Touch Film Stack Roll Continuous Roll-to-Roll Adhesion
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Solution Overview
Problem
Conventional methods for manufacturing touch film stacks face challenges with misalignment and low productivity due to the need for high accuracy in sheet-to-sheet adhesion and multiple cutting steps, which hinder continuous production processes.
Innovation Solution
The method employs continuous roll-to-roll adhesion production, where a composite layer roll with a bottom substrate and conductive layers is formed, followed by patterning and application of strip layers, and then adhered with optically clear adhesive to create a touch film stack roll, which is partially cut to eliminate alignment issues and reduce material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If sheet-to-sheet adhesion is used with batch production, then alignment accuracy can be maintained, but productivity is reduced due to multiple cutting steps and inability to use continuous process
Solution Approach 1:
The patent implements continuous roll-to-roll adhesion production where multiple layers are adhered continuously on rolling substrates without interruption. This continuous process eliminates the batch production cycle, allowing uninterrupted manufacturing while maintaining alignment accuracy through the rolling mechanism, thereby significantly improving productivity
Solution Approach 2:
The patent performs cutting operations after the adhesion process rather than before. The continuous rolled structure is first formed with all layers properly aligned, then cutting is performed to separate individual touch panels. This preliminary formation of the complete structure before cutting eliminates the need for multiple pre-cutting steps and reduces material waste
2Ease of manufacture
If multiple cutting steps are performed on roll materials to provide material sheets, then material sheets can be obtained, but continuous process cannot be used resulting in low productivity
Solution Approach 1:
The patent maintains continuous rolling of all material layers through the adhesion process without interrupting for cutting. The rolling substrates continuously feed material layers through the adhesion zone, enabling uninterrupted production. Cutting is performed as a final step after adhesion, preserving the continuous manufacturing flow and maximizing productivity
3Manufacturing precision
If batch production with sheet-to-sheet adhesion is used, then alignment can be controlled, but unnecessary alignment steps between upper and lower conductive layers are required
Solution Approach 1:
The continuous roll-to-roll process inherently maintains alignment between upper and lower conductive layers through the rolling mechanism. All layers are adhered simultaneously in a continuous motion, eliminating the need for separate alignment steps between individual layers that are required in batch production. This simplifies the manufacturing process while maintaining precision
Solution Approach 2:
The patent combines multiple adhesion operations into a single continuous process. Instead of adhering layers separately in batch operations requiring individual alignment steps, all layers are adhered together in one continuous rolling process, merging multiple steps into one efficient operation that reduces complexity
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 approach significantly reduces misalignment and increases productivity by allowing for continuous production, simplifying the cutting process, and enabling easier removal of strip layers for electrical connections, resulting in improved yield and quality of touch film stack sheets.
Implementation Method 1
a top optically clear adhesive is as a whole adhered to the patterned top conductive layer of the top material layer roll
Data Source
AI summary
A method for forming a touch film stack roll is provided. First, a stack roll is provided. The stack roll comprises a bottom substrate roll, a patterned bottom conductive layer, a bottom strip layer and a top conductive roll. The bottom strip layer covers the bottom conductive terminals of the patterned bottom conductive layer. Then, the top conductive roll is patterned to form a patterned top conductive layer with top conductive terminals. Next, a top strip layer is formed on the top conductive terminals. Later, a top OCA roll is attached to the stack roll to cover the top strip layer to obtain the touch film stack roll.