DESCRIPTION

APPARATUS AND METHOD FOR MANUFACTURING A PHOTOSENSITIVE LAMINATED BODY

Technical Field'

The present invention relates to an apparatus and method for manufacturing a photosensitive laminated body, by providing an elongate photosensitive web having a photosensitive material layer and a protective film successively laminated on a support layer, peeling off a predetermined length of the protective layer, and applying an exposed length of the photosensitive material layer,, from which the length of the protective layer has been peeled off, to a substrate.

Background Art

Substrates for liquid crystal panels, substrates for printed wiring boards, and substrates for PDP panels, for example, include a photosensitive sheet (photosensitive body) having a photosensitive material (photosensitive resin) layer applied to a substrate surface. The photosensitive sheet is usually constructed as a laminated assembly, made up of a photosensitive material layer and a protective film that are laminated on a flexible plastic support layer.

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

such as glass substrates, resin substrates, or the like, at given spaced intervals and to peel protective film lengths off from the photosensitive sheet, which correspond to photosensitive material layer lengths to be applied to the respective substrates .

According to a film applying method and apparatus disclosed in Japanese Laid-Open Patent Publication No. 11- 34280, for example, as shown in FIG. 16 of the accompanying drawings , a laminated film Ia that is unreeled from a film roll 1 is wound around guide rolls 2a, 2b, and extends along a horizontal film feed plane.

The laminated film Ia that extends along the horizontal film feed plane is wound around a suction roll 4. A partial- cutter 5 and a cover film peeler 6 are disposed between the guide roll 2b and the suction roll 4.

The partial cutter 5 includes a pair of disk cutters 5a, 5b. Upon operating the partial cutter 5, the disk cutters 5a, 5b move transversely across the laminated film Ia in order to cut a cover film (not shown) and a photosensitive resin layer (not shown) on the reverse side of the cover film, which are disposed on the laminated film Ia.

The cover film peeler 6 includes an adhesive tape roll 7, two pairs of presser rollers 8a, 8b, and a takeup roll 9. When placed in operation, an adhesive tape 7a unreeled from the adhesive tape roll 7 is pressed against the cover film by the presser rollers 8a, 8b. Then, the adhesive tape 7a,

with the cover film sticking thereto, is wound by the takeup roll 9. Therefore, the cover film is peeled off from the photosensitive resin layer, leaving a length thereof determined by the disk cutters 5a, 5b, and the cover film is wound together with the adhesive tape 7a around the takeup roll 9.

The suction roll 4 is followed by a pair of lamination rolls 12a, 12b, positioned downstream thereof, for pressing the laminated film Ia against upper surfaces of a plurality of substrates 11, which are successively fed at spaced intervals by a substrate feeder 10. A support film takeup roll 13 is disposed downstream of the lamination rolls, 12a, 12b, for winding light-permeable support films (not shown) from between the respective substrates 11. The cover film and the photosensitive resin layer on the laminated film Ia are cut by the disk cutters 5a and 5b, as they move transversely across the laminated film Ia, in the following manner:

When the laminated film Ia is applied to the substrates 11 while the laminated film Ia is continuously supplied to the lamination rolls 12a, 12b, then the partial cutter 5 is displaced in unison with the laminated film Ia while cutting the cover film and the photosensitive resin layer. Alternatively, a film reservoir may be disposed between the partial cutter 5 and the lamination rolls 12a, 12b, and while the laminated film Ia is continuously supplied to the lamination rolls 12a, 12b downstream of the film reservoir.

the partial cutter 5 cuts the cover film and the photosensitive resin layer at a time when the laminated film Ia is held at rest upstream of the film reservoir.

According to another cutting process, when the laminated film Ia is applied to successive substrates 11 while the laminated film Ia is intermittently supplied to the lamination rolls 12a, 12b, the partial cutter 5 is actuated to cut the cover film and the photosensitive resin layer during periods when the laminated film Ia is not fed. Alternatively, similar to the case when the laminated film Ia is continuously fed to the lamination rolls 12a, 12b, a film reservoir may be employed to allow the laminated /film Ia to be applied to successive substrates 11, while permitting the partial cutter 5 to cut the cover film and the photosensitive resin layer independently of each other.

If the laminated film Ia is applied to successive substrates 11 while the laminated film Ia is continuously supplied to the lamination rolls 12a, 12b, then it is difficult to adjust the timing at which the laminated film Ia with the cover film remaining thereon and the substrate 11 are supplied to the lamination rolls 12a, 12b, possibly resulting in defective products . Since a mechanism for moving the partial cutter 5 in unison with the laminated film Ia or the film reservoir is required, the overall apparatus is of a complex structure. The apparatus is also large in size due to the need for space in which to move the partial cutter 5 in unison with the laminated film Ia and in

which to install the film reservoir. When tension variations, caused when the laminated film Ia is cut by the partial cutter 5, are transmitted to the laminated film applicator, the laminated film Ia tends to be applied to the substrate 11 under different conditions, resulting in a reduction in product quality.

If the laminated film Ia is applied to successive substrates 11 while the laminated film Ia is intermittently supplied to the lamination rolls 12a, 12b, then the laminated film Ia with the cover film remaining thereon and the substrate 11 can be positioned relatively highly accurately with respect to each other, and a mechanism for moving the partial cutter 5 and the film reservoir are not required. Accordingly, the rate of defective products is lower, and the apparatus is simpler and smaller than the case in which the laminated film Ia is continuously supplied to the lamination rolls 12a, 12b.

However, between intermittent feed cycles, the laminated film Ia is held at rest in contact with the lamination rolls 12a, 12b for a long period of time. Heat applied from the lamination rolls 12a, 12b to the laminated film Ia, which is held at rest, causes striped irregularities between the area of the laminated film Ia held in contact with the lamination rolls 12a, 12b and other areas of the laminated film Ia that are not in contact with the lamination rolls 12a, 12b. In addition, thermally induced discoloration in the thermosensitive resin layer may

be caused at the area where the laminated film Ia is held in contact with the lamination rolls 12a, 12b. As a result, the quality of the laminated film Ia is lowered.

