Method of manufacturing image display device

Abstract

According to a method of manufacturing an image display device of the present invention, a photo-curable resin composition in a liquid state is applied to a surface of a light-transmitting cover member including a light-shielding layer or a surface of the image display member to a thickness greater than that of the light-shielding layer. Then, in this state, the photo-curable resin composition is irradiated with a UV ray to be pre-cured, thereby forming a pre-cured resin layer. Next, the image display member and the light-transmitting cover member are stacked via the pre-cured resin layer and thereafter, the pre-cured resin layer is irradiated with a UV ray to be completely cured, thereby forming a light-transmitting cured resin layer.

1 . A method of manufacturing an image display device where an image display member and a light-transmitting cover member with a light-shielding layer formed on a peripheral part thereof are stacked via a light-transmitting cured resin layer formed of a liquid photo-curable resin composition, such that a light-shielding layer forming surface of the light-transmitting cover member is arranged on the side of the image display member, the method comprising the following steps (A) to (D):
 <Step (A)>   a step of applying the liquid photo-curable resin composition to the light-shielding layer forming surface of the light-transmitting cover member or a surface of the image display member to a thickness greater than that of the light-shielding layer so as to cancel a step formed between the light-shielding layer and the light-shielding layer forming surface of the light-transmitting cover member;   <Step (B)>   a step of irradiating the applied photo-curable resin composition with a UV ray to pre-cure the photo-curable resin composition, thereby forming a pre-cured resin layer;   <Step (C)>   a step of bonding the light-transmitting cover member to the image display member such that the light-shielding layer and the pre-cured resin layer are placed inside; and   <Step (D)>   a step of irradiating the pre-cured resin layer held between the image display member and the light-transmitting cover member with a UV ray to completely cure the pre-cured resin layer to stack the image display member and the light-transmitting cover member via the light-transmitting cured resin layer, thereby obtaining the image display device.   
     
     
         2 . The manufacturing method according to  claim 1 , wherein the image display member is a liquid crystal display panel, an organic EL display panel, a plasma display panel, or a touch panel. 
     
     
         3 . The manufacturing method according to  claim 1 , wherein in the step (A) the photo-curable resin composition is applied to a thickness from 1.2 to 50 times that of the light-shielding layer. 
     
     
         4 . The manufacturing method according to  claim 1 , wherein in the step (B) the photo-curable resin composition is irradiated with a UV ray to be pre-cured to make the cure rate of the pre-cured resin layer from 10 to 80%. 
     
     
         5 . The manufacturing method according to  claim 1 , wherein in the step (D) the pre-cured resin layer is irradiated with a UV ray to be completely cured to make the cure rate of the light-transmitting cured resin layer 90% or greater. 
     
     
         6 . The manufacturing method according to  claim 1 , wherein the liquid photo-curable resin composition includes a polyurethane-based (meth)acrylate or a polyisoprene-based (meth)acrylate, and a tackifier. 
     
     
         7 . The manufacturing method according to  claim 1 , wherein in the step (B) at least part of the photo-curable resin composition existing on the light-shielding layer is irradiated with a UV ray to be pre-cured to make the cure rate of the pre-cured resin layer on the light-shielding layer from 30 to 80%. 
     
     
         8 . The manufacturing method according to  claim 7 , wherein in the step (B) the cure rate of the pre-cured resin layer on the surface of the light-transmitting cover member is from 0 to 80%. 
     
     
         9 . The manufacturing method according to  claim 7 , wherein in the step (B) the cure rate of the pre-cured resin layer on the light-shielding layer is higher than that of the pre-cured resin layer on the surface of the light-transmitting cover member. 
     
     
         10 . The manufacturing method according to  claim 7 , wherein a shielding plate to shield a UV ray or an attenuation plate to attenuate a UV ray is disposed between a UV source and the applied photo-curable resin composition during UV irradiation in the step (B). 
     
     
         11 . The manufacturing method according to  claim 1 , wherein the photo-curable resin composition includes an acrylate-based oligomer component, an acrylic monomer component, a plasticizer component, and a photopolymerization initiator component, and the plasticizer component includes a solid tackifier and a liquid oil component.