KR102184384B1 - Manufacturing method for optical film - Google Patents

Abstract

The present invention relates to a method for producing an optical film, and according to an aspect of the present invention, in the same production line, each of a plurality of types of raw materials 1 having various widths and one type of raw material 1 is attached via a predetermined adhesive. In the optical film production method that sequentially produces multiple types of optical films while changing the production pattern according to the combination of raw materials 2 and 3, the sum of the raw material replacement time and the adhesive replacement time according to the production order of each optical film is calculated, respectively. However, when a specific type of raw material 1 is selected, the remaining amount of raw material 1 is minimized, and the optical film including the selection step of selecting a production sequence for each optical film that minimizes the sum of the raw material replacement time and the adhesive replacement time is selected. A production method is provided.

Description

Production method for optical film {Manufacturing method for optical film}

The present invention relates to a method for producing an optical film.

Optical films, for example, polarizing plates used in various display devices, are through (1) a step of obtaining a polarizer, (2) a step of laminating a polarizer protective layer, and (3) a step of laminating a protective film or a release film. Is manufactured. In the process of obtaining a polarizer, a polarizer is obtained mainly by dyeing and stretching a polyvinyl alcohol (PVA) film. In the process of laminating the polarizer protective layer, a triacetyl cellulose (TAC) film is attached to both surfaces of the polarizer through an adhesive to laminate the polarizer protective layer.

At this time, the TAC film is attached using an adhesive, and different types of adhesives may be used for each type of polarizing plate. In addition, it is manufactured with different optical films depending on the width and thickness of the raw material used in the stretching process. In this way, the type of the polarizing plate varies depending on the width/thickness of the raw material and the type of adhesive.

On the other hand, when producing various types of films in one production line, the production line is operated with various manufacturing methods (raw material width/raw material thickness/adhesive type, etc.) determined for each product using various raw materials. At this time, when production patterns such as raw materials (thickness change, width change, adhesive change, etc.) are changed, there is a problem that product production is stopped for a certain period of time.

It is an object of the present invention to provide a method for producing an optical film capable of minimizing equipment drift that occurs when exchanging production patterns when producing several types of optical films in a single production line.

In order to solve the above problems, according to one aspect of the present invention, in the same production line, raw materials 2 and 3 each attached to a plurality of types of raw materials 1 having various widths and to any one type of raw material 1 through a predetermined adhesive. In the production method of an optical film that sequentially produces a plurality of types of optical films while changing the production pattern according to the combination of, the sum of the raw material replacement time and the adhesive replacement time according to the production order for each optical film is calculated, When raw material 1 of is selected, a method for producing an optical film comprising a selection step of selecting a production sequence for each optical film that minimizes the remaining amount of raw material 1 and minimizes the sum of the raw material replacement time and the adhesive replacement time is provided. do.

As described above, the method for producing an optical film according to an embodiment of the present invention has the following effects.

In a single production process, when the production pattern changes, such as when the width of raw materials changes, when the width of raw materials changes, when the thickness of raw materials changes, and when the type of adhesive changes, such as when producing several types of optical films, such production pattern exchange time And by minimizing the number of times, it is possible to minimize equipment drift.

Since material 1 is difficult to reuse when the remaining amount is small, loss of raw material 1 can be reduced through optimal planning.

1 is a conceptual diagram illustrating a method of producing an optical film according to an embodiment of the present invention.

Hereinafter, a method for producing an optical film according to an embodiment of the present invention will be described in detail with reference to the accompanying drawings.

In addition, regardless of the reference numerals, the same or corresponding components are given the same or similar reference numbers, and duplicate descriptions thereof will be omitted, and the size and shape of each component member shown for convenience of explanation are exaggerated or reduced. Can be.

The present invention relates to a method of producing an optical film having different production patterns including raw materials and adhesive types for each optical film. In particular, it relates to a method in which a plurality of types of optical products having different production patterns including raw materials 1, 2, and 3 and adhesive types are manufactured in a single production line. In this document, the optical film is a polarizing plate, raw material 1 may be a PVA film, and raw materials 2 and 3 may be a TAC film. For example, raw material 1 may have a length of about 20,000 to 70,000 m, and raw materials 2 and 3 may each have a length of about 3,000 m. As such, raw material 1 has a long length and a small remaining amount, it is difficult to reuse, so it is necessary to establish an optimal production plan.

In the production method of an optical film according to an embodiment of the present invention, in the same production line, the raw materials 2 and 3 are each attached to a plurality of types of raw materials 1 having various widths and one type of raw material 1 through a predetermined adhesive. It relates to a method of sequentially producing a plurality of types of optical films while changing the production pattern according to the combination.

At this time, in the production method of the optical film, the sum of the raw material replacement time and the adhesive replacement time according to the production order for each optical film is calculated, but when a specific type of raw material 1 is selected, the remaining amount of raw material 1 is minimized, and the raw material It includes a selection step of selecting a production sequence for each optical film that minimizes the sum of the replacement time and the adhesive replacement time.

