(19) United States
`(12) Patent Application Publication (10) Pub. No.: US 2006/0177587 A1
`(43) Pub. Date:
`Aug. 10, 2006
`Ishizuka et al.
`
`US 2006O177587A1
`
`(54) OPTICAL COMPENSATORY SHEET
`PRODUCING METHOD AND APPARATUS,
`THERMAL TREATING METHOD AND
`APPARATUS, AND DUST REMOVING
`METHOD AND APPARATUS
`
`(75) Inventors: Seiji Ishizuka, Kanagawa (JP);
`Munehiro Ura, Kanagawa (JP);
`Tadashi Sugiyama, Kanagawa (JP);
`Kenji Nakajima, Kanagawa (JP);
`Kazuhiko Fujiwara, Kanagawa (JP);
`Naoyuko Kawanishi, Kanagawa (JP)
`Correspondence Address:
`SUGHRUE MION, PLLC
`2100 PENNSYLVANIA AVENUE, N.W.
`SUTE 8OO
`WASHINGTON, DC 20037 (US)
`(73) Assignee: FUJI PHOTO FILM CO., LTD.
`(21) Appl. No.:
`11/377,672
`
`(22) Filed:
`
`Mar. 17, 2006
`Related U.S. Application Data
`(60) Continuation of application No. 10/919,377, filed on
`Aug. 17, 2004, which is a division of application No.
`
`09/851,416, filed on May 9, 2001, now Pat. No.
`6,812,982.
`Foreign Application Priority Data
`
`(30)
`
`May 12, 2000 (JP)...................................... 2OOO-140023
`Jul. 6, 2000 (JP)...................................... 2000-204557
`Jul. 21, 2000 (JP)...................................... 2000-220330
`
`Publication Classification
`
`(51) Int. Cl.
`(2006.01)
`BOSD 3/04
`(2006.01)
`BOSD 3/12
`(52) U.S. Cl. ......................................... 427/348; 427/372.2
`
`ABSTRACT
`(57)
`An optical compensatory sheet producing apparatus pro
`duces an optical compensatory sheet having a liquid crystal
`layer. In the apparatus, a rubbing unit is Supplied with resin
`film having a first layer including resin, and Subjects the first
`layer to a rubbing process, so as to form an orientation layer.
`A dust remover removes dust from the orientation layer by
`use of liquid Such as perfluorocarbon, to which the orienta
`tion layer is insoluble. A liquid crystal layer coater is
`disposed downstream from the dust remover, for coating the
`orientation layer with coating liquid including liquid crys
`talline compound, so that the liquid crystal layer is formed.
`
`
`
`
`
`S.
`
`
`
`
`
`112
`
`112
`
`112
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`SEC et al. v. MRI
`SEC Exhibit 1025.001
`IPR 2023-00199
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`Patent Application Publication Aug. 10, 2006 Sheet 1 of 18
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`US 2006/0177587 A1
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`8 / 8 ?.
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`SEC et al. v. MRI
`SEC Exhibit 1025.002
`IPR 2023-00199
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`Patent Application Publication Aug. 10, 2006 Sheet 2 of 18
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`US 2006/0177587 A1
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`
`
`
`
`.
`
`
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`s
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`SEC et al. v. MRI
`SEC Exhibit 1025.003
`IPR 2023-00199
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`Patent Application Publication Aug. 10, 2006 Sheet 3 of 18
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`US 2006/0177587 A1
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`F. G. 3 A
`AIR
`
`AIR
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`
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`SEC et al. v. MRI
`SEC Exhibit 1025.004
`IPR 2023-00199
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`Patent Application Publication Aug. 10, 2006
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`Sheet 4 of 18
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`US 2006/0177587 A1
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`CN
`CY
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`SEC et al. v. MRI
`SEC Exhibit 1025.005
`IPR 2023-00199
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`Patent Application Publication Aug. 10, 2006 Sheet 5 of 18
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`US 2006/0177587 A1
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`SEC et al. v. MRI
`SEC Exhibit 1025.006
`IPR 2023-00199
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`Patent Application Publication Aug. 10, 2006 Sheet 6 of 18
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`US 2006/0177587 A1
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`FIG. 6
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`
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`SEC et al. v. MRI
`SEC Exhibit 1025.007
`IPR 2023-00199
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`Patent Application Publication Aug. 10, 2006 Sheet 7 of 18
`F. G.
