Optical Film Continuous Bonding with Pre-Marked Defect Separation
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Solution Overview
Problem
Conventional methods for manufacturing optical display devices face challenges such as increased costs and reduced production speed due to batch processing, defect detection interruptions, and inefficient use of optical films, particularly in large-screen television production.
Innovation Solution
A method involving unwinding and feeding a long sheet material with a polarizing plate, pressure-sensitive adhesive layer, and release film, where the material is slit to match the optical display unit's dimensions, allowing for continuous production and defect separation without interrupting the cutting process, and utilizing the release film as a carrier for continuous bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If defect inspection is performed using a sensor-based cutting mechanism, then defects can be detected and removed, but when multiple defects exist in close regions, the cutting process is repeatedly interrupted, reducing bonding speed
Solution Approach 1:
The patent performs preliminary defect inspection and marks defect positions on the optical film before the bonding process. By pre-identifying and marking all defects in advance, the system avoids repeated sensor-based interruptions during bonding. The marked defect positions are then used to guide selective cutting after bonding, allowing continuous high-speed bonding while still achieving defect removal.
2Ease of manufacture
If optical films are stored in stacked form with end faces, then storage is simplified, but adhesive overflow occurs at end faces and contamination with dirt is caused
Solution Approach 1:
The patent introduces a release film as an intermediary layer between stacked optical films. The release film prevents direct contact between the end faces of optical films, thereby preventing adhesive overflow and contamination while maintaining the simplicity of stacked storage. The release film acts as a protective barrier that can be easily removed when needed.
3Ease of manufacture
If pre-cut optical films are used for bonding, then bonding can be performed, but multi-process steps and storage management increase manufacturing costs
Solution Approach 1:
The patent performs preliminary defect inspection and marking on long optical films before bonding, but delays the actual cutting until after bonding. This preliminary marking without immediate cutting eliminates the need for separate pre-cutting processes and storage management, while still enabling precise defect removal. The optical films are cut only at marked defect positions after bonding, simplifying the overall process.
Solution Approach 2:
The patent enables continuous bonding by using long optical films without pre-cutting. The bonding process proceeds continuously along the length of the optical film, with defect removal performed subsequently at marked positions. This eliminates interruptions for pre-cutting and storage/management operations, maintaining continuous productive action throughout the manufacturing process.
Data Source
AI summary
The invention provides a method for manufacturing an optical display device including an optical display unit and an optical film that includes a polarizing plate and is bonded to the optical display unit. The method comprises the steps of: unwinding and feeding a long sheet material from a roll of the long sheet material, wherein the long sheet material includes the optical film, a pressure-sensitive adhesive layer and a release film laminated in this order and has undergone a slitting process in a direction parallel or at a constant angle to an absorption axis of the polarizing plate so that it has a width corresponding to a short or long side of the optical display unit; inspecting the optical film of the fed long sheet material to detect a defect; cutting a part of the long sheet material other than the release film into a length corresponding to a long or short side of the optical display unit, while separating the detected defect; bonding a non-defective cut piece of the optical film to a surface of the optical display unit; and rejecting a defect-containing part of the optical film.