the moving base 154 outwardly of and closely to the cylinder 156b. The cutter 168 is capable of cutting off a masking tape 36 at a suitable position thereon while the masking tape 36 is being attracted to and held by the suction pads 160a, 160b. The masking tape applying mechanism 130 also has a backing table 170 for holding the photosensitive web 22 from below, at an applying position where a masking tape 36 is to be applied to the photosensitive web 22 by the suction pads 160a, 160b. The backing table 170 is vertically movably supported by cylinders 172a, 172b. The backing table 170 is movable by moving units 174 back and forth in the direction indicated by the arrow A.

According to the second embodiment, the tape roll 132 is mounted on the rotatable shaft 138 of the label reel-out unit 134. Since the rotatable shaft 138 is rotated by the motor 136, the release paper strip 64 is unreeled together with the masking tapes 36 from the tape roll 132 when the

rotatable shaft 138 is rotated.

After the release paper strip 64 and the masking tapes 36 are horizontally fed by being guided by the guide rollers 140, they are folded back through the sharp angle by the folding member 142. Therefore, the leading end of a masking tape 36 is released from the release paper strip 64, and attracted to and held by the suction pad 160a. Then, the folding member 142 is moved to the left in FIG. 23, separating the masking tape 36 from the release paper strip 64. The suction pad 160a is vertically moved by the cylinder 156a, attracting and holding the surface of the masking tape 36 released from the release paper strip 64.

The moving base 154 moves in correspondence with the attracting position of the masking tape 36 to bring the suction pad 160b to the trailing end of the masking tape 36. The suction pad 160b is vertically moved by the cylinder 156b, attracting and holding the trailing end of the masking tape 36.

After the masking tape 36 has been released from the release paper strip 64, the release paper strip 64 which has been folded back through the sharp angle by the folding member 142 is guided by the guide rollers 144 and fed to the takeup shaft 146. The motor 148 rotates the takeup shaft 146 to wind the release paper strip 64 around the takeup shaft 146.

When the suction pads 160a, 160b attract and hold the leading and trailing ends of the masking tape 36, the cutter

168 that is disposed near the suction pad 160b is actuated to cut off the trailing end of the masking tape 36. Then, the moving base 154 moves along the rail 152 in the direction indicated by the arrow B to place the masking tape 36 attracted by the suction pads 160a, 160b into the applying position where the masking tape 36 is to be applied to the photosensitive web 22.

When the masking tape 36 is placed in the applying position, the label reel-out unit 134 and the backing table 170 move in the direction indicated by the arrow A in synchronism with the photosensitive web 22, during which time the masking tape 36 is applied to the photosensitive web 22.

Specifically, the backing table 170 is lifted by the cylinders 172a, 172b until it supports the lower surface of the photosensitive web 22. The suction pads 160a, 160b are lowered by the cylinders 156a, 156b to hold the masking tape 36 against the photosensitive web 22, and the presser bar 166 is lowered by the cylinders 162a, 162b to hold the masking tape 36 against the photosensitive web 22. The masking tape 36 is thus reliably applied to the photosensitive web 22.

FIG. 24 shows in schematic side elevation an apparatus 180 for manufacturing a photosensitive laminated body according to a second embodiment of the present invention. Those parts of the manufacturing apparatus 180 which are identical to those of the manufacturing apparatus 20

according to the first embodiment are denoted by identical reference characters, and will not be described in detail below.

As shown in FIG. 24, the manufacturing apparatus 180 has a detecting mechanism 44a, a cooling mechanism 182 disposed downstream of the inter-substrate web cutting mechanism 48, and a base peeling mechanism 184 disposed downstream of the cooling mechanism 182. The detecting mechanism 44a has photoelectric sensors 82a, 82b which are spaced from each other by a predetermined distance L and disposed in confronting relation to backup rollers 83a, 83b, respectively.