`
`US 2006/0177587 A1
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`ANIONIC POLYMER
`
`-(CH-CH) – H-H), -(H-H),
`O Na O th-O
`
`CO CO
`
`CO CO
`
`O Na O Na
`
`FIG. 8
`ALKYL MODIFIED PWA
`
`-(CH-CH)
`OH
`
`(CH-CH)
`p
`CEO
`
`(CH-CH)
`o
`CEO
`
`-
`
`CH
`
`FIG 9
`
`R
`
`O(CH), OCOCH=CH
`
`R O-R
`OC R
`O
`
`R
`
`R
`
`DISCOTIC
`LIQUID
`CRYSTAL
`COMPOUND
`
`R= -O-CO-()-O-(CH,), -o-Co-CH=CH,
`
`SEC et al. v. MRI
`SEC Exhibit 1025.008
`IPR 2023-00199
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`Patent Application Publication Aug. 10, 2006 Sheet 8 of 18
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`US 2006/0177587 A1
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`OZL
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`
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`SEC et al. v. MRI
`SEC Exhibit 1025.009
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`Patent Application Publication Aug. 10, 2006 Sheet 9 of 18
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`US 2006/0177587 A1
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`FIG 11
`
`
`
`126
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`SEC et al. v. MRI
`SEC Exhibit 1025.010
`IPR 2023-00199
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`Patent Application Publication Aug. 10, 2006 Sheet 10 of 18
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`US 2006/0177587 A1
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`FIG 12
`
`
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`SEC et al. v. MRI
`SEC Exhibit 1025.011
`IPR 2023-00199
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`Patent Application Publication Aug. 10, 2006 Sheet 11 of 18
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`US 2006/0177587 A1
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`FIG 13
`
`
`
`
`
`O O. O. O. O. O.
`O O O o O O o O O O. O. O. o.o.
`O: O O O O O O O O O O O O Go O O.
`OO O. O. O. O. O. O. O. O. o O o O o o o
`ro, o O O o O O o O O o O OO o O G.
`O O. O. O. O. O. O. O. O. O. O. O. O. O. O. O.G.
`O O o O O O o O O o O O O o O old
`
`
`
`
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`SEC et al. v. MRI
`SEC Exhibit 1025.012
`IPR 2023-00199
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`Patent Application Publication Aug. 10, 2006 Sheet 12 of 18
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`US 2006/0177587 A1
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`
`
`3
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`SEC et al. v. MRI
`SEC Exhibit 1025.013
`IPR 2023-00199
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`Patent Application Publication Aug. 10, 2006 Sheet 13 of 18
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`US 2006/0177587 A1
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`
`
`V g H *
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`5) I „H
`
`No.zz-z-z-ZZZZZZZZZZZZZZZZZZZZZ_4C!' |- Ø Ø Ø
`
`
`
`SEC et al. v. MRI
`SEC Exhibit 1025.014
`IPR 2023-00199
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`Patent Application Publication Aug. 10, 2006 Sheet 14 of 18
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`US 2006/0177587 A1
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`212
`
`
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`SEC et al. v. MRI
`SEC Exhibit 1025.015
`IPR 2023-00199
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`Patent Application Publication Aug. 10, 2006 Sheet 15 of 18
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`US 2006/0177587 A1
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`
`
`s
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`SEC et al. v. MRI
`SEC Exhibit 1025.016
`IPR 2023-00199
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`Patent Application Publication Aug. 10, 2006 Sheet 16 of 18
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`US 2006/0177587 A1
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`FIG 17 A
`
`
`
`Wet Removal
`
`of Dust
`
`Circulating
`
`FOW
`(liter/min)
`UltraSOnic
`WaVeS
`
`Pre SS Ullre
`(N/In)
`
`3) In Particles
`(Per n)
`
`10pm
`Particles
`(Per m)
`
`SCratches
`
`Numer OuS
`
`Locally
`Existed
`
`SEC et al. v. MRI
`SEC Exhibit 1025.017
`IPR 2023-00199
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`

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`Patent Application Publication Aug. 10, 2006 Sheet 17 of 18
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`US 2006/0177587 A1
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`FIG 17B
`
`Dry Removal of
`Dust
`
`Wet
`Removal
`Of DuSt
`
`Comp.
