Optical Film Segmentation for Large-Area Panel Attachment
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Solution Overview
Problem
Large-area display panels face attachment issues due to the drooping of rollers when using optical films with absorption axes parallel to the longitudinal direction, leading to quality deterioration in display units.
Innovation Solution
A manufacturing method involving the formation and alignment of sheet pieces from a pre-processing optical film with a release film, adhesive layer, and surface protection film, where the sheet pieces are connected to create a post-processing optical film with an absorption axis orthogonal to the longitudinal direction, using specific connection members to ensure proper alignment and adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an optical film with absorption axis parallel to the longitudinal direction is used, then the manufacturing process is simple, but the roller droops down when the panel size increases, causing attachment failure
Solution Approach 1:
The optical film is divided into multiple sheet pieces stacked in the width direction, with each sheet having a smaller width that corresponds to the short edge of the panel. This segmentation allows the total width to match the long edge of the panel while keeping individual sheet widths small enough to prevent roller drooping during attachment, thus maintaining both manufacturing simplicity and attachment reliability.
2Area of stationary object
If the panel size increases, then the display area is larger, but the roller droops down causing attachment failure between optical film and panel
Solution Approach 1:
The optical film is segmented into multiple sheets stacked in the width direction, where each sheet's width corresponds to the panel's short edge. This allows the combined width to cover the panel's long edge while keeping individual sheet dimensions small enough to prevent roller drooping, ensuring reliable attachment even for large-area panels.
Solution Approach 2:
The invention changes the orientation relationship between the absorption axis and the longitudinal direction of the optical film. By making the absorption axis orthogonal to the longitudinal direction, the optical film can be oriented such that its width corresponds to the panel's short edge rather than the long edge, preventing roller drooping while still covering the entire panel area.
3Area of stationary object
If the roller width increases to cover larger panels, then the coverage area is larger, but the roller droops down causing attachment failure
Solution Approach 1:
Instead of using a single wide roller to cover large panels, the optical film is segmented into multiple sheets with smaller widths. Each sheet can be handled by a narrower roller that maintains its shape stability, while the stacked arrangement of multiple sheets provides the necessary coverage area for large panels.
Data Source
AI summary
Provided is a method for an optical film which elongates by forming a plurality of sheet pieces by cutting a pre-processing optical film in a width direction of the pre-processing optical film, aligning the plurality of sheet pieces in such a manner that first end portions parallel to the longitudinal direction of the pre-processing optical film are opposite to each other, and connecting end portions of the plurality of sheet pieces to each other.