The above problems could be solved by shortening the period of time in which the laminated film Ia stays in contact with the lamination rolls 12a, 12b. However, since a certain period of time is needed for the partial cutter 5 to cut the cover film transversely, and a longer period of time is required to cut the cover film if the laminated film Ia is provided with a larger width in order to manufacture larger sized products, it is difficult to reduce the time period that the laminated film Ia stays in contact with the lamination rolls 12a, 12b.

Disclosure of Invention

It is a general Object of the present invention to provide an apparatus and method for efficiently manufacturing a high quality photosensitive laminated body, by applying an elongate photosensitive web accurately onto a substrate using a simple .process and arrangement.

A major object of the present invention is to provide an apparatus and method for manufacturing a photosensitive laminated body, by applying the elongate photosensitive web neatly onto a substrate, without being affected by tension variations.

Another object of the present invention is to provide an apparatus and method for manufacturing a photosensitive

laminated body, by applying the elongate photosensitive web neatly onto a substrate, without being affected by heat. Still another object of the present invention is to provide an apparatus and method for manufacturing a photosensitive laminated body quickly within a shortened period of time.

According to the present invention, a substrate and a photosensitive material layer are positioned highly accurately while the elongate photosensitive web is fed at a first low speed. During this time, in which the photosensitive material layer is not yet applied to the substrate by an applicator, a processing unit forms a, processed region on the elongate photosensitive web, within a minimum distance required for the processing unit to move along a direction in which the elongate photosensitive web is fed. When the photosensitive material layer is applied to the substrate, processing for forming the processed region on the elongate photosensitive web is not being conducted, and the elongate photosensitive web and the substrate are fed at a second speed, which is higher than the first speed. An applied substrate, which refers to a substrate with a given length of a photosensitive material layer applied thereto, is thus manufactured efficiently and highly accurately, without being adversely affected by tension variations caused when the processed region is formed on the elongate photosensitive web.

The applied substrate is cut off by a cutter, which is

disposed downstream of the applicator, while the elongate photosensitive web and the substrate are fed at the first low speed.

While the elongate photosensitive web and the substrate are fed at the first low speed, an adhesive label is applied to peel-off sections of the elongate photosensitive web, where the processed region has been formed.

A speed controller controls the first and second speeds, based on a positional relationship between the applicator and the processed region, according to detected information of the processed region that is detected by a detector disposed upstream of the applicator.

If the elongate photosensitive web is stopped at the applicator longer than a predetermined period of time, then striped irregularities tend to develop in the elongate photosensitive web due to heat, between an area of the elongate photosensitive web held in contact with the applicator and other areas of the elongate photosensitive web that are not held in contact with the applicator. Further, if the elongate photosensitive web requires a certain period of time until passing through the applicator, the photosensitive material layer is liable to develop thermally induced discoloration. The first low speed is established in view of these time periods. The first speed is set as a combination of a stop speed, at which feeding of the elongate photosensitive web is stopped for a predetermined period of time, and a low

speed at which the elongate photosensitive web is fed, during a period of time in which neither striped irregularities nor thermally induced discoloration are developed. While the processed region formed on the elongate photosensitive web is placed in the applicator and the substrate is positioned, the distance that the elongate photosensitive web is fed from the processing unit to the applicator is set roughly at an integral multiple of the distance between residual sections positioned on respective opposite sides of a peel-off section, in order to enable the processing unit to form the processed region.

The above and other objects, features, and advantages of the present invention will become more apparent from the following description when taken in conjunction with the accompanying drawings in which a preferred embodiment of the present invention is shown by way of illustrative example.

Brief Description of Drawings FIG. 1 is a schematic side elevational view of a manufacturing apparatus according to an 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 plan view of the elongate photosensitive web, with adhesive labels bonded

thereto ;

FIG. 4 is a front elevational view of an applying mechanism of the manufacturing apparatus;

FIG. 5 is a block diagram of a control system of the * manufacturing apparatus ;

FIG. 6 is a schematic side elevational view showing an initial state during which a photosensitive web is set in the manufacturing apparatus;

FIG. 7 is a timing chart pertaining to operations of various components of the manufacturing apparatus;

FIG. 8 is a schematic side elevational view of a portion of the manufacturing apparatus , showing the manner in which the manufacturing apparatus is initially operated;

FIG. 9 is a schematic side elevational view of a portion of the manufacturing apparatus, showing operation thereof upon initiation of a lamination process performed on a first glass substrate;

FIG. 10 is a schematic side elevational view of a portion of the manufacturing apparatus , showing an operation for cutting off a leading end of the photosensitive web, after initiation of the lamination process performed on the first substrate;

FIG. 11 is a schematic side elevational view of a portion of the manufacturing apparatus , showing operation thereof upon completion of the lamination process performed on the first glass substrate;

FIG. 12 is a schematic side elevational view of a

portion of the manufacturing apparatus, showing operation thereof upon initiation of a lamination process performed on a second glass substrate;

FIG. 13 is a fragmentary cross-sectional view of glass substrates, wherein a photosensitive resin layer is transferred onto the glass substrates;

FIG. 14 is a schematic side elevational view of a portion of the manufacturing apparatus, showing operation thereof upon completion of the lamination process performed on the second glass substrate;

FIG. 15 is a schematic side elevational view of a portion of the manufacturing apparatus, showing a manner in which the elongate photosensitive web is severed between substrates on which the elongate photosensitive web has been applied; and

FIG. 16 is a schematic cross-sectional view of a conventional film applying apparatus, as disclosed in Japanese Laid-Open Patent Publication No. 11-34280.