`EX. 8a.
`
`Comp.
`Ex. 8b
`
`Sample
`5 a.
`
`Sample
`5b
`
`Existed
`
`- Rubber
`Roll
`
`Rubber
`ROL
`
`Rubber
`ROl
`
`Rubber
`ROl
`
`3 O
`
`3 O
`
`3O
`
`
`
`
`
`OI
`
`O
`
`Pressure NOIle
`(N/m)
`
`NOne
`
`19 6
`
`Non - Contact
`Feeding
`
`6
`
`
`
`
`
`
`
`
`
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`
`
`
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`
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`SEC et al. v. MRI
`SEC Exhibit 1025.018
`IPR 2023-00199
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`Patent Application Publication Aug. 10, 2006 Sheet 18 of 18
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`US 2006/0177587 A1
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`
`
`8 { * 5) I „H
`
`(LHV HO I H d)
`
`SEC et al. v. MRI
`SEC Exhibit 1025.019
`IPR 2023-00199
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`

`

`US 2006/0177587 A1
`
`Aug. 10, 2006
`
`OPTICAL COMPENSATORY SHEET PRODUCING
`METHOD AND APPARATUS, THERMAL
`TREATING METHOD AND APPARATUS, AND
`DUST REMOVING METHOD AND APPARATUS
`0001. This is a continuation of Application No.: 10/919,
`377 filed Aug. 17, 2004, which is a divisional of Application
`No. 09/851,416 filed May 9, 2001, now U.S. Pat. No.
`6,812,982. The entire disclosures of the prior applications,
`application Nos. 09/851,416 and 09/851,416 are considered
`part of the disclosure of the accompanying application and
`are hereby incorporated by reference.
`
`BACKGROUND OF THE INVENTION
`0002) 1. Field of the Invention
`0003. The present invention relates to an optical com
`pensatory sheet producing method and apparatus, thermal
`treating method and apparatus, and dust removing method
`and apparatus. More particularly, the present invention
`relates to an optical compensatory sheet producing method
`and apparatus in which an optical compensatory sheet can be
`obtained with high quality for good contrast and color in a
`liquid crystal display unit, and thermal treating method and
`apparatus, and dust removing method and apparatus for the
`optical compensatory sheet.
`0004 2. Description Related to the Prior Art
`0005. A liquid crystal display unit (LCD) is characterized
`in having a shape with a small thickness, being lightweight
`and using low electric power in comparison with a cathode
`ray tube (CRT) to display an image. LCD is used widely as
`a component incorporated in a portable type of word pro
`cessor and a desk-top type of personal computer. In LCD,
`twisted nematic liquid crystal is used. In general, LCD
`include a liquid crystal cell and a pair of polarizing plates
`between which the liquid crystal cell is disposed. The liquid
`crystal cell is constituted by a liquid crystal panel and an
`electrode for applying Voltage to the between the orientation
`layers. To display an image in LCD, there are two modes
`include a birefringence mode and an optically rotary mode.
`0006 A super twisted nematic LCD (hereinafter referred
`to as STN-LCD) utilizing the birefringence mode uses a
`Super twisted nematic liquid crystal showing a twisted angle
`more than 90 degrees and having steep electro-optical
`characteristics. Such STN-LCD, therefore, has an advantage
`of giving display data of a large size by driving in time
`sharing mode. However, the STN-LCD has disadvantages in
`providing good contrast only when set in the yellow mode
`(yellowish green/deep blue) or blue mode (blue/pale yel
`low). A phase difference plate (uniaxial stretched polymer
`film or compensatory liquid crystal cell) is required to give
`black-and-white display.
`0007 TN-LCD, when set in an optically rotary mode,
`shows quick response (as quick as several tens of millisec
`onds) and high display contrast. Hence, the optical rotary
`mode has a number of advantages compared with the
`birefringence mode or other modes. However, TN-LCD has
`disadvantages that color or contrast on display varies with
`changes in viewing angle to LCD, and its display charac
`teristics are not comparable to display characteristics of
`CRT.
`
`0008. In order to improve the viewing angle characteris
`tics (i.e., to enlarge the viewable angle), arrangement of a
`phase difference film (optical compensatory sheet) between
`a pair of polarizing plates and the liquid crystal cell has been
`known. The optical compensatory sheets show no optical
`effect when an LCD is seen in the direction vertical to the
`screen of the display because phase difference in the direc
`tion perpendicular to the surface of LCD is almost zero.
