Attachment Roll Sagging Suppression in Display Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional systems for manufacturing display units face defects due to sagging attachment rolls when attaching optical films to large-area panels, leading to reduced precision and productivity.
Innovation Solution
A system that includes a sagging suppressing unit with a magnetic force generating unit, which uses magnetic forces to prevent the attachment roll from sagging, and a suction part to remove foreign substances, improving the attachment precision and quality of optical films on panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the attachment roll length is increased to attach optical film to large-area panels, then the attachment area is improved, but the attachment roll sags in downward direction due to weight
Solution Approach 1:
The patent introduces a support structure that provides upward support force to counteract the downward gravitational force on the attachment roll. The support structure includes support rollers positioned beneath the attachment roll to prevent sagging, directly applying the counterweight principle to balance the weight of the long attachment roll during operation.
2Area of stationary object
If the attachment roll length is increased to attach optical film to large-area panels, then the attachment area is improved, but the precision of optical film attachment deteriorates
Solution Approach 1:
By supporting the attachment roll from below with support rollers, the system prevents gravitational sagging that would cause misalignment and attachment defects. This maintains the horizontal position and flatness of the attachment roll, ensuring precise optical film attachment across the entire large-area panel surface.
3Shape
If separate equipment is added to reconnect and wind optical films, then the roll sagging problem is addressed, but productivity is reduced
Solution Approach 1:
The patent integrates the support function directly into the attachment unit by incorporating support rollers within the attachment roll structure. This eliminates the need for separate equipment to handle roll stability, as the support function is merged with the attachment function, maintaining productivity while solving the sagging problem.
Solution Approach 2:
The attachment roll structure is designed to be self-supporting through integrated support rollers that are part of the attachment unit itself. The system serves its own support needs without requiring external assistance or separate processing equipment, enabling continuous operation and maintaining high productivity.
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
The system effectively suppresses sagging of the attachment roll, enhancing the precision and quality of optical film attachment on panels, reducing defects and improving productivity in display unit manufacturing.
Implementation Method 1
a sagging suppressing unit which suppresses the attachment roll from sagging... a magnetic force generating unit which generates magnetic force
Implementation Method 2
a suction part to remove foreign substances
Data Source
AI summary
Provided is a system for manufacturing a display unit, the system including: a carrying unit which carries an optical film including a polarizing film including an adhesive layer and a release film to which the polarizing film is bonded to be peeled off through the adhesive layer; a cutting unit which cuts the optical film by a predetermined depth, in which the release film is not cut, and forms a polarizing film sheet piece on the optical film; a peeling unit which peels the polarizing film sheet piece from the release film; and an attachment unit which attaches the polarizing film sheet piece peeled from the release film to a panel, in which the attachment unit includes: a pair of attachment rolls which presses and attaches the polarizing film sheet piece onto one surface of the panel; and a magnetic force generating unit or a suction part, which suppresses an upper attachment roll positioned at an upper side between the pair of attachment rolls from sagging by using magnetic force or suction.