Best Mode for Carrying Out the Invention

FIG. 1 is a schematic side elevational view of an apparatus 20 for manufacturing a photosensitive laminated body according to an 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 onto glass substrates 24, during a process for manufacturing color filters used in

liquid crystal panels 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 made up 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 includes a web reel-out mechanism 32, accommodating therein a photosensitive web roll 22a in the form of a rolled photosensitive web 22, and enabling reeling out of the photosensitive web 22 from the photosensitive web roll 22a, a partial cutting mechanism 36 (processing unit) for forming a transversely severable partially cut region 34 (processed region) in the protective film 30 of the reeled out photosensitive web 22, and a label bonding mechanism 40 (label bonding unit) for bonding adhesive labels 38 (see FIG. 3), each having a non-sticky portion 38a, to the protective film 30.

Downstream of the label bonding mechanism 40 are disposed a peeling mechanism 44 (peeler) for peeling certain lengths of the protective film 30 from the photosensitive web 22, a substrate feeding mechanism 45 (substrate feeder) for heating a glass substrate 24 to a predetermined temperature and feeding the heated glass substrate 24 to an applying position, and an applying mechanism 46 (applicator)

for applying a photosensitive resin layer 28, which has been exposed by peeling off the protective film 30, to the glass substrate 24.

A detecting mechanism 47 (detector) for directly detecting a partially cut region 34, which is positioned at a boundary on the photosensitive web 22, is disposed upstream of and near to the applying position in the applying mechanism 46. An inter-substrate web cutting mechanism 48 (cutter), which cuts the photosensitive web 22 between two adjacent substrates 24, is disposed downstream of the applying mechanism 46. A web leading end cutting mechanism 48a, which is operated when the manufacturing apparatus 20 itself is placed in operation, is disposed upstream of the inter-substrate web cutting mechanism 48. A joining base 49, which joins the trailing end of a photosensitive web 22 that has essentially been used up and the leading end of a photosensitive web 22 that has yet to be used, is disposed downstream of and closely to the web reel-out mechanism 32. The joining base 49 is followed downstream by a film end position detector 51 for controlling a transverse shift of the photosensitive web 22 due to winding irregularities of the photosensitive web roll 22a. A film end position is adjusted by transversely moving the web reel-out mechanism 32. However, the film end position may also be adjusted by a position adjusting mechanism comprising a combination of rollers . The web reel-out mechanism 32 may include a plurality of

photosensitive web rolls 22a, which are loaded in a transverse array, for simultaneously unreeling respective photosensitive webs 22 from the photosensitive web rolls 22a. The partial cutting mechanism 36 is disposed downstream of a pair of rollers 50, which calculates the diameter of the photosensitive web roll 22a that is wound within the web reel-out mechanism 32. The partial cutting mechanism 36 has a pair of circular blades 52a, 52b that are spaced a distance from each other along the direction (indicated by the arrow A) in which the photosensitive web 22 is fed, and a suction plate 53 disposed below and in confronting , relation to the circular blades 52a, 52b for attracting the photosensitive web 22 downwardly. The circular blades 52a, 52b move transversely across the photosensitive web 22 to form partially cut regions 34 at given positions in the photosensitive web 22. The partial cutting mechanism 36 is disposed in a position so that the length of the feed path of the photosensitive web 22, from the partial cutting mechanism 36 to the applying mechanism 46, is roughly an integral multiple of the distance between the partially cut regions 34, at opposite ends of the glass substrate 24.

As shown in FIG. 2, the partially cut regions 34 need to be formed across at least the protective film 30. Actually, the circular blades 52a, 52b are designed to cut into the photosensitive resin layer 28 as well as the base film 26 in order to reliably cut the protective film 30.

The circular blades 52a, 52b may be fixed and moved transversely across the photosensitive web 22 in order to form the partially cut regions 34, or may be rotated, rather than slipping, over the photosensitive web 22 and moved transversely across the photosensitive web 22 to thereby form the partially cut regions 34. The partially cut regions 34 may also be formed by a cutting process using a laser beam or ultrasonic energy, or by a cutting process using a knife blade, a strip-shaped pressing blade (Thompson blade), or the like, rather than the illustrated circular blades 52a, 52b.

The partially cut regions 34 serve to set a spacing interval between two adjacent glass substrates 24. For example, partially cut regions 34 are formed in the protective film 30 at positions that are 10 mm spaced inwardly from respective edges of the glass substrates 24. The section of the protective film 30 that is interposed between the partially cut regions 34 functions as a mask, when the photosensitive resin layer 28 is applied in the applying mechanism 46 as _λ a frame to the glass substrate 24, as shall be described later.

The label bonding mechanism 40 supplies adhesive labels 38, which interconnect a front peel-off section 30aa and a rear peel-off section 30ab, in order to leave a residual section 30b of the protective film 30 between the glass substrates 24. As shown in FIG. 2, the front peel-off section 30aa, which is to be peeled off initially, and the

rear peel-off section 30ab, which is to be peeled off subsequently, are positioned on both respective sides of the residual section 30b.

As shown in FIG. 3, each of the adhesive labels 38 has a rectangular strip shape and is made of the same resin material as the protective film 30. Each of the adhesive labels 38 has a non-adhesive (or slightly adhesive) area 38a positioned centrally thereon, which is free of adhesive, and a first adhesive area 38b and a second adhesive area 38c, which are disposed respectively on longitudinally opposite ends of the non-adhesive area 38a, i.e., on longitudinally opposite end portions of the adhesive label 38. The first adhesive area 38b and the second adhesive area 38c are bonded respectively to the front peel-off section 30aa and the rear peel-off section 30ab.

As shown in FIG." 1, the label bonding mechanism 40 is movable together with the partial cutting mechanism 36, along the direction (indicated by the arrow A) in which the photosensitive web 22 is fed. The label bonding mechanism 40 includes suction pads 54a through 54e, for applying a plurality of adhesive labels 38 at spaced intervals of up to about 250 mm, and a suction plate 55 disposed below the suction pads 54a through 54e in order to attract the photosensitive web 22 downwardly. The peeling mechanism 44 comprises a suction drum 62 for reducing tension variations in a portion of the photosensitive web 22, which is positioned upstream of the

suction drum 62, so as to stabilize the tension of the photosensitive web 22 when it is laminated. A peeling roller 63 is disposed near the suction drum 62. The protective film 30, which is peeled off from the photosensitive web 22 at a sharp peel-off angle by the peeling roller 63, is wound by a protective film takeup unit 64, except for a residual section 30b thereof.