`However, the optical compensatory sheet serves to compen
`sate for phase difference (depending upon wavelengths of
`light) that occurs when LCD is viewed in an oblique
`direction.
`0009 JP-A 6-075115, U.S.P. No. 5,506,706 (correspond
`ing to JP-A 6-075116), and JP-A 4-276076 disclose an
`optical compensatory sheet having the negative birefrin
`gence and inclined optical axis. In more detail, the disclosed
`sheet is produced by stretching polymer Such as polycar
`bonate or polyester, and has the directions of the main
`refractive indices which are inclined from the normal of the
`sheet. To prepare the above sheet by the stretching treatment,
`extremely complicated treatments are required. Therefore,
`an optical compensatory sheet of a large Surface are cannot
`be easily produced according to the disclosed process.
`0010 Also, an optical compensatory sheet comprising
`liquid crystalline polymer is known. For instance, U.S.P.. No.
`5,064,697 (corresponding to JP-A 3-009326) and JP-A
`3-291601 disclose an optical compensatory sheet for LCD
`which is prepared by applying a coating of polymer showing
`liquid crystal property on an orientation layer provided on a
`Support film. However, polymers having a liquid crystalline
`property have a shortcoming in low productivity and are
`unsuitable for mass production, because it needs orientation
`by ripening for a long time at high temperature. JP-A
`5-215921 discloses the use of a birefringence plate (optical
`compensatory sheet) comprising a Support and a polymer
`izable rod-like compound showing liquid crystal property
`and positive birefringence. The birefringence plate is pre
`pared by applying a coating of Solution of the rod-like
`compound to the Support and curing the compound with
`heat. The cured layer of the prior document, however, does
`not show negative birefringence. Hence, the resulting com
`pensatory sheet cannot enlarge satisfactorily the viewing
`angle in all directions.
`0011 U.S.P. No. 5,646,703 (corresponding to EP-A 0 646
`829) discloses an optical compensatory sheet greatly enlarg
`ing the viewing angle in all directions. The optical compen
`satory sheet has a representative structure comprising a
`transparent Support, an orientation layer thereon, and a layer
`of discotic liquid crystalline compound provided on the
`orientation layer.
`0012 To produce an optical compensatory sheet with a
`large area, a transparent resin film with a large area must be
`coated with a discotic liquid crystal compound in a state
`substantially free from defects. So it has been conceived to
`reduce the number of the defects in consideration of enlarg
`ing LCD.
`0013 To produce the optical compensatory sheet, a rub
`bing process rubs a Surface of a resin layer overlaid on the
`resin film for forming an orientation layer by use of a
`rubbing sheet (of fabric). This creates dust such as minute
`particles of resin. The dust becomes collectively stuck on a
`surface of the orientation layer, to create the defects (uneven
`
`SEC et al. v. MRI
`SEC Exhibit 1025.020
`IPR 2023-00199
`
`

`

`US 2006/0177587 A1
`
`Aug. 10, 2006
`
`orientation or local failure in orientation) in an oriented State
`of a liquid crystal layer of the optical compensatory sheet.
`When LCD is provided with the optical compensatory sheet,
`the defects occur in a display state. To avoid failure in
`removal of dust, the rubbing sheet about a rubbing roller
`should be exchanged and renewed frequently. However,
`there is a problem in that occurrence of the defects gradually
`becomes frequent according to dust. Furthermore, renewal
`of the rubbing sheet must be periodical, and inconsistent to
`continuous operation of the manufacture.
`0014 JP-A9-073081 discloses a producing method of an
`optical compensatory sheet. Transparent resin film in a
`continuous shape is coated with solution including resin for
`forming an orientation layer, then is subjected to a rubbing
`process. So the orientation layer is formed, then is coated
`with Solution including discotic liquid crystalline com
`pound. Then the coating is dried. The resin film is thermally
`treated next. The resin film is heated to discotic nematic
`forming temperature, to form a liquid crystal layer oriented
`at a predetermined angle of an orientation axis.
