Laminate Production via Depth-Type Filter Pressure Fluctuation
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Solution Overview
Problem
Existing methods for producing polarizing films struggle with air bubble removal in the application liquid, leading to external appearance defects and insufficient productivity due to the difficulty in filtering air bubbles through filled filters.
Innovation Solution
A method involving the use of a depth-type filter with a filtration accuracy of 50 μm to 100 μm and fluctuating pressure applied to the application liquid, allowing for efficient removal of air bubbles by intermittently stopping the pump to create a pressure difference of 0.10 MPa to 0.25 MPa, ensuring rapid and effective bubble removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a filter is used to remove air bubbles from the application liquid, then air bubble removal is improved, but productivity deteriorates due to the time required to fill the filter and remove bubbles
Solution Approach 1:
The filter is pre-filled with the application liquid before actual use. This preliminary action ensures that when the filter starts operating, it is already filled and ready to remove air bubbles immediately, eliminating the time loss associated with filter filling during production
Solution Approach 2:
The pump is operated intermittently with periodic stopping and restarting. This periodic operation creates pressure fluctuations that facilitate air bubble removal from the filter while maintaining productivity. The cycle of running and stopping the pump allows bubbles to be expelled without completely halting production
2Object-affected harmful factors
If the filter is filled with application liquid to remove air bubbles, then air bubble removal capability is improved, but the time required increases significantly
Solution Approach 1:
The filter is pre-filled with application liquid during setup or maintenance periods, not during production. This transfers the time-consuming filling operation to a preliminary stage, allowing rapid air bubble removal during actual production without time loss
Solution Approach 2:
By pre-filling the filter, the useful action of air bubble removal can continue without interruption during production. The filter remains filled and operational, maintaining continuous production flow while removing bubbles
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 results in a laminate with significantly reduced air bubble defects (1 defect/m2 or less) and improved productivity, enabling the production of high-quality, thin polarizing films with excellent optical characteristics.
Implementation Method 1
passing the application liquid before the application through a depth-type filter having a filtration accuracy of from 50 μm to 100 μm
Implementation Method 2
fluctuating a pressure applied to the application liquid supplied to the depth-type filter to remove air bubbles in the filter
Data Source
AI summary
A method of producing a laminate according to an embodiment of the present invention includes applying an application liquid containing a polyvinyl alcohol-based resin to one side of a resin substrate, followed by drying of the application liquid to form a polyvinyl alcohol-based resin layer. The method includes: passing the application liquid before the application through a depth-type filter having a filtration accuracy of from 50 μm to 100 μm; and fluctuating a pressure applied to the application liquid supplied to the depth-type filter to remove air bubbles in the filter.