A tension control mechanism 66 for imparting tension to the photosensitive web 22 is disposed downstream of the peeling mechanism 44. The tension control mechanism 66 has a cylinder 68 that is actuatable to angularly displace a tension dancer 70 so that the tension dancer 70 is held in rolling contact with the photosensitive web 22 to adjust the tension thereof. The tension control mechanism 66 may be employed only when necessary, or may be dispensed with altogether.

The detecting mechanism 47 has a photoelectric sensor 72, such as a laser sensor, a photosensor, or the like, for directly detecting changes in the photosensitive web 22 due to wedge-shaped grooves in the partially cut regions, 34, steps produced by different thicknesses of the protective films 30, or any combination thereof. A detected signal from the photoelectric sensor 72 is used as a boundary position signal, which is representative of a boundary position in the protective film 30. The photoelectric sensor 72 is disposed in confronting relation to a backup roller 73. Alternatively, a non-contact displacement gauge.

or an image inspecting means such as a CCD camera or the like, could be employed instead of the photoelectric sensor 72.

Positional data of the partially cut regions 34, which are detected by the detecting mechanism 47, can be statistically processed and converted into graphic data in real time. When such positional data, as detected by, the detecting mechanism 47, shows an undue variation or bias, the manufacturing apparatus 20 generates a warning. The manufacturing apparatus 20 may employ a different system for generating boundary position signals. In such a different system, the partially cut regions 34 are not directly detected, but marks are applied to the photosensitive web 22. For example, holes or recesses may be formed in the photosensitive web 22, near to the partially cut regions 34, or the photosensitive web 22 may be slit by a laser beam or an aqua jet, or may be marked by an ink jet or a printer. These marks on the photosensitive web 22 are detected, and detected signals are used as boundary position signals.

The substrate feeding mechanism 45 includes a plurality of substrate heating units (e.g., heaters) 74 disposed so as to sandwich and heat the glass substrates 24 therebetween, and a feeder 76 for feeding the glass substrates 24 in the direction indicated by the arrow C. Temperatures of the glass substrates 24 in the substrate heating units 74 are monitored at all times . When the monitored temperature of a

glass substrate 24 becomes abnormal, the feeder 76 is inactivated and a warning is issued, whereby information indicating the abnormality is sent so as to reject and discharge the abnormal glass substrate 24 in a subsequent process. The monitored temperature is also used for purposes of quality control and production management . The feeder 76 includes an air-floated plate (not shown) for floating and feeding the glass substrates 24 in the direction indicated by the arrow C. Alternatively, the feeder 76 may comprise a roller conveyor for feeding the glass substrates 24.

Temperatures of the glass substrates 24 should preferably be measured inside the substrate heating units 74, or immediately prior to the applying position, according to a contact process (for example, using a thermocouple) or by a non-contact process.

A substrate storage frame 71 storing a plurality of glass substrates 24 is disposed upstream of the substrate heating units 74. The glass substrates 24 that are stored in' the substrate storage frame 71 are attracted one by one by suction pads 79 mounted on the hand 75a of a robot 75, and are taken out from the substrate storage frame 71 and inserted into the substrate heating units 74.

Downstream from the substrate heating units 74 are disposed a stopper 77 that abuts against a leading end of a glass substrate 24 for holding the glass substrate 24, and a position sensor 78 that detects the position of the leading

end of the glass substrate 24. The position sensor 78 detects the position of the leading end of the glass substrate 24 while on its way toward the applying position. After the position sensor 78 has detected the position of '5 the leading end of the glass substrate 24, the glass substrate 24 is fed a predetermined distance and positioned between rubber rollers 80a, 80b of the applying mechanism 46. Preferably, a plurality of position sensors 78 are disposed at spaced intervals along the feed path, in order 0 to monitor the times at which the glass substrate 24 reaches respective positions of the position sensors 78, thereby checking a delay due to slippage of the glass substrate 24 as the glass substrate 24 begins to be fed. As shown in FIG. 1, glass substrates 24 are heated by the substrate 5 heating units 74 while the glass substrates 24 are being fed. However, the glass substrates 24 may also be heated in a batch-heating oven and fed by a robot.

The applying mechanism 46 includes a pair of vertically spaced laminating rubber rollers 80a, 80b that can be heated 0 to a predetermined temperature. The applying mechanism 46 also has a pair of backup rollers 82a, 82b held in rolling contact with the rubber rollers 80a, 80b, respectively. The backup roller 82b is pressed against the rubber roller 80b by a roller clamp unit 83. 5 As shown in FIG. 4, the roller clamp unit 83 has a drive motor 93 including a drive shaft coupled to a speed reducer 93a, which has a drive shaft 93b thereof coaxially

connected to a ball screw 94. A nut 95 is threaded over the ball screw 94 and fixed onto a slide base 96. Tapered cams 97a, 97b are fixedly mounted on respective opposite ends of the slide base 96, in a transverse direction of the photosensitive web 22, as indicated by the arrow B. The tapered cams 97a, 97b are progressively higher in the direction indicated by the arrow Bl. Rollers 98a, 98b are positioned in rolling contact with the respective tapered cams 97a, 97b and are held rotatably on respective lower ends of pressing cylinders 84a, 84b.

As shown in FIG. 1, a contact prevention roller 86 is movably disposed near the rubber roller 80a, for preventing the photosensitive web 22 from contacting the rubber roller 80a. A preheating unit 87 that preheats the photosensitive web 22 to a predetermined temperature is disposed upstream of and in proximity to the applying mechanism 46. The preheating unit 87 comprises a heating means, such as an infrared bar heater or the like.

