Optical Laminate Production via Integrated Thin Glass Lamination
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Solution Overview
Problem
The production efficiency of optical laminates using thin glass is hindered by the fragility and poor handleability of thin glass materials, which complicates the lamination process and reduces efficiency.
Innovation Solution
An integrated production method where thin glass with a thickness of 100 um or less is continuously produced and laminated with an optical film using an adhesive application layer, allowing for bonding without taking up the glass, and curing the adhesive to form a layer between the glass and film, optimizing line speeds and preventing breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If thin glass material is used to achieve weight saving and thinning, then the weight and thickness of the image display apparatus are reduced, but the handleability deteriorates due to increased fragility
Solution Approach 1:
The patent combines the glass substrate production process with the optical film lamination process into a single integrated production line. The glass substrate is continuously produced and immediately laminated with optical films without being taken up or handled separately, eliminating the handling steps that cause breakage while maintaining weight reduction benefits
2Length of stationary object
If thin glass material is used, then the thickness of the image display apparatus is reduced, but the handleability deteriorates due to increased fragility
Solution Approach 1:
The production method integrates glass substrate formation and optical film lamination in one continuous process. The glass substrate is produced thin (50 μm or less) and immediately laminated without intermediate handling, achieving thickness reduction while preventing breakage through elimination of separate handling steps
3Weight of moving object
If thin glass material is used, then weight saving is achieved, but production efficiency is reduced due to poor handleability
Solution Approach 1:
The patent merges multiple production steps (glass substrate production and optical film lamination) into a single integrated continuous process. This eliminates intermediate handling and transfer operations that reduce productivity, while maintaining the weight savings achieved through thin glass usage
Solution Approach 2:
The production method implements continuous production where the glass substrate is continuously formed and immediately continuously laminated with optical films. This continuous process eliminates interruptions and repositioning operations, maintaining high production efficiency while using thin glass materials
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 enhances production efficiency by maintaining high-speed line processes and preventing glass breakage, enabling the production of lightweight, high-transmittance optical laminates with improved handleability and protective properties.
Implementation Method 1
bonding the thin glass and the optical film through intermediation of the application layer while thin glass is inserted into a pair of rolls from below, followed by curing the adhesive to form an adhesive layer between the optical film and the thin glass
Data Source
Figure 1
AI summary
Provided is a production method for an optical laminate, which is excellent in production efficiency even through use of a thin glass. The production method for an optical laminate includes: a thin glass production step of producing a thin glass having a thickness of 100 µm or less; and a lamination step of laminating an optical film on one surface, or each of both surfaces, of the thin glass, the thin glass production step and the lamination step being performed in an integrated line, the lamination step including applying an adhesive onto the optical film to form an application layer, and bonding the thin glass and the optical film through intermediation of the application layer, followed by curing the adhesive to form an adhesive layer between the optical film and the thin glass.