Optical Film Lamination for Display Units

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Solution Overview

Problem

Current display unit manufacturing methods face challenges in efficiently attaching optical films to polarizing plates, leading to light loss, increased manufacturing time, and higher costs due to complex processes and material wastage.

Innovation Solution

A display unit manufacturing method involving a panel with a light source side polarizing plate and a screen unit side polarizing plate, where the optical film is attached directly onto the light source side polarizing plate from a roll, with the optical film forming unit including a supply roll, cutting means, and attaching means to simplify the process and reduce material loss.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If optical film is attached using conventional methods, then the attachment process is complex and time-consuming, but the manufacturing efficiency is low and material loss is high

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidmanufacturing time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent segments the optical film attachment process into distinct functional units: a supply roll for feeding the optical film, a pressing unit for attachment, and a cutting unit for trimming. This segmentation allows each unit to operate independently and efficiently, improving overall manufacturing productivity while reducing process complexity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The optical film is pre-wound on a supply roll before the attachment process begins. This preliminary preparation allows the film to be continuously fed onto the polarizing plate without interruption, eliminating the need for manual film handling and significantly reducing manufacturing time

Inventive Principle:

Principle #10Preliminary action

2Illumination intensity

If conventional optical film attachment methods are used, then the process is simple, but light loss occurs and brightness is reduced

Engineering Contradiction:

ImprovebrightnessVSAvoidlight loss

Core Design Contradiction:

Illumination intensityVSLoss of energy

Solution Approach 1:

The patent replaces manual or conventional mechanical attachment methods with a controlled pressing mechanism that applies uniform pressure through a pressing unit. This mechanical substitution ensures proper adhesion without causing film deformation or air pockets that would scatter light and reduce brightness

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent controls the attachment process by adjusting parameters such as pressing pressure, pressing duration, and film tension. By optimizing these parameters, the film is attached smoothly without creating defects that would cause light loss, thereby maintaining high brightness

Inventive Principle:

Principle #35Parameter changes

3Loss of substance

If optical film is attached from a roll, then material usage is efficient, but the attachment process becomes more complex

Engineering Contradiction:

Improveraw material lossVSAvoidprocess complexity

Core Design Contradiction:

Loss of substanceVSDevice complexity

Solution Approach 1:

The patent designs the attachment device with multi-functional units that can handle the optical film from supply to attachment to cutting in a single integrated system. The supply roll, pressing unit, and cutting unit work together as a universal attachment system, reducing material waste while maintaining manageable complexity through functional integration

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent introduces an intermediary pressing unit that mediates between the supply roll and the polarizing plate. This intermediary component controls the film feeding process, ensures proper positioning, and facilitates smooth attachment, thereby reducing material loss without significantly increasing overall process complexity

Inventive Principle:

Principle #24Intermediary (Mediator)

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 method allows for easy attachment of thin optical films, reduces light loss, simplifies the manufacturing process, and decreases raw material usage, thereby improving brightness and lowering manufacturing costs.

Implementation Method 1

attaching an optical film onto the light source side polarizing plate by supplying the optical film onto the light source side polarizing plate from a roll around which the optical film is wound

Methodology Applied

Scientific EffectRoll feeding:

Implementation Method 2

a cutting means which cuts the optical film

Methodology Applied

Scientific EffectMechanical cutting:

Implementation Method 3

an optical film attaching means which presses and attaches the optical film onto the light source side polarizing plate

Methodology Applied

Scientific EffectPressing attachment:

Data Source

PatentUS10324331B2Method of manufacturing display unit and system for laminating optical film

Publication Date: 2019.06.18 SHANJIN OPTOELECTRONICS (NANJING) CO

AI summary

The present specification relates to a display unit manufacturing method and an optical film laminating system.