Carrier Film Light Blocking Layer UV Resin Curing
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Solution Overview
Problem
The manufacturing process for window glass for large-sized display devices is complex and costly due to the need for a UV molding process, which requires multiple mask uses, leading to increased mask wear and production expenses, and can result in surface defects from overflowing UV resin.
Innovation Solution
A method involving a carrier film with a light blocking layer that functions as a UV mold, allowing for the omission of the UV molding process, where the carrier film is attached to a window base and UV resin is applied and cured, with the light blocking layer's area designed to be smaller than the window base, preventing resin overflow and maintaining surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a UV molding process with multiple masks is used, then the window glass can be manufactured with proper shape, but the manufacturing cost increases and mask wear increases
Solution Approach 1:
The patent merges the UV mold function with the carrier film by forming a light blocking layer directly on the carrier film. This integration eliminates the need for separate UV masks, reducing the number of components and simplifying the manufacturing process while maintaining the ability to form the window glass with the proper shape.
Solution Approach 2:
The carrier film is given multiple functions: it serves as both the support substrate for the window glass and as the UV mold through the integrated light blocking layer. This multi-functionality eliminates the need for separate masking components, reducing manufacturing complexity and cost.
2Manufacturing precision
If a UV molding process with multiple masks is used, then the window glass can be manufactured with proper shape, but the device complexity increases
Solution Approach 1:
The UV mold function is merged into the carrier film structure itself through the light blocking layer. This eliminates the need for separate masking devices and complex mask alignment procedures, significantly simplifying the overall device complexity while maintaining manufacturing precision.
Solution Approach 2:
The patent extracts the UV mold function from the separate masking system and integrates it directly into the carrier film. This extraction and integration eliminates unnecessary intermediate components and process steps, reducing device complexity.
3Productivity
If UV resin is pre-cured during primary UV irradiation, then the resin sets faster, but the resin may flow over the window base area causing defects
Solution Approach 1:
The light blocking layer is designed with a specific area that is smaller than the window base area, creating a local quality difference. This allows UV resin to be pre-cured in the center region during primary UV irradiation while leaving a peripheral region uncured, preventing overflow while maintaining fast curing speed.
Solution Approach 2:
The patent performs preliminary UV irradiation to partially cure the resin before final curing. The light blocking layer is strategically designed to allow this preliminary action to occur in a controlled manner, setting the resin in the center area while maintaining fluidity in the peripheral area to prevent defects.
4Manufacturing precision
If the light blocking layer area is made smaller than the window base area, then resin overflow is prevented, but the UV resin coverage must be precisely controlled
Solution Approach 1:
The light blocking layer creates a local quality distinction between the center region (where resin is pre-cured) and the peripheral region (where resin remains uncured). This design inherently controls resin coverage by preventing pre-curing at the edges, eliminating the need for complex process controls while maintaining precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach simplifies the manufacturing process, reduces costs by eliminating the need for multiple UV molding steps, and prevents resin overflow defects, ensuring uniform coating and maintaining the original glass surface quality.
Implementation Method 1
a light blocking layer that functions as a UV mold
Implementation Method 2
primarily curing the UV resin by performing primary UV irradiation
Data Source
AI summary
A method for manufacturing a window glass according to an embodiment of the present disclosure includes: preparing a carrier film; forming an assembly by attaching the carrier film to a window base; coating a UV resin on a jig; placing the assembly on the jig so that the window base faces downwards; attaching the assembly and the UV resin on the jig to each other by using a roller; primarily curing the UV resin by performing primary UV irradiation to an upper portion of the assembly attached with the UV resin on the jig; removing an uncured portion of the UV resin; and secondarily curing a remaining portion of the UV resin from which the uncured portion of the UV resin has been removed by performing secondary UV irradiation to the remaining portion of the UV resin.