Continuous Display Polarizer Defect Segmentation
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Solution Overview
Problem
The challenge in manufacturing display units lies in efficiently identifying and excluding defective areas in polarizing films to improve yield and prevent defective products, as existing methods struggle to completely remove defects from optical film laminated structures, resulting in significant defects per unit length of polarizing film.
Innovation Solution
A method and apparatus that continuously manufacture display units by detecting defects in n unit examination areas, forming slit lines to separate normal and defective sheet pieces, and preventing defective pieces from being bonded to the panel, using a defect detection system and slit line forming mechanism to identify and exclude defective areas based on light intensity differences and predetermined reference conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If continuous manufacturing is used to improve productivity, then manufacturing speed increases, but defect detection and exclusion becomes more difficult
Solution Approach 1:
The optical film is divided into multiple unit examination areas (n areas) along the carrying direction. Each area is independently evaluated for defects, and slit lines are selectively formed only in areas containing defects. This segmentation allows continuous manufacturing to proceed while systematically identifying and excluding defective portions without stopping the production line.
Solution Approach 2:
Defect detection is performed in advance on multiple unit examination areas before the film reaches the cutting position. Based on the detection results, the control unit determines which areas contain defects and pre-calculates the positions where slit lines should be formed. This preliminary action ensures that defective areas are excluded before bonding occurs, maintaining continuous production flow.
2Reliability
If all areas are examined for defects to improve product quality, then yield increases, but processing time increases
Solution Approach 1:
The examination process is divided into n unit examination areas along the carrying direction. Instead of examining the entire film length as one unit, each area is independently assessed. Slit lines are formed only in specific areas where defects are detected, rather than processing the entire film. This selective approach maintains high product quality while reducing unnecessary processing time in defect-free areas.
Solution Approach 2:
The film is treated differently based on local defect conditions. Areas without defects are processed continuously without interruption, while only specific areas containing defects receive slit line treatment. This local quality approach ensures that product quality is maintained in defective areas while preserving manufacturing efficiency in defect-free areas.
3Reliability
If slit lines are formed to exclude defective areas, then defective products are reduced, but manufacturing complexity increases
Solution Approach 1:
The system replaces complex manual inspection and decision-making with an automated defect detection device and control unit. The detection device automatically identifies defects in each unit examination area, and the control unit automatically determines slit line positions and controls their formation. This substitution of mechanical/manual processes with automated systems reduces manufacturing complexity while effectively excluding defective areas.
Solution Approach 2:
The defect detection device provides real-time feedback on the presence and location of defects in each unit examination area. The control unit uses this feedback information to dynamically determine where slit lines should be formed. This feedback mechanism ensures that defective areas are accurately identified and excluded, reducing defective products while maintaining a relatively simple manufacturing process through automated control.
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 enhances the yield and manufacturing speed of display units by accurately identifying and excluding defective areas, thereby improving productivity and reducing defective products.
Implementation Method 1
detecting a defect of the optical film before the optical film is carried to a cutting position
Implementation Method 2
detecting a defect of the optical film before the optical film is carried to a cutting position
Data Source
AI summary
A method of continuously manufacturing a display unit according to an exemplary embodiment of the present invention, which bonds sheet pieces of a polarizing film formed by cutting a roll-type optical film into sheet pieces having a predetermined sheet pieces to a panel to manufacture the display unit, continuously carries an optical film, detects a defect of the optical film, extracts a defective area based on information on the detected defect, forms a slit line in a horizontal direction with respect to a carrying direction of the optical film based on the defective area, determines whether the sheet piece of the polarizing film divided by the slit line is a defective sheet piece or a normal sheet piece, peels the sheet piece determined as a normal sheet piece from a release film, and bonds the normal sheet piece and a panel.