Optical Film Transport Roll Positioning to Prevent Slit Line Deformation
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Solution Overview
Problem
In the manufacturing of display units, the optical film is prone to deformation due to concentrated tension when the slit line comes into contact with transport rollers, leading to issues like separation of the polarizing film from the release film, attachment of foreign substances to the adhesive layer, and tearing or splitting of the release film.
Innovation Solution
A system that includes a transport unit, cutting unit, separating unit, and attaching unit, where the transport unit has a horizontal or transport direction changing roll positioned to avoid the slit line during transport stops, ensuring the slit line is not supported by these rolls, and the cutting unit cuts the optical film without cutting the release film, allowing for controlled slit line formation and minimizing deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the optical film is repeatedly transported and stopped during the cutting process, then the cutting process can be performed to form slit lines, but the slit line comes into contact with and is supported by transport rollers, causing tension concentration and deformation of the optical film
Solution Approach 1:
A support roller is introduced as an intermediary component to specifically support the optical film at the slit line position during transport stops. This support roller acts as a mediator between the transport system and the optical film, preventing the film from contacting and being supported by the main transport rollers, thereby eliminating tension concentration and deformation while enabling the cutting process to proceed.
2Device complexity
If the slit line is supported by transport rollers during transport stops, then the transport process can be simplified, but tension is concentratedly applied to the slit line causing separation of polarizing film from release film and attachment of foreign substances
Solution Approach 1:
The support roller serves as a specialized intermediary that provides localized support at the slit line position without requiring complex modifications to the overall transport process. This simple yet effective intermediary prevents harmful contact between the optical film and transport rollers, maintaining film integrity including preventing polarizing film separation and foreign substance attachment.
Solution Approach 2:
The support roller is positioned in advance at the location where the slit line will be formed, so that when the cutting process creates the slit line and transport stops, the support is already in place to prevent tension concentration. This preliminary positioning ensures that the protective support is ready before the problematic contact can occur.
3Productivity
If transport rollers support the optical film during stops, then continuous transport can be maintained, but the release film is torn or split due to concentrated tension on the slit line
Solution Approach 1:
The support roller acts as a dedicated intermediary that provides support precisely where needed (at the slit line position) without disrupting the continuous transport flow. This localized support prevents tension concentration that would otherwise cause release film tearing or splitting, maintaining both productivity and release film integrity throughout the manufacturing process.
Data Source
AI summary
A system for manufacturing a display unit including: a transport unit which transports an optical film comprising a polarizing film, an adhesive layer, and a release film, by a predetermined transport length and stops the transport of the optical film; a cutting unit which cuts the optical film in a width direction at a predetermined cutting position without cutting the release film; a separating unit which separates the release film from the polarizing film at the cutting position; and an attaching unit which attaches the polarizing film, from which the release film is separated, to a panel. The transport unit includes a horizontal roll satisfying the following conditional expression:I*n<H<I*(n+1)in which I is the predetermined transport length, n is an integer equal to or greater than 0, and H is a horizontal distance between a rotation center of the horizontal roll and the cutting position.