The cooling mechanism 182 supplies cold air to an applied substrate 24a to cool the applied substrate 24a after the photosensitive web 22 is cut off between applied substrates 24a by the inter-substrate web cutting mechanism 48. Specifically, the cooling mechanism 182 supplies cold air having a temperature of 10° C at a rate ranging from 1.0 to 2.0 m/min. According to a modification, the cooling mechanism 182 may be dispensed with, and the applied substrates 24a may be cooled naturally in a photosensitive laminated body storage frame 192 to be described below.

The base peeling mechanism 184 disposed downstream of the cooling mechanism 182 has a plurality of suction pads 186 for attracting the lower surface of an applied substrate 24a. While the applied substrate 24a is being attracted under suction by the suction pads 186, the base film 26 and

the masking tape 36 are peeled off from the applied substrate 24a by a robot hand 188. Electric neutralizing blowers (not shown) for ejecting ion air to four sides of the laminated area of the applied substrate 24a are disposed upstream, downstream, and laterally of the suction pads 186. The base film 26 and the masking tape 36 may be peeled off from the applied substrate 24a while a table for supporting the applied substrate 24a thereon is being oriented vertically, obliquely, or turned upside down for dust removal.

The base peeling mechanism 184 is followed downstream by a photosensitive laminated body storage frame 192 for storing a plurality of photosensitive laminated bodies 116. A photosensitive laminated body 116 that is produced when the base film 26 and the masking tape 36 are peeled off from the applied substrate 24a by the base peeling mechanism 184 is attracted by suction pads 196 on a hand 194a of a robot 194, taken out from the base peeling mechanism 184, and placed into the photosensitive laminated body storage frame 192.

Dust removal fan units (or duct units) 197 are mounted on three sides, other than charging and removal port sides, of the substrate storage frame 81 and the photosensitive laminated body storage frame 192. The fan units 197 introduce neutralizing clean air into the substrate storage frame 81 and the photosensitive laminated body storage frame 192.

To the lamination process controller 110, there are connected the lamination controller 112, the substrate heating controller 114, and also a base peeling controller 198. The base peeling controller 198 controls the base peeling mechanism 184 to peel off the base film 26 from the applied substrate 24a that is supplied from the applying mechanism 42, and also to discharge the photosensitive laminated body 116 to a downstream process. The base peeling controller 198 also handles information about the applied substrate 24a and the photosensitive laminated body 116.

According to the third embodiment, in the detecting mechanism 44a, the photoelectric sensor 82a which is positioned upstream of the photoelectric sensor 82b first detects the masking tape 36 on the photosensitive web 22.

Thereafter, the downstream photoelectric sensor 82b detects the masking tape 36 on the photosensitive web 22. The distance L between the backup rollers 83a, 83cb corresponds to the length of the photosensitive resin layer 28 applied to the glass substrate 24.

The actual applied length of the photosensitive resin layer 28 can accurately be calculated from the number of pulses between the time when the upstream photoelectric sensor 82a detects the masking tape 36 and the time when the downstream photoelectric sensor 82b detects the masking tape 36 on the photosensitive web 22. Based on the calculated actual applied length of the photosensitive resin layer 28,

the rate at which the photosensitive web 22 is fed is adjusted to apply the photosensitive resin layer 28 centrally to the glass substrate 24.

According to the third embodiment, therefore, the distance between the masking tapes 36 on the photosensitive web 22, i.e., the length H of the photosensitive resin layer 28 applied to the glass substrate 24, is accurately detected to apply the photosensitive resin layer 28 centrally to the glass substrate 24 (see FIG. 25). If the length Hl of the photosensitive resin layer 28 which is detected by the detecting mechanism 44a is larger than the normal length H, as shown in FIG. 26, then the photosensitive resin layer 28 is applied centrally to the glass substrate 24 such that the opposite ends of the photosensitive resin layer 28 are spaced equal distances outwardly from the ends of the applied length L .

If the length H2 of the photosensitive resin layer 28 which is detected by the detecting mechanism 44a is smaller than the normal length H, as shown in FIG. 27, then the photosensitive resin layer 28 is applied centrally to the glass substrate 24 such that the opposite ends of the photosensitive resin layer 28 are spaced equal distances inwardly from the ends of the applied length L. In this case, a target displacement of the applied position of the photosensitive resin layer 28 is about one-half the displacement that occurs if the opposite ends of the photosensitive resin layer 28 are not spaced equal distances

inwardly from the ends of the applied length L.

