Optical Film Manufacturing Slit Line Bubble Removal
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Solution Overview
Problem
Bubbles generated during the manufacturing of optical films, particularly when using polarization and protective films connected by an adhesive, lead to reduced optical characteristics and errors in display units.
Innovation Solution
A manufacturing method involving the formation of slit lines in the width direction of the optical film by cutting the second film without cutting the first film at the connection portion, allowing for the removal of bubbles by passing the film between conveying rolls, which helps in complete pressing and reduces defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If adhesive tape is used to connect the ends of polarization film or protective film for continuous manufacturing, then productivity is improved, but bubbles are generated in the optical film reducing manufacturing precision
Solution Approach 1:
The invention extracts and removes the harmful adhesive tape connection method from the manufacturing process. Instead of using adhesive tape to connect film ends, the patent uses a bonding film that is integrated into the lamination structure, allowing continuous manufacturing without the bubble-generating adhesive tape method.
Solution Approach 2:
The invention introduces a bonding film as an intermediary element between the polarization film and protective film. This bonding film serves as the connection medium for joining film ends, replacing the problematic adhesive tape while maintaining continuous manufacturing capability and preventing bubble formation.
2Ease of manufacture
If adhesive tape is used to connect film ends, then ease of manufacture is improved, but optical characteristics are reduced due to bubble generation
Solution Approach 1:
The invention removes the adhesive tape connection method that compromises optical quality. The bonding film is integrated into the lamination structure, providing a reliable connection that maintains optical characteristics while remaining easy to manufacture.
Solution Approach 2:
The invention uses a composite structure where the bonding film is laminated between the polarization film and protective film. This composite approach provides both ease of manufacture through integrated connection and reliability by preventing bubble formation that would degrade optical characteristics.
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 effectively removes bubbles from the optical film, enhancing its optical properties and reducing errors in display units manufactured using the film.
Implementation Method 1
pressing the first film and the second film with the optical film by passing both the first film and the second film between a pair of pressing rolls
Implementation Method 2
conveying the optical film by passing the optical film with the slit line in the slit forming between a pair of conveying rolls
Data Source
AI summary
Provided is a manufacturing method of an optical film, which manufactures an optical film in which at least a first film and a second film are stacked, the method including: pressing the first film and the second film with the optical film by passing both the first film and the second film between a pair of pressing rolls; forming a slit line in a width direction of the optical film by cutting the second film without cutting the first film at a rear end of a connection portion when the connection portion is included, to which a unit film is connected by a connection member between the first film and the second film which are pressed in the pressing; and conveying the optical film by passing the optical film with the slit line in the slit forming between a pair of conveying rolls.