`0015. In FIG. 18, an example of thermal treating appa
`ratus is depicted. There are plural air blow openings 102
`disposed above and below resin film 101 as web, and
`arranged in an alternate manner with one another. The air
`blow openings 102 supply hot air, blow both surface of the
`resin film 101, and apply heat thereto. Exhaust openings 103
`are opposed to respectively the air blow openings 102, and
`ejects the hot air from the resin film 101.
`0016.
`In the optical compensatory sheet, the liquid crystal
`layer must be oriented according to an orientation axis
`previously intended.
`0017. In the thermal treating apparatus according to the
`prior art, it is likely that offsetting of an orientation axis
`occurs in a width direction of the discotic liquid crystal
`layer. If the offsetting of the orientation axis is over a
`tolerable range, portions of the resin film must be discarded.
`There are problems in that yield of products of the optical
`compensatory sheet decreases to increase the manufacturing
`cost, and that efficiency in manufacturing operation becomes
`lower according to inspection of the offsetting of the orien
`tation axis and the discarding operation.
`0018. In manufacturing the optical compensatory sheet,
`dust must be removed from the resin film by a dust removing
`apparatus. U.S.P.. No. 4,577.362 (corresponding to JP-A
`59-150571) discloses an example of dust removal in a dry
`type. A non-woven fabric or blade is pressed against a
`surface of the resin film. Also, JP-A 10-309553 discloses
`dust removal in which compressed air with high cleanness is
`supplied to blow the resin film and separate dust from the
`same. An exhaust opening Sucks the dust by ejecting the air.
`Also, there is an apparatus characterized in that an ultrasonic
`vibrator is used to vibrate an air flow, which separates dust
`with higher shearing force for the purpose of efficient
`cleaning.
`0019. Also, JP-A 10-290964 discloses a dry type of dust
`removal in which electrostatic charge is used. Positive and
`negative ions of air are injected to neutralize the charge.
`Dust is separated and then eliminated by use of another flow
`O a1.
`
`0020. Also, a wet type of dust removal is also known.
`There is a method in which the resin film is traveled through
`a cleaning liquid in a cleaning liquid bath, and an ultrasonic
`vibrator is driven to separate dust from the resin film in the
`cleaning liquid bath. Furthermore, U.S.P.. No. 3,956,790
`(corresponding to JP-B 49-013020) discloses a method in
`which the resin film is Supplied with cleaning liquid, and
`then compressed air blows the resin film to such the dust.
`0021 Those cleaning methods are effective to dust of
`particles of at least 10 um or tens of Lim, or dust stuck
`weakly. However, it is experimentally found that the known
`cleaning methods are nearly ineffective to dust of particles
`of 10 um or less, or dust stuck with strong adhesion.
`0022. To solve such problems. JP-B 5-050419 (corre
`sponding to JP-A 62-060749) proposes a method in which a
`cleaning rod is pressed against the resin film to remove dust.
`For the cleaning rod, the resin film immediately after being
`coated with solvent is Supplied. The cleaning rod is caused
`to rotate in reverse to the traveling to clear the dust while the
`Solvent remains. According to the document, a space is
`formed between the resin film and the cleaning rod with a
`Small thickness. Dust having a size over the space is stopped
`from passing the rod. Also, more minute dust is separated by
`transmission of shearing force in the solvent liquid, so that
`dust of a small size or strongly stuck dust can be removed
`effectively.
`0023. Also, JP-A 62-065872 discloses a dust removing
`method in which a blade with a sharp edge is used to contact
`the resin film.
`0024 However, problems arise in the method of JP-B
`5-050419 (corresponding to JP-A 62-060749) and JP-A
`62-065872. The cleaning rod or the like directly contact the
`surface of the resin film. The cleaning rod or the like is
`formed from Super hard alloy resistant to abrasion, and has
`a very Smooth Surface. Damages or Scratches may occur in
`the resin film if hard foreign matter or dust becomes
`Squeezed between the cleaning rod and the resin film.
`
`SUMMARY OF THE INVENTION
`0025. In view of the foregoing problems, an object of the
`present invention is to provide an optical compensatory
`sheet producing method and apparatus in which an optical
`compensatory sheet can be easily and efficiently obtained
`with high quality for good contrast and color in a liquid
`crystal display unit.
`0026. Another object of the present invention is to pro
`vide a thermal treating method and apparatus in which sheet
`material can be heated without irregularity.
`0027 Still another object of the present invention is to
`provide a dust removing method and apparatus capable of
`removing dust from sheet material without Scratching or
`damaging its Surface.