Glass substrates 24 are fed from the applying mechanism 46 and through the inter-substrate web cutting mechanism 48 along a feed path 88, which extends in the direction indicated by the arrow C. The feed path 88 comprises an array of rollers, including film feed rollers 90 and substrate feed rollers 92, with the web leading end cutting mechanism 48a interposed therebetween. The distance between the rubber rollers 80a, 80b and the substrate feed rollers 92 is equal to or less than the length of one glass

substrate 24.

The inter-substrate web cutting mechanism 48 and the web leading end cutting mechanism 48a are movable along a direction (i.e., the direction indicated by the arrow C) in which the photosensitive web 22 and the glass substrates 24 are fed. The inter-substrate web cutting mechanism 48 and the web leading end cutting mechanism 48a include respective cutting blades 89, 89a, which are movable transversely across the photosensitive web 22, and respective suction plates 91, 91a disposed respectively in confronting relation to the cutting blades 89, 89a, for attracting the photosensitive web 22 upwardly. ,

In the manufacturing apparatus 20, the web reel-out mechanism 32, the partial cutting mechanism 36, the label bonding mechanism 40, the peeling mechanism 44, the tension control mechanism 66/ and the detecting mechanisms 47 are disposed above the applying mechanism 46. Conversely, the web reel-out mechanism 32, the partial cutting mechanism 36, the label bonding mechanism 40, the peeling mechanism 44, the tension control mechanism 66, and the detecting mechanisms 47 may be disposed below the applying mechanism 46, so that the photosensitive web 22 is inverted vertically, and the photosensitive resin layer 28 is joined to the lower surfaces of the glass substrates 24. Alternatively, all mechanisms of the manufacturing apparatus 20 may be linearly arrayed.

As shown in FIG. 5, the manufacturing apparatus 20 is

controlled in its entirety by a process , controller 100 (speed controller). The manufacturing apparatus 20 also includes a substrate heating controller 102, a partial cutting controller 104, a label bonding controller 106, a - lamination controller 108, and a film cutting controller 110, etc., for controlling different functional components of the manufacturing apparatus 20. Such controllers are interconnected to the process controller 100 through an in- process network 112. The process controller 100 is connected to a factory network, which incorporates the manufacturing apparatus 20 therein, and performs information processing for production, e.g., production management and mechanism operation management, based on instructional information (condition settings and production information) that is received from a management computer through the network.

The substrate heating controller 102 controls the substrate heating units 74 so as to receive glass substrates 24 from an upstream process and heat the received glass substrates 24 to a desired temperature, further controls the substrate feeding mechanism 45 to feed the heated glass substrates 24 to the applying mechanism 46, and also controls the handling of information concerning the glass substrates 24. The partial cutting controller 104 controls a process for operating the partial cutting mechanism 36, at a predetermined timing, in order to form the partially cut

regions 34 in the photosensitive web 22. The label bonding controller 106 controls a process for operating the label bonding mechanism 40, at a predetermined timing, in order to bond the adhesive labels 38 onto the photosensitive web 22. The lamination controller 108 controls the applying mechanism 46, based on the positional information, detected by the detecting mechanism 47, of the partially cut regions 34 of the photosensitive web 22.

The film cutting controller < 110 controls a process for operating the inter-substrate web cutting mechanism 48 and the web leading end cutting mechanism 48a, at a predetermined timing, in order to cut the photosensitive web 22 between glass substrates 24, or to cut off an unwanted leading end portion of the photosensitive web 22. The installation space for the manufacturing apparatus 20 is divided, by a partition wall 111, into a first clean room 112a and a second clean room 112b. The first clean room 112a houses therein the web reel-out mechanism 32, the partial cutting mechanism 36, the label bonding mechanism 40, the peeling mechanism 44, and the tension control mechanism 66. The second clean room 112b houses therein the detecting mechanism 47 as well as the other components that follow the detecting mechanism 47. The first clean room 112a and the second clean room 112b are connected to each other by a pass-through region 114.

In the manufacturing apparatus 20, the partition wall 111 prevents heated air from the applying mechanism 46 from

rising and thermally affecting the photosensitive web 22, e.g., from wrinkling, deforming, thermally shrinking, or stretching the photosensitive web 22. The partition wall 111 further separates an upper area of the manufacturing apparatus 20, i.e., the first clean room 112a, where dust particles are liable to occur and fall, from a lower area of the manufacturing apparatus 20, i.e., the second clean room 112b, thereby keeping the applying mechanism 46 clean. It is desirable to keep the pressure in the second clean room 112b higher than the pressure in the first clean room 112a, so as to prevent dust particles from flowing from the first clean room 112a into the second clean room 112b.

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

Initially, in order to position 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 ..partial cutting mechanism 36, the label bonding mechanism 40, the peeling mechanism 44, and the applying mechanism 46, so as to reach the film feed rollers 90, which grip the leading end of the photosensitive web 22 (see FIG. 6). At this time, the contact prevention roller 86 has been displaced in a direction indicated by the arrow, in order to prevent the photosensitive web 22 from contacting the heated rubber rollers 80a, 80b. The

photosensitive web 22 thereby is prevented from being excessively heated and having its quality lowered prior to being applied onto a glass substrate 24.

Operation of the functional components of the manufacturing apparatus 20, when operated in a lamination mode, shall be described below with reference to the timing chart shown in FIG. 7.

As shown in FIG. 8, the contact prevention roller 86 is elevated in the direction indicated by the arrow, whereupon the film feed rollers 90 and the rubber roller 80a are rotated to feed the photosensitive web 22, at a speed Vl, along the rubber roller 80a in the direction indicated^ by the arrow C .