According to the third embodiment, furthermore, the protective film 30 is peeled off the photosensitive web 22 unreeled from the web reel-out mechanism 32, and then the masking tape 36 is applied to the photosensitive resin layer 28. Thereafter, the photosensitive web 22 is laminated onto the glass substrate 24 to transfer the photosensitive resin layer 28, and the base film 26 and the masking tape 36 are peeled off by the base peeling mechanism 184, thereby producing a photosensitive laminated body 116. The photosensitive laminated body 116 can therefore be manufactured easily automatically.

FIG. 28 schematically shows in side elevation a manufacturing apparatus 200 according to a fourth embodiment of the present invention. Those parts of the manufacturing apparatus 200 according to the fourth embodiment which are identical to those of the manufacturing apparatus 20 according to the first embodiment are denoted by identical reference characters, and will not be described in detail below.

The manufacturing apparatus 200 includes the inter- substrate web cutting mechanism 48 which is usually not used except for cutting off the photosensitive web 22 in case of trouble and separating the photosensitive web 22 to discharge defective sections. The manufacturing apparatus 200 has a cooling mechanism 182 and an automatic base peeling mechanism 202 which are disposed downstream of the

web leading end cutting mechanism 48a. The automatic base peeling mechanism 202 serves to continuously peel off, together with masking tapes 36, an elongate base film 26 applied to glass substrates 24 that are spaced at given intervals. The automatic base peeling mechanism 202 has a prepeeler 204, a peeling roller 206 having a relatively small diameter, a takeup shaft 208, and an automatic applying unit 210.

As shown in FIGS. 29 and 30, the prepeeler 204 has a pair of nip roller assemblies 212, 214 and a peeling bar

216. The nip roller assemblies 212, 214 are movable toward and away from each other in the direction in which glass substrates 24 are fed. The nip roller assemblies 212, 214 have vertically movable upper rollers 212a, 214a and lower rollers 212b, 214b. When the upper rollers 212a, 214a are lowered, the upper rollers 212a, 214a and the lower rollers 212b, 214b grip glass substrates 24 therebetween. The peeling bar 216 is vertically movable between adjacent glass substrates 24. The upper rollers 212a, 214a may be replaced with presser bars or presser pins.

The photosensitive web 22 is reheated to a temperature in the range from 30° C to 120° C at the peeling roller 206 or at a position immediately before the peeling roller 206. When the photosensitive web 22 is thus reheated, the photosensitive resin layer (color material layer) 28 is prevented from being peeled off therefrom when the base film 26 is peeled off, so that a high-quality laminated surface

can be produced on the glass substrates 24. For heating the photosensitive web 22, the peeling roller 206 may comprise a heating roller such as a hot water roller or the like, or may be associated with a bar heater or an IR heater. The automatic base peeling mechanism 202 is followed downstream by a measuring unit 218 for measuring the area of a photosensitive resin layer 28 that is actually applied to a glass substrate 24. The measuring unit 218 has a plurality of spaced cameras 220 each comprising a CCD or the like. As shown in FIG. 31, the measuring unit 218 has four cameras 220, for example, for capturing the images of four corners Kl through K4 of a glass substrate 24 to which a photosensitive resin layer 28 is applied. Alternatively, the measuring unit 218 may have at least two cameras for capturing the images of each of longitudinal and transverse sides of a glass substrate 24, rather than the four corners Kl through K4 thereof.

The measuring unit 218 may comprise color sensors or laser sensors for detecting end faces of a glass substrate 24 or may comprise a combination of LED sensors, photodiode sensors, or line sensors for detecting end faces of a glass substrate 24. At least two of these sensors should desirably be employed to capture the image of each of the end faces for detecting the linearity of each of the end faces.