`0028. In order to achieve the above and other objects and
`advantages of this invention, an optical compensatory sheet
`producing method for producing an optical compensatory
`sheet having a liquid crystal layer is provided. A first layer
`of Support material is subjected to a rubbing process, so as
`to form an orientation layer, the first layer including resin.
`Dust is removed from the orientation layer by use of liquid
`to which the orientation layer is insoluble. After the remov
`
`SEC et al. v. MRI
`SEC Exhibit 1025.021
`IPR 2023-00199
`
`

`

`US 2006/0177587 A1
`
`Aug. 10, 2006
`
`ing step, the orientation layer is coated with coating liquid
`including liquid crystalline compound, thereby the liquid
`crystal layer being formed.
`0029. In a preferred embodiment, the removing step
`includes polishing the orientation layer with the liquid in a
`direction equal to a direction of the rubbing process.
`0030. An optical compensatory sheet producing appara
`tus produces an optical compensatory sheet having a liquid
`crystal layer. In the apparatus, a rubbing unit is Supplied with
`Support material having a first layer including resin, for
`Subjecting the first layer to a rubbing process, so as to form
`an orientation layer. A dust remover removes dust from the
`orientation layer by use of liquid to which the orientation
`layer is insoluble. A liquid crystal layer coater is disposed
`downstream from the dust remover, for coating the orien
`tation layer with coating liquid including liquid crystalline
`compound, thereby the liquid crystal layer being formed.
`0031
`Furthermore, a liquid bath contains the liquid. The
`dust remover includes a cleaning roller, dipped in the liquid
`at least partially, for contacting the orientation layer, to
`polish the orientation layer with the liquid in the direction of
`the rubbing process.
`0032. Furthermore, a resin layer coater is disposed
`upstream from the rubbing unit, for coating the Support
`material with first coating liquid including the resin, to
`obtain the first layer. A thermal treating unit is disposed
`downstream from the liquid crystal layer coater, for heating
`the liquid crystalline compound at phase forming tempera
`ture, to form the liquid crystal layer. A curing unit cures the
`liquid crystal layer to obtain the optical compensatory sheet.
`0033. The liquid is perfluorocarbon having 6-12 carbon
`atOmS.
`0034. In another preferred embodiment, the liquid is
`straight chain siloxane having 2-4 silicon atoms.
`0035) Furthermore, a dry-type dust remover is disposed
`upstream from the dust remover, for removing dust from the
`orientation layer by blow of compressed air.
`0036 Consequently, an optical compensatory sheet can
`be easily and efficiently obtained with high quality for good
`contrast and color in a liquid crystal display unit, because the
`dust remover removes dust from the orientation layer by use
`of liquid to which the orientation layer is insoluble, and
`because the orientation layer is polished with the liquid in a
`direction equal to a direction of the rubbing process.
`0037 According to one aspect of the invention, a thermal
`treating apparatus for a coating layer formed by coating
`traveling web with coating liquid is provided. At least one
`hot air supply unit blows the coating layer with hot air. At
`least one exhaust unit is disposed upstream or downstream
`from the hot air supply unit in a traveling direction of the
`web, for Sucking the hot air from the coating layer.
`0038 Furthermore, a controller adjusts a first flow speed
`at which the hot air is supplied by the hot air supply unit, and
`a second flow speed at which the hot air is sucked by the
`exhaust unit.
`0.039 The hot air supply unit includes a hot air generator
`for generating the hot air. An air blow opening is disposed
`to face the coating layer. A Supply fan or blower is controlled
`by the controller, for sending the hot air from the hot air
`
`generator through the air blow opening. The exhaust unit
`includes an exhaust opening disposed to face the coating
`layer. An exhaust fan or blower is controlled by the con
`troller, for sending the hot air from the exhaust opening.
`0040. The controller controls the supply fan or blower
`and the exhaust fan or blower, to keep a flow speed of the
`hot air equal to or lower than 1 m/sec with reference to a web
`width direction crosswise to the traveling direction.
`0041 As viewed in the web width direction, the air blow
`opening has 1.05-2 times as great a size as a width of the
`web.
`0042. Furthermore, a flow speed sensor detects the flow
`speed of the hot air on the coating layer. The controller
`controls the supply fan or blower and the exhaust fan or
`blower according to the flow speed.