At this time, the partial cutting mechanism 36, which is controlled by the partial cutting controller 104, has its suction plate 53 lifted in the direction indicated by the arrow so as to attract the photosensitive web 22, and the partial cutting mechanism 36 is moved at the speed Vl in unison with the photosensitive web 22 in the direction indicated by the arrow A., The circular blades 52a, 52b are moved at a speed V3 transversely across the photosensitive web 22, cutting into the protective film 30 and the photosensitive resin layer 28 or the base film 26, thereby to form partially cut regions 34 at two locations spaced from each other by a distance corresponding to the residual section 30b. The photosensitive web 22 now has a front peel-off section 30aa and a rear peel-off section 30ab

formed thereon, with a residual section 30b interposed therebetween (see FIG. 2). After the partially cut regions 34 have been formed, the suction plate 53 is lowered and moved away from the photosensitive web 22, so that the partial cutting mechanism 36 returns to its original position.

The speed V3 at which the circular blades 52a, 52b move transversely across the photosensitive web 22 is set to a value such that the partially cut regions 34 can be completed while the photosensitive web 22 is moving at a speed equal to or lower than the speed Vl in the direction indicated by the arrow A. While the partially cut regions 34 are being formed, the rubber roller 80b is in a lowered position, and the photosensitive web 22 is not applied to the glass substrate 24 by the applying mechanism 46.

The photosensitive web 22, with the partially cut regions 34 formed therein, is continuously fed at the speed Vl to fhe label bonding mechanism 40. When the partially cut regions 34 arrive at the label bonding mechanism 40, the label bonding controller 106 controls the label bonding mechanism 40 to raise the suction plate 55 in the direction indicated by the arrow in FIG. 8. The suction plate 55 attracts the base film 26 in the vicinity of the residual section 30b on the photosensitive web 22, and moves at the speed Vl in the direction indicated by the arrow A in unison with the photosensitive web 22. Adhesive labels 38, which are attracted by the suction pads 54a through 54e, are

bonded to the front ■ peel-off section 30aa and to the rear peel-off section 30ab, across the residual section 30b of the protective film 30 (see FIG. 3). After the adhesive labels 38 have been bonded, the suction plate 55 is lowered and moved away from the photosensitive web 22, so that the label bonding mechanism 40 returns to its original position.

The label bonding mechanism 40 completes the bonding process while the photosensitive web 22 moves at a speed equal to or lower than the speed Vl in the direction indicated by the arrow A. During the bonding process, the applying mechanism 46 does not apply the photosensitive web 22.

As shown in FIG. 1, the photosensitive web 22 with the adhesive labels 38 bonded thereto is continuously fed to the peeling mechanism 44. In the peeling mechanism 44, the base film 26 of the photosensitive web 22 is attracted to the suction drum 62, whereby the protective film 30 connected by the adhesive labels 38 is peeled off from the photosensitive web 22, thus leaving the residual section 30b. The protective film 30 is peeled off at a sharp peel-off angle by the peeling roller 63, and is wound by the protective film takeup unit 64.

At this time, since the photosensitive web 22 is firmly held by the suction drum 62, 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 62. Consequently, such

shocks are not transferred to the applying mechanism 46, and hence the laminated sections of the glass substrates 24 are effectively prevented from developing striped defective regions therein. After the protective film 30 has been peeled off from the base film 26 by the peeling mechanism 44, leaving the residual section 30b, the tension control mechanism 66 adjusts the tension of the photosensitive web 22, and then the partially cut regions 34 of the photosensitive web 22 are detected by the photoelectric sensor 72 of the detecting mechanism 47.

Based on the detected information of the partially cut regions 34, the film feed rollers 90 are rotated to feed the photosensitive web 22 a predetermined length to the applying mechanism 46.

The glass substrate 24 is heated to a predetermined temperature by the substrate heating unit 74, under control of the substrate heating controller 102. At a predetermined timing based on the detected information from the photoelectric sensor 72 of the detecting mechanism 47, the glass substrate 24 is fed by the substrate feeding mechanism 45, and is introduced and positioned at a given position between the rubber rollers 80a, 80b.

Then, as shown in FIG. 4, under control of the lamination controller 108, the ball screw 94 is rotated in a given direction by the speed reducer 93a coupled to the drive motor 93, thereby moving the slide base 96 in the

direction indicated by the arrow B2, in unison with the nut 95 that is threaded over the ball screw 94. Therefore, the cam surfaces of the tapered cams 97a, 97b, which are in contact with the rollers 98a, 98b, are raised, thereby displacing the rollers 98a, 98b upwardly. The pressing cylinders 84a, 84b are elevated, lifting the backup roller 82b and the rubber roller 80b, so as to sandwich the glass substrate 24 at a predetermined pressure between the rubber rollers 80a, 80b (see FIG. 9). At this time, the pressure is adjusted by the amount of air pressure that is supplied to the pressing cylinders 84a, 84b.

After the photosensitive web 22 and the substrate 24 have been sandwiched by the rubber rollers 80a, 80b, the upper roller 80a and the film feed rollers 90 are rotated at a speed V2 (V2 > Vl ) in order to feed the photosensitive web 22 and the substrate "24 in the direction indicated by the arrow C. The photosensitive resin layer 28 is melted by heat and transferred to (i.e., laminated on) the glass substrate 24. During the laminating process, the partial cutting mechanism 36 and the label bonding mechanism 40 do not perform the partial cutting process and the label bonding process. Thus, since the laminating process is not adversely affected by tension variations, which would otherwise be caused by such processes, the laminating process is carried out neatly and effectively.

The photosensitive resin layer 28 is laminated onto the glass substrate 24 under the following conditions: The

photosensitive resin layer 28 is fed at a speed in the range from 1.0 m/min. to 10.0 m/min . , the rubber rollers 80a, 80b have a temperature ranging from 100° C to 150° C and a hardness in the range from 40 to 80, and the applied pressure (linear pressure) of the rollers 80a, 80b ranges from 50 N/cm to 400 N/cm.