Surface inspection units (not shown) may be employed to detect surface defects of photosensitive laminated bodies

116, such as surface irregularities caused by the photosensitive web 22 itself, laminated film density irregularities caused by the manufacturing facility, wrinkles, striped patterns, dust particles, and other foreign matter. When such a surface defect is detected, the manufacturing apparatus 200 issues an alarm, ejects defective products, and manages subsequent processes based on the detected surface defect.

According to the fourth embodiment , the applied substrate 24a to which the photosensitive web 22 is laminated is cooled by the cooling mechanism 182 and then delivered to the prepeeler 204. In the prepeeler 204, the nip roller assemblies 212, 214 grip the trailing and leading ends of two adjacent glass substrates 24, and the nip roller assembly 212 moves in the direction indicated by the arrow C at the same speed as the glass substrates 24, with the nip roller assembly 214 being decelerated in its travel in the direction indicated by the arrow C.

Consequently, as shown in FIG. 30, the photosensitive web 22 between the glass substrates 24 are flexed between the nip roller assemblies 212, 214. Then, the peeling bar 216 is lifted to push the photosensitive web 22 upwardly, peeling the masking tapes 36 off from the trailing and leading ends of the two adjacent glass substrates 24. In the automatic base peeling mechanism 202, the takeup shaft 208 is rotated to continuously wind the base film 26 and the masking tape 36 from the applied substrate

24a. After the photosensitive web 22 is cut off in case of trouble and separated to discharge defective sections, the leading end of the base film 26 on an applied substrate 24a to which the photosensitive web 22 starts being laminated and the trailing end of the base film 26 wound on the takeup shaft 208 are automatically applied to each other by the automatic applying unit 210.

The glass substrate 24 from which the base film 26 and the masking tape 36 are peeled off is placed in an inspecting station combined with the measuring unit 218. In the inspecting station, the glass substrate 24 is fixed in place, and the four cameras 220 captures the images of the glass substrate 24 and the photosensitive resin layer 28. The captured images are processed to determine applied positions a through d (see FIG. 31).

In the inspecting station, the glass substrate 24 may be fed along without being stopped, and transverse ends of the glass substrate 24 may be detected by cameras or image scanning, and longitudinal ends thereof may be detected by timing sensors. Then, the glass substrate 24 may be measured based on the detected data produced by the cameras or image scanning and the sensors .

According to the fourth embodiment, after the photosensitive web 22 has been laminated onto glass substrates 24, the photosensitive web 22 between two adjacent applied substrates 24a is not cut off. Rather, the base film 26 and the masking tape 36 can continuously be

peeled off from the applied substrate 24a and wound around the takeup shaft 208 which is in rotation. The base film 26 and the masking tape 36 that have been peeled off can easily be processed. The base film 26 and the masking tape 36 can be processed more easily if they are made of the same material.

The masking tapes 36 are made economical if they are made of a water-soluble material, e.g., paper (clean paper). The adhesive layers of the masking tapes 36 may be made of a water-soluble or heat-peelable adhesive.

According to the fourth embodiment, the same advantages as those of the third embodiment are achieved, e.g., the photosensitive laminated body 116 can be manufactured automatically and efficiently. Furthermore, the manufacturing apparatus 200 is simple in structure.

Industrial Applicability

According to the present invention, since the position of a masking tape that is applied to an elongate photosensitive web is directly or indirectly detected, the masking tape can be positioned highly accurately with respect to an applying position even if the elongate photosensitive web is stretched or contracted. The relative positions of the masking tape and a substrate are adjusted based on the detected information that is obtained. Consequently, a photosensitive material layer of the elongate photosensitive web can accurately be applied to a

desired area of the substrate through a simple process and arrangement, making it possible to produce a high-quality photosensitive laminate body efficiently.

Furthermore, after a protective film has been continuously peeled off from the elongate photosensitive web, the masking tape is applied to the exposed photosensitive material layer of the elongate photosensitive web. Therefore, since the photosensitive web is not partly cut or perforated or otherwise processed to leave portions of the protective film on the photosensitive web, no dust and dirt particles are produced from the photosensitive web. Applied substrates are thus reliably prevented from being smeared. It is possible to manufacture high-quality photosensitive laminated bodies efficiently and economically.