Lamination Optical Function Element Sheet Forming
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Solution Overview
Problem
Existing methods for forming optical function element sheets on multiple surfaces of base films cannot simultaneously form lamination optical function elements on three or more surfaces and fail to correct longitudinal misalignment caused by temperature changes during the formation process, leading to eccentricity issues in the final product.
Innovation Solution
A method and apparatus for continuously forming lamination optical function element sheets by simultaneously forming optical function elements on both surfaces of multiple base films using roll dies with position detection marks for alignment, and using ultraviolet or heat curable resins that are semi-cured during lamination and fully cured later to ensure precise bonding and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If optical function elements are formed on multiple surfaces of base films simultaneously, then productivity is improved, but manufacturing precision deteriorates due to longitudinal misalignment caused by temperature changes
Solution Approach 1:
Position detection marks are formed on the base films before the actual optical function elements are formed. These marks serve as reference points that are detected by sensors to calculate and correct longitudinal misalignment before the optical elements are fully formed, preventing alignment errors from propagating through the manufacturing process
Solution Approach 2:
Sensors detect the positions of the pre-formed position detection marks on the base films, and this detection information is fed back to the control system. The control system uses this feedback to calculate longitudinal misalignment and adjust the forming process in real-time, maintaining manufacturing precision while enabling simultaneous multi-surface formation
2Strength
If lamination is performed with fully cured resin, then bonding strength is improved, but manufacturing precision deteriorates due to inability to correct misalignment
Solution Approach 1:
Position detection marks are formed on the base films before lamination, enabling pre-detection and calculation of longitudinal misalignment. This preliminary detection allows the system to determine the degree of misalignment before the lamination process begins
Solution Approach 2:
The resin's curing state is changed from fully cured to partially cured during the lamination process. This parameter change allows the resin to remain moldable and adjustable, enabling correction of longitudinal misalignment through the position detection marks while still achieving sufficient bonding strength for the lamination
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 enables the formation of lamination optical function elements on three or more surfaces without eccentricity, ensuring accurate alignment and reducing misalignment caused by temperature changes, thereby producing high-quality optical function element sheets.
Implementation Method 1
using ultraviolet or heat curable resins that are semi-cured during lamination and fully cured later
Implementation Method 2
using ultraviolet or heat curable resins that are semi-cured during lamination and fully cured later
Data Source
AI summary
Provided are a method and an apparatus for continuously forming a laminated optical function element sheet which has optical function elements formed on three or more faces by laminating a first optical function element sheet which has an optical function element formed on both of the front and back faces with a second optical function element sheet which has an optical function element formed on at least one of the two faces. The method comprises a first optical function element sheet forming step of molding, forming, or printing an optical function element on both of the front and back faces of a first base film, a second optical function element sheet forming step of molding, forming or printing an optical function element on at least one of the two faces of a second base film, and a laminating and bonding step of simultaneously performing the first and second optical function element sheet forming steps to laminate and bond the formed first and second optical function element sheets and form a laminated optical function element sheet.