As shown in FIG. 10, when the leading end of the glass substrate 24 reaches a position near the film feed rollers 90, the film feed rollers 90 are moved away from the glass substrate 24. When the leading end of the photosensitive web 22, which projects forwardly in the direction indicated by the arrow C in front of the glass substrate 24, reaches a predetermined position with respect to the web leading end cutting mechanism 48a, the web leading end cutting mechanism 48a is controlled by the film cutting controller 110 so as to lower the suction plate 91a, in order to attract the photosensitive web 22 and move the cutting blade 89a transversely across the photosensitive web 22, thereby cutting off the unwanted leading end of the photosensitive web 22. At this time, the web leading end cutting mechanism 48a moves at the speed V2 in unison with the photosensitive web 22, in the direction indicated by the arrow C, thereby cutting the photosensitive web 22. After cutting off the leading end of the photosensitive web 22, the web leading end cutting mechanism 48a returns to its standby position, and is not used while the manufacturing apparatus 20 is in normal operation.

As shown in FIG. 11. after the photosensitive web 22 has been laminated by the rubber rollers 80a, 80b up to the trailing end of the glass substrate 24, rotation of the rubber roller 80a is stopped (see the interval al in FIG. 7). After the photosensitive web 22 has been stopped by the rubber roller 80a, the glass substrate 24 together with the laminated photosensitive web 22 thereon (also referred to as an "applied substrate 24a") is clamped by the substrate feed rollers 92. The rubber roller 80b is retracted away from the rubber roller 80a, thereby unclamping the applied substrate 24a. Specifically, as shown in FIG. 4, the speed reducer 93a coupled to the drive motor 93 is reversed, causing the ball screw 94 and the nut 95 to move the slide base 96 in the direction indicated by the arrow Bl. Therefore, the cam surfaces of the tapered cams 97a, 97b in contact with the rollers 98a, 98b are lowered, thereby displacing the pressing cylinders 84a, 84b downwardly. The backup roller 82b and the rubber roller 80b are also lowered to unclamp the applied substrate 24a.

At a predetermined time before rotation of the rubber roller 80a is stopped, the glass substrate 24 is released from the stopper 77 and is fed at a speed V4 by the feeder 76 of the substrate feeding mechanism 45. The glass substrate 24 is introduced across the position sensor 78 to a given position between the undamped rubber rollers 80a, 80b, and waits at that position.

After elapse of a predetermined time period (e.g., 1 second) after stoppage of the rubber roller 80a, the rubber roller 80a and the substrate feed rollers 92 begin rotating to feed the photosensitive web 22 and the applied substrate 24a at a speed Vl, which is lower than the speed V2 used during the laminating process, in the direction indicated by the arrow C for a predetermined period of time (e.g., 3 seconds, see the interval a2 in FIG. 7). Then, rotation of the rubber roller 80a and the substrate feed rollers 92 is stopped for a predetermined period of time (e.g., 1 second; see the interval a3 shown in FIG. 7). At this time, an inter-substrate position 22b on the photosensitive web 22 is moved to a position below and near to the rubber roller 80a. During a period of time (intervals al - a3 ) after the applied substrate 24a has been produced and until the next applied substrate 24a starts being produced, feeding of the photosensitive web 22 is stopped or the photosensitive web 22 is fed at a low speed (the speed Vl) while in contact with the rubber roller 80a. Since the photosensitive web 22 stops being fed only for a short period of time (e.g., 1 second), the photosensitive resin layer 28 is not adversely affected by heat from the rubber roller 80a, and hence striped irregularities in the boundary area, between the area held in contact with the rubber roller 80a and the area that is not held in contact with the rubber roller 80a, are prevented from developing. It has also been confirmed that

the photosensitive web 22 does not develop striped irregularities, which could cause quality problems, even if the photosensitive web 22 is continuously fed at a low speed. Further, if the period of time represented by the intervals al - a3 is limited to 5 seconds or shorter, the photosensitive resin layer 28 of the photosensitive web 22 does not suffer from thermally induced discoloration due to heat, and hence the photosensitive resin layer 28 can be maintained in a neat state.

After the lamination process performed on the first applied substrate 24a by the rubber rollers 80a, 80b is finished, the photosensitive web 22 is stopped while remaining partially in contact with the rubber roller 80a, and then is moved at the speed Vl and stopped again (the intervals al - a3 in FIG. 7). During this time, the suction plate 53 of the partial cutting mechanism 36 is elevated and attracts the photosensitive web 22. Thereafter, the suction plate 53 moves at the speed Vl, in the direction indicated by the arrow A in FIG. 1, in unison with the photosensitive web 22. At the same time, the circular blades 52a, 52b move transversely across the photosensitive web 22, forming partially cut regions 34 in the photosensitive web 22.

The length of the feed path for the photosensitive web 22, from the partial cutting mechanism 36 to the applying mechanism 46, is set roughly to an integral multiple of the distance between adjacent residual sections 30b (see FIG.

3). As the partially cut regions 34 are being formed by the partial cutting mechanism 36, the residual section 30b, where the laminating process is not performed, can be placed in the applying mechanism 46. Similarly, after the suction plate 55 of the label bonding mechanism 40 has been lifted to attract the photosensitive web 22, the suction plate 55 moves at the speed Vl, in the direction indicated by the arrow A in FIG. 1, in unison with the photosensitive web 22. At the same time, the adhesive labels 38 attracted by the suction pads

54a through 54e are bonded onto the partially cut regions 34 formed by the partial cutting mechanism 36 (see FIG. 4). The label bonding process is performed by the label bonding mechanism 40 concurrently with the process of forming the partially cut regions 34, which is performed by the partial cutting mechanism 36.

In the intervals al - a3 , since the photosensitive web 22 is ' stopped or fed at the speed Vl, which is lower than the speed used during the laminating process, the partial cutting mechanism 36 and -the label bonding mechanism 40 move a small distance in the direction indicated by the arrow A. Therefore, even though these mechanisms also move along the direction in which the photosensitive web 22 is fed, the manufacturing apparatus 20 is not large in size. Since the partially cut regions 34 are formed and the adhesive labels 38 are bonded while the partial cutting mechanism 36 and the label bonding mechanism 40 move in

synchronism with the feeding motion of the photosensitive web 22, the photosensitive web 22 is free from tension variations. Therefore, a film reservoir between the label bonding mechanism 40 and the peeling mechanism 44 is not required, and the manufacturing apparatus 20 is relatively simple in structure.

