Lamination Sheet With Offset Tabs For Display Panel Production
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Solution Overview
Problem
Existing cutting methods for manufacturing display panels are inefficient as they require individual attachment of multiple lamination sheets to a substrate, slowing down the production process.
Innovation Solution
A lamination sheet design featuring a base film, a laminated material layer, and a cover film with removing tabs allows for the simultaneous attachment of multiple laminated material unit sheets to a substrate, enabling a simplified and efficient manufacturing process through punching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple lamination sheets are attached individually to a substrate using existing cutting methods, then each sheet can be precisely positioned, but the production speed becomes slow
Solution Approach 1:
The patent merges multiple lamination sheets into a single integrated lamination sheet structure with multiple laminated material unit sheets arranged in parallel. This allows all sheets to be attached to the substrate simultaneously in one operation, transforming the sequential attachment process into a parallel process, thereby significantly improving production speed without increasing process complexity
Solution Approach 2:
The lamination sheet is segmented into multiple laminated material unit sheets (first, second, and third sheets) that are spatially separated and arranged in parallel. Each unit sheet can be independently positioned and attached to different regions of the substrate, enabling simultaneous attachment operations while maintaining precise positioning control for each individual sheet
2Ease of operation
If a lamination sheet is designed with removing tabs extending beyond the laminated material layer, then the base film and cover film can be easily removed, but the tabs may overlap and complicate the cutting process
Solution Approach 1:
The removing tabs are designed with asymmetric positioning where the base film removing tab and cover film removing tab are offset from each other in the longitudinal direction. Specifically, the base film removing tab is positioned closer to the first laminated material unit sheet while the cover film removing tab is positioned closer to the second laminated material unit sheet. This asymmetric arrangement prevents tab overlap and simplifies the cutting process while maintaining easy film removal capability
Solution Approach 2:
The removing tabs are positioned in different longitudinal locations rather than at the same position, utilizing the longitudinal dimension to separate their functions. This spatial separation in the longitudinal direction allows both tabs to extend beyond their respective laminated material layers for easy removal while avoiding mutual overlap that would complicate the cutting process
Data Source
AI summary
A lamination sheet includes a base film; a laminated material layer applied on the base film; and a cover film disposed on the laminated material layer, wherein the laminated material layer is interposed between the base film and the cover film and one edge of the base film comprising a base film removing tab extending beyond one edge of the laminated material layer and the base film removing tab not overlapping the laminated material layer; one edge of the cover film comprising a cover film removing tab extending beyond one edge of the laminated material layer and the cover film removing tab not overlapping the laminated material layer; and at least a part of the base film removing tab is formed not to overlap the cover film removing tab. A method for manufacturing a lamination sheet is also provided.