`0043. The air blow opening includes plural air blow
`nozzles arranged in the traveling direction.
`0044) In another preferred embodiment, the air blow
`nozzles are arranged in a matrix manner.
`0045. In still another preferred embodiment, the air blow
`nozzles are slit-shaped and extend crosswise to the traveling
`direction.
`0046.
`In an additional preferred embodiment, the air
`blow nozzles are disposed in a ZigZag manner.
`0047 The hot air supply unit is disposed 3-300 mm
`distant from the coating layer.
`0048. The at least one hot air supply unit comprises plural
`hot air Supply units. The at least one exhaust unit comprises
`plural exhaust units disposed alternately with the plural hot
`air Supply units in the traveling direction.
`0049 Furthermore, a far infrared heater applies heat
`energy to the coating layer in addition to the hot air from the
`hot air Supply unit.
`0050. The coating liquid includes liquid crystalline com
`pound, and the coating layer is a liquid crystal layer of an
`optical compensatory sheet.
`0051 Consequently, web can be heated without irregu
`larity, because the exhaust unit is disposed upstream or
`downstream from the hot air Supply unit in a traveling
`direction of the web.
`0052 According to another aspect of the invention, a dust
`removing apparatus for web is provided. A first dust remover
`removes dust from the web by blowing a first surface of the
`web with compressed air. A rinsing unit is disposed down
`stream from the first dust remover with reference to the web
`being traveled, for removing dust from the web by rinsing
`the first surface with liquid. A second dust remover is
`disposed between the first dust remover and the rinsing unit,
`including a cleaning member and a pinch member for
`contacting respectively the first Surface and a second Surface
`of the web, to nip the web, wherein the cleaning member
`polishes the first surface with liquid, to remove dust from the
`web.
`0053. The cleaning member and the pinch member are a
`cleaning roller and a rotatable pinch roller. Furthermore, a
`liquid bath contains the liquid in which the cleaning roller is
`dipped at least partially.
`
`SEC et al. v. MRI
`SEC Exhibit 1025.022
`IPR 2023-00199
`
`

`

`US 2006/0177587 A1
`
`Aug. 10, 2006
`
`0054 Each of the cleaning roller and the pinch roller
`includes a roller body, and a resilient roll fitted about the
`roller body.
`0055) Furthermore, a feeder travels the web at one trav
`eling speed. A motor rotates the cleaning roller at one
`peripheral speed different from the traveling speed.
`0056. The first dust remover includes at least one air blow
`opening for blowing the first Surface with the compressed air
`to separate the dust from the web. At least one exhaust
`opening for Sucking the compressed air to eject the dust.
`0057 The at least one air blow opening and the at least
`one exhaust opening are slit-shaped and extend in a web
`width direction crosswise to a traveling direction of the web.
`0.058. The first dust remover includes an ultrasonic vibra
`tor for ultrasonically vibrating the compressed air to be
`Supplied from the air blow opening.
`0059. The second dust remover further includes an ultra
`Sonic vibrator, disposed in the liquid bath, for applying
`ultrasonic waves to the cleaning roller dipped in the liquid,
`to remove dust from the cleaning roller.
`0060) Furthermore, a drier is disposed downstream from
`the rinsing unit, for blowing the web with air to dry the
`liquid.
`0061 The drier includes at least one air blow opening for
`blowing the first surface with the air to separate the liquid
`from the web. At least one exhaust opening for sucking the
`air to eject the liquid.
`0062) The at least one air blow opening and the at least
`one exhaust opening are slit-shaped and extend in a web
`width direction crosswise to a traveling direction of the web.
`0063. The drier includes an ultrasonic oscillator for ultra
`sonically vibrating the air to be supplied from the air blow
`opening.
`0064. Furthermore, at least one pair of rotatable edge
`rollers Support first and second edges of the first or second
`Surface, to guide the web in a non-contact state from a
`central portion of the web.
`0065. In another preferred embodiment, furthermore, a
`hovering roller is opposed to the first or second Surface, for
`guiding the web. Plural holes or slits are formed in a
`peripheral wall of the hovering roll. A fan or blower blows
`the web through the plural holes or slits with compressed air,
`to keep the web in a non-contact state from the web.
