Optical Film Defect Detection via Light Projection
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Solution Overview
Problem
Existing methods for detecting defects in optical films during manufacturing, such as press, imprint, and folding, are limited in their ability to detect various forms of defects, particularly those caused by foreign substances, thickness changes, and external forces, leading to incomplete defect detection in display panels.
Innovation Solution
A system and method that project light through an optical film onto a screen, using a lighting unit, imaging unit, and analyzing unit to capture and analyze the projected image, allowing for the detection of defects like press, imprint, and folding by adjusting the distances and angles between the lighting unit, screen, and optical film within specific ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If light is irradiated directly onto the optical film surface, then foreign substance defects can be detected, but other defects such as press, imprint, and folding cannot be effectively detected
Solution Approach 1:
The patent introduces a screen positioned at a specific distance behind the optical film to project the transmitted light pattern. This adds a spatial dimension to the detection system, allowing defects that alter light transmission paths (press, imprint, folding) to be visualized as projected patterns on the screen, thereby expanding detection capability beyond surface-level foreign substance detection
Solution Approach 2:
The screen acts as an intermediary element between the optical film and the detection system. It captures and projects the light transmission pattern, making invisible or subtle defects (such as internal stress patterns from press or imprint) visible as projected images, thus enabling comprehensive defect detection without direct contact with the film
2Area of stationary object
If the screen is positioned close to the optical film, then the projected image is compact, but the detection resolution and defect visibility are reduced
Solution Approach 1:
The patent optimizes the distance parameter between the screen and optical film within a specific range (90-130mm) to achieve the desired balance. By adjusting this spatial parameter, the system projects defects to an appropriate size on the screen that maintains both compactness and sufficient resolution for accurate detection, demonstrating parameter optimization to resolve the contradiction
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 detection of various defects in optical films, improving the detection rate by projecting light onto a screen and analyzing the resulting image, which enhances the identification of defects such as pressed, stamped, and folded defects, leading to improved quality control in display panels.
Implementation Method 1
a lighting unit, which is spaced apart from the optical film, and irradiates light toward one surface (e.g., a front surface or a rear surface) of the optical film; a screen, which is spaced apart from the other surface (e.g, a rear surface or a front surface) of the optical film, and on which a defect existing in the optical film is projected and displayed according to the pass of the light irradiated from the lighting unit through the optical film
Data Source
AI summary
The present disclosure relates to a system and a method of detecting a defect of an optical film, and more particularly, to a system and a method of detecting a defect of an optical film, which obtain an image of a defect of an optical film projected onto a screen and detect the defect of the optical film.As an exemplary embodiment of the present disclosure, a system for detecting a defect of an optical film may be provided. The system for detecting a defect of an optical film may include: a lighting unit, which is spaced apart from the optical film, and irradiates light toward one surface of the optical film; a screen, which is spaced apart from the other surface of the optical film, and on which a defect existing in the optical film is projected and displayed according to the pass of the light irradiated from the lighting unit through the optical film; an imaging unit, which is spaced apart from the screen, and obtains an image of the defect of the optical film projected onto the screen; and an analyzing unit, which analyzes the obtained image, and detects the defect of the optical film based on a result of the analysis.