Liquid Crystal Display Polarizer Carrier Film Cutting Method
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Solution Overview
Problem
The continuous bonding process for liquid crystal display elements faces issues such as low productivity, position shift of polarizing plates due to curling, and mechanical strength reduction of the carrier film, leading to potential breakage and defects like voids and light leakage.
Innovation Solution
A method involving cutting the long sheet material to a depth that reaches the carrier film over 80% of the cut width, with the carrier film cut to less than half its thickness at both end portions, and peeling it off at an acute angle to prevent breakage and ensure continuous bonding without degradation in appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the pressure-sensitive adhesive layer is completely cut to prevent deformation, then the appearance quality is improved, but the carrier film may be broken by tensile force during feeding or peeling
Solution Approach 1:
The patent applies different cutting depths to different regions of the carrier film. The central portion is cut to a depth that reaches the carrier film to prevent adhesive deformation, while the end portions are cut to a depth of less than half the carrier film thickness to maintain mechanical strength and prevent breakage during feeding and peeling processes.
2Manufacturing precision
If the carrier film is deeply cut to ensure complete separation of adhesive layer, then the bonding quality is improved, but the risk of carrier film breakage increases during peeling
Solution Approach 1:
The patent implements region-specific cutting depths where the central portion of the carrier film is cut deeply to reach the carrier film for complete adhesive separation, while the end portions are cut shallowly to less than half the carrier film thickness, maintaining sufficient mechanical strength to prevent breakage during the peeling process.
3Manufacturing precision
If the cutting depth is increased to reach the carrier film, then the pressure-sensitive adhesive layer is completely cut preventing deformation, but the carrier film strength is reduced leading to potential breakage
Solution Approach 1:
The patent applies a differentiated cutting strategy where the central portion of the carrier film is cut to a depth reaching the carrier film to ensure complete separation of the pressure-sensitive adhesive layer, while the end portions are cut to a depth of less than half the carrier film thickness, preserving the mechanical strength needed to prevent breakage during handling and peeling.
Data Source
AI summary
A method for manufacturing a liquid crystal display element, includes: providing a long sheet material including a laminate of an optical film containing a polarizer, a pressure-sensitive adhesive layer, and a carrier film temporarily bonded to the pressure-sensitive adhesive layer; cutting the long sheet material at predetermined intervals, while maintaining the continuity of the carrier film; peeling off the carrier film by a tensile force; and continuously bonding the resulting optical film pieces to liquid crystal panels, respectively, through the pressure-sensitive adhesive layer exposed by the peeling off, while feeding the resulting optical film pieces, wherein the cutting is performed to such a depth as to substantially reach the carrier film, and the carrier film is cut to a depth less than half of the thickness of the carrier film at least both end portions in the width direction of the carrier film.