Continuous Optical Display Peeling Control for Film Uniformity
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Solution Overview
Problem
Existing methods for continuously manufacturing optical display devices often result in non-uniform peeling of polarization films, leading to defects like stripe patterns and incomplete separation of adjacent film pieces, which can cause attachment issues during lamination.
Innovation Solution
A system and method that control the peeling, feeding, and laminating units to position the peeling point at a target location, ensuring complete separation of film pieces and preventing attachment errors by managing speeds and positions of the release film, polarization film, and panel during the lamination process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the release film is wound by generating vibration through friction force at the front end of the peeling unit, then the sheet piece of the polarization film can be peeled from the release film, but the sheet piece becomes non-uniform and stripe defects are formed
Solution Approach 1:
The patent extracts the harmful vibration generation mechanism (friction-based winding at the front end) and replaces it with a controlled winding system positioned at the rear end. The release film is wound by a winding roller after the peeling process, separating the winding function from the peeling zone to eliminate vibration-induced non-uniformity while maintaining continuous production capability.
2Productivity
If the feeding speed and laminating speed are equally controlled, then the lamination process can proceed continuously, but adjacent sheet pieces remain connected by the adhesive layer and cannot be completely separated
Solution Approach 1:
The patent introduces dynamic speed control where the feeding speed and laminating speed are differentially adjusted. The feeding unit supplies the polarization film at a speed different from the laminating speed, creating a speed differential that enables complete separation of adjacent sheet pieces while maintaining continuous production. This dynamic speed adjustment prevents the adhesive layer from bonding adjacent pieces together.
3Device complexity
If the sheet piece of the polarization film is peeled at the front end of the peeling unit, then the peeling process can be simplified, but the sheet piece becomes non-uniform leading to stripe defects
Solution Approach 1:
The patent relocates the winding operation from the front end (peeling dimension) to the rear end (transport dimension) of the peeling unit. By positioning the winding roller at the rear end, the system maintains peeling simplicity at the front while adding controlled winding at the back, effectively using spatial reconfiguration to eliminate vibration and improve sheet uniformity without significantly increasing process complexity.
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 stabilizes the peeling process, reduces defects such as stripe patterns, and ensures complete separation of film pieces, improving the uniformity and quality of the optical display device manufacturing.
Implementation Method 1
a release film which is extended in a longitudinal direction, and a plurality of sheet pieces of a polarization film which are arranged in a longitudinal direction and includes adhesive layers. The sheet pieces of a polarization film are adhered to the release film through the adhesive layer
Implementation Method 2
a peeling unit, which peels the sheet pieces of the polarization film from the release film by folding back inwardly the release film of the optical films fed by the feeding unit
Implementation Method 3
a laminating unit, which laminates on the panel the sheet piece of the polarization film peeled from the release film, while transferring the panel
Data Source
AI summary
A system for continuously manufacturing an optical display device and methods thereof are described. The system and method include a feeding unit for feeding an optical film, which includes a release film and a plurality of sheet pieces of a polarized film. The system and method further include a peeling unit for peeling the sheet pieces of the polarized film; a winding unit for winding the release film form the sheet pieces of the polarized film; and a controlling unit. The controlling unit controls at least one of the feeding unit, the winding unit, and the laminating unit.