While the partial cutting mechanism 36 and the label bonding mechanism 40 are performing their respective processes, the residual section 30b of the photosensitive web 22 is placed in the applying mechanism 46, although a laminating process is not actually performed by the applying mechanism 46. Consequently, even if tension variations are caused by processes that are performed upstream of the applying mechanism 46, such tension variations will not adversely affect the photosensitive web 22 in the applying mechanism 46.

When the processes performed respectively by the partial cutting mechanism 36 and the label bonding mechanism 40 are finished, the photosensitive web 22 is released from the suction plates 53, 55, while the partial cutting mechanism 36 and the label bonding mechanism 40 are stopped from moving in the direction indicated by the arrow A and are returned to their original positions.

The rubber roller 80b is lifted, thus clamping the next glass substrate 24 and the photosensitive web 22 between the rubber rollers 80a, 80b. The rubber rollers 80a, 80b and the substrate feed rollers 92 are rotated to begin

laminating the photosensitive web 22 onto the glass substrate 24, as they are fed at the speed V2 , and also to feed the applied substrate 24a in the direction indicated by the arrow C (see FIG. 12). At this time, as shown in FIG. 13, the applied substrate 24a has opposite ends covered with the residual section 30b. Therefore, when the ^' photosensitive resin layer 28 is transferred onto the glass substrate 24, the photosensitive resin layer 28 is transferred so as to form a picture frame like arrangement . While the photosensitive web 22 is laminated onto the glass substrate 24, the partial cutting mechanism 36 does not form partially cut regions 34, and the label bonding mechanism 40 also does not bond adhesive labels 38. Therefore, the photosensitive web 22 can be laminated onto the glass substrate 24 highly accurately, without being adversely affected by tension variations. There is no need to consider periods of time, which otherwise would be required by the processes of forming the partly cut regions 34 and bonding the adhesive labels 38. Because the photosensitive web 22 and the glass substrate 24 can be fed at the high speed V2 while allowing the laminating process to be performed, the applied substrate 24a can be produced more efficiently.

When the trailing end of the first applied substrate 24a reaches the substrate feed rollers 92, the upper substrate feed roller 92 is lifted to unclamp the first applied substrate 24a, whereas the lower substrate feed

roller 92 along with the other rollers of the feed path 88 are continuously rotated to feed the applied substrate 24a. When the trailing end of the next (i.e., the second) applied substrate 24a reaches a position near the rubber rollers 80a, 80b, as shown in FIG. 14, the rubber rollers 80a, 80b and the substrate feed rollers 92 are again stopped from rotating (see the interval al in FIG. 7). As shown in FIG. 15, the upper substrate feed roller 92 is lowered to clamp the second applied substrate 24a, while the rubber roller 80b is lowered so as to unclamp the second applied substrate 24a. Then, the rubber roller 80a and the substrate feed rollers 92 are rotated to feed the second applied substrate 24a and the photosensitive web 22 at a speed Vl, which is lower than the speed V2 used during the laminating process. At this time, the inter-substrate position 22b of the photosensitive web 22, which exists between the first applied substrate 24a that has passed beyond the substrate feed rollers 92 and the second applied substrate 24a, reaches the inter-substrate web cutting mechanism 48, whereupon the photosensitive web 22 at the inter-substrate position 22b is attracted by the suction plate 91 of the inter-substrate web cutting mechanism 48. The inter- substrate web cutting mechanism 48 moves the suction plate 91 at the speed Vl, in the direction indicated by the arrow C, in unison with the photosensitive web 22, while also moving the cutting blade 89 transversely across the photosensitive web 22, thereby cutting the photosensitive

web 22 between the applied substrates 24a. After the photosensitive web 22 has been cut, the inter-substrate web cutting mechanism 48 returns to its original position.

The length of the feed path for the photosensitive web 22, from the applying mechanism 46 to the inter-substrate web cutting mechanism 48, is set roughly to an integral multiple of the length of the applied substrate 24a, along the direction in which the applied substrate 24a is fed. While the residual section 30b, where the laminating process is not performed, is being placed in the applying mechanism 46, the inter-substrate web cutting mechanism 48 cuts the photosensitive web 22. Therefore, tension variations, which are caused when the inter-substrate web cutting mechanism 48 cuts the photosensitive web 22, do not adversely affect production of the applied substrate 24a.

While the inter-substrate web cutting mechanism 48 cuts the photosensitive web 22, the partial cutting mechanism 36 and the label bonding mechanism 40, which are disposed upstream of the inter-substrate web cutting mechanism 48, form partially cut regions 34 in the photosensitive web 22, and also bond adhesive labels 38 to the photosensitive web 22, concurrently with each other.

The above processing operations are carried out similarly on third and subsequent applied substrates 24a. After the photosensitive web 22 has been cut between applied substrates 24a, the base film 26 and the residual section 30b are peeled off the applied substrate 24a, thereby

manufacturing the photosensitive laminated body 116 (see FIG. 1).

In the above embodiment, after the photosensitive web 22 has been cut between applied substrates 24a by the inter- substrate web cutting mechanism 48, the base film 26 and the residual section 30b are peeled off from each of the applied substrates 24a, thereby manufacturing the photosensitive laminated body 116. However, the photosensitive laminated body 116 may also be manufactured without cutting the photosensitive web 22 between applied substrates 24a, whereby the base film 26 is continuously wound up and the residual section 30b is peeled off. In this case, the _/ inter-substrate web cutting mechanism 48 can be dispensed with. Although a certain preferred embodiment of the present invention has been shown and described above in detail, it shall be understood that various changes and modifications may be made to the disclosed embodiment without departing from the scope of the invention as set forth in the appended claims.