`0.066 Consequently, it is possible to remove dust from
`sheet material without Scratching or damaging its surface,
`because the cleaning member and pinch member nip the
`web, and the cleaning member polishes the first surface with
`liquid.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`0067. The above objects and advantages of the present
`invention will become more apparent from the following
`detailed description when read in connection with the
`accompanying drawings, in which:
`0068 Fig. 1A is an explanatory view in elevation, illus
`trating an optical compensatory sheet producing apparatus
`of the invention;
`
`0069 FIG. 1B is an explanatory view in section, illus
`trating an optical compensatory sheet;
`0070 FIG. 2 is an explanatory view in elevation, illus
`trating another optical compensatory sheet producing appa
`ratus supplied with a roll of support material web with a
`resin layer;
`0071
`FIG. 3A is a plan illustrating a rubbing unit in the
`optical compensatory sheet producing apparatus;
`0072 FIG. 3B is a side elevation illustrating the same as
`FIG. 3A:
`0073 FIG. 4 is an explanatory view illustrating a dust
`remover units:
`0074 FIG. 5 is an explanatory view in elevation, illus
`trating another preferred optical compensatory sheet pro
`ducing apparatus having an additional dust remover;
`0075 FIG. 6 is an explanatory view in elevation, illus
`trating the dust remover in the apparatus of FIG. 5:
`FIG. 7 illustrates a structure of anionic polymer;
`0076)
`0.077
`FIG. 8 illustrates a structure of alkyl modified
`polyvinyl alcohol:
`0078 FIG. 9 illustrates a structure of a discotic liquid
`crystal compound;
`0079 FIG. 10 is an explanatory view in section, illus
`trating a thermal treating apparatus of the invention;
`0080 FIG. 11 is an explanatory view in plan, illustrating
`a hot air Supply unit together with resin film;
`0081
`FIG. 12 is an explanatory view in plan, illustrating
`one preferred hot air Supply unit having nozzles arranged in
`a ZigZag.
`0082 FIG. 13 is an explanatory view in plan, illustrating
`another preferred hot air Supply unit having hole-shaped
`nozzles;
`0083 FIG. 14 is an explanatory view in elevation, illus
`trating an overall arrangement of a sheet producing system
`having the thermal treating apparatus;
`0084 FIG. 15A is an explanatory view illustrating a dust
`removing apparatus of the invention;
`0085 FIG. 15B is a cross section illustrating a hovering
`roller in the dust removing apparatus together with a fan;
`0086 FIG. 15C is a cross section illustrating a first dust
`remover unit of a dry type;
`0087 FIG. 15D is a plan illustrating a pair of edge rollers
`in combination;
`0088 FIG. 16 is a block diagram illustrating an overall
`arrangement of a sheet producing system having the dust
`removing apparatus;
`0089 FIG. 17A is a table illustrating results of experi
`ments according to comparative examples;
`0090 FIG. 17B is a table illustrating results of experi
`ments according to samples of the invention; and
`0091
`FIG. 18 is an explanatory view illustrating a ther
`mal treating apparatus according to the prior art.
`
`SEC et al. v. MRI
`SEC Exhibit 1025.023
`IPR 2023-00199
`
`

`

`US 2006/0177587 A1
`
`Aug. 10, 2006
`
`DETAILED DESCRIPTION OF THE
`PREFERRED
`
`EMBODIMENT(S) OF THE PRESENT
`INVENTION
`0092. A method of manufacturing an optical compensa
`tory sheet of the invention is characterized in dust removal
`in a wet type after a rubbing process of an orientation layer
`laminated on a transparent resin film.
`0093. The manufacturing method includes plural steps as
`follows:
`1. Step of Supplying transparent resin film;
`0094)
`2. Step of forming a preliminary resin layer by
`0.095
`coating a surface of the resin film with Solution having resin
`to form an orientation layer, and by drying:
`0.096
`3. Step of rubbing for forming the orientation layer
`on the resin film according to a rubbing treatment of the
`surface of the preliminary resin layer on the resin film;
`0097. 4. Step of dust removal, either by eliminating dust
`from the Surface of the orientation layer according to a wet
`type, or by eliminating dust from the Surface of the orien
`tation layer according to a dry type and then a wet type;
`0.098
`5. Step of coating the orientation layer with a
`coating layer including a liquid crystalline compound;
`0099 6. Step of drying the coating layer to evaporate
`Solvent i