Laminate Sheet Raised Portions Prevent Roll Defects
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Solution Overview
Problem
Conventional laminate sheets face issues with defects and surface smoothness when wound into rolls due to roll pressure and foreign matter, leading to errors in data reading/writing for optical disks and image quality issues for displays.
Innovation Solution
A laminate sheet design featuring a long release sheet with an adhesive layer and a base material, where raised portions are formed by half-cutting on the auxiliary sheet or base material to create gaps between the adhesive and release sheets, preventing roll pressure-induced defects and maintaining surface smoothness without the need for additional protective materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the laminate sheet is wound into a roll with normal roll pressure, then the roll structure is stable and compact, but arc-shaped marks and defects are formed on the adhesive sheet due to roll pressure
Solution Approach 1:
A protective material is provided on the adhesive sheet before winding into a roll. This protective material acts as a buffer to prevent direct contact and pressure between adjacent adhesive sheets during rolling, thereby preventing arc-shaped marks and defects while maintaining roll stability
Solution Approach 2:
The protective material serves as an intermediary layer between the adhesive sheet and other layers during the winding process. It absorbs and distributes the roll pressure, preventing the formation of defects on the adhesive sheet surface while allowing the roll to maintain its structural integrity
2Manufacturing precision
If the roll pressure is reduced to prevent arc-shaped marks, then the adhesive sheet surface quality is maintained, but the roll structure becomes unstable and prone to collapsing
Solution Approach 1:
The protective material is pre-applied to the adhesive sheet before winding, creating a cushioning layer that allows the use of normal roll pressure without damaging the adhesive sheet surface, thus maintaining both surface quality and roll stability
Solution Approach 2:
The introduction of protective material changes the pressure distribution parameters during rolling. The protective material has different mechanical properties (softer, more compressible) than the adhesive sheet, allowing it to absorb pressure and prevent mark formation while maintaining roll integrity
3Manufacturing precision
If additional protective materials are added to prevent defects, then the adhesive sheet surface quality is maintained, but the manufacturing complexity and cost increase
Solution Approach 1:
The protective material is integrated with the adhesive sheet to form a combined laminate structure. This merging of functions (protective + adhesive) into a single integrated component prevents defects without requiring separate protective devices or complex multi-layer structures
Data Source
AI summary
A laminate is produced in which a long release sheet 2A, an adhesive layer 3A and a base material 4A are laminated together, and the base material 4A and the adhesive layer 3A are cut (half cut) so as not to penetrate through the release sheet 2A, so as to divide the base material 4A and the adhesive layer 3A into cover sheet portions 51A, bolstering portions 52A and a remainder portion 53A. The remainder portion 53A is then peeled off and removed, and an outer end portion of each of the bolstering portions 52A is half cut so as not to penetrate through the release sheet 2A, raised portions 6A being formed through the half cutting. The laminate sheet can be produced at low cost, and defects can be prevented from being formed on the adhesive sheet when the laminate sheet is wound into a roll.