Here, the raw material replacement time means the replacement time of the raw material 1, and the adhesive replacement time can be understood as including the replacement time of the raw materials 2 and 3.

In addition, in the captain stage, it is preferable that the remaining amount of raw material 1 becomes 0, and the production order for each optical film is selected to minimize the sum of the raw material replacement time and the adhesive replacement time.

For example, the production method of the optical film of the present invention, in the case of manufacturing A, B, C, D products manufactured by different at least one of the width of raw material 1 and the type of adhesive in a single production line, raw material Considering the basic length and remaining amount of 1, the width/thickness replacement time of raw material 1, and the adhesive change time, determining in what order the production of A, B, C, and D products minimizes equipment dead time. do.

On the other hand, the type of raw material 1 varies according to the width and/or thickness of raw material 1, and when at least one of the raw material width and thickness is different, the replacement time of raw material 1 occurs.

In addition, in the selection step, a production order for each optical film in which the sum of the number of replacements of the raw material 1 and the number of replacements of the adhesive is minimum may be selected.

In addition, the production method of the optical film may further include a production step of sequentially producing each optical film according to a selected production sequence.

In this case, the production amount for each optical film may be determined based on the total amount of the required amount for each optical film and the available production amount of the production line in the corresponding period (eg, week 1) in the production step.

On the other hand, if the total required amount for each optical film in the corresponding cycle (week 1) is smaller than the available production capacity of the production line, and a predetermined optical film is to be produced in the corresponding cycle (week 1) and the next cycle (week 2), the next cycle ( At least a portion of the output of Week 2) can be produced together in the cycle.

At this time, at least a part of the production amount of the next cycle (week 2) may be determined as less than or equal to the difference between the total amount of the available production amount of the production line and the required amount for each optical film.

Hereinafter, with reference to [Table 1] to [Table 3], the production method of the optical film will be specifically described. [Table 1] to [Table 3] are merely exemplary situations, and do not limit the scope of the present invention.

Referring to [Table 1], in the case of producing 8 optical films from P01 to P08, P01 and P02 have the same width (W1) and thickness (30) of raw material 1, and P03, P04, P05, P06, P07 has the same width (W2) and thickness (60) of raw material 1.

In addition, P01 and P03 have the same width as W3, P02, P04, and P05 have the same width as W1, and P06 has the same width as W2. At this time, W1, W2, and W3 represent different widths. In addition, P01, P02, P03, P04, P06, P07 use NR adhesive (general adhesive), and P05, P08 use UV adhesive.

In addition, P01, P03 are produced according to route 1, P02 is produced according to route 2, and P04, P05, P06, P07, P08 are produced according to route 0, and as different routes, the replacement time between routes is 3.5 It takes time.

In addition, the basic length of raw material 1 is 18,000m when the width is W1 and the thickness is 30, 21,000m when the width is W1 and the thickness is 60, and when the width is W3 and the thickness is 60, it is 15,000m. to be.

In addition, when the width is the same, the time to replace the raw material 1 so that the thickness is different is 4 hours, and the replacement time of the adhesives (NR, UV) is 6 hours.

[Table 1]

[Table 2] below shows the time required to change the width of raw material 1.

[Table 2]

In addition, the available output of each production line for each week (e.g., week 1, week 2, week 3, and week 4) is 27,000 m, respectively, at week 1 and week 3, and at week 2 and week 4, respectively. It is 18,000m.

At this time, as described above, according to the present invention, the production order of each optical film can be selected for each cycle (week 1, week 2), and the results are shown in [Table 3].

The optical film production method is, when producing multiple types of optical films sequentially while changing the production pattern according to the combination of raw materials 1, 2, 3 and adhesive type on the same production line, the raw material replacement time according to the production order of each optical film And a calculation step of calculating the sum of the adhesive replacement time and each.

However, when a specific type of raw material 1 is selected, a selection step of selecting a production sequence for each optical film in which the remaining amount of the raw material 1 is minimized and the sum of the raw material replacement time and the adhesive replacement time is minimized.

[Table 3]

In [Table 3], when both the width and thickness of the raw material are changed, the total replacement time was calculated as the sum of the width replacement time and the thickness replacement time.

On the contrary, when there are two or more types of replacement items (eg, path replacement, adhesive type replacement), only the replacement time of the item with a large replacement time (adhesive type replacement) can be calculated as the total replacement time.

In addition, in [Table 3], even if the parking is changed (eg, change from week 1 to week 2), it was calculated that the replacement time occurred, but differently, the parking price changed (for example, from week 1 If it is changed to week 2), the replacement time can be calculated as zero.

On the other hand, in the production stage, the production amount for each optical film may be determined based on the total required amount of each optical film and the available production amount of the production line in the corresponding cycle (for example, week 1).

In addition, the total of the required amount for each optical film in the corresponding cycle (week 1) is smaller than the available production amount of the production line, and the predetermined optical film is the corresponding cycle (for example, week 1) and the next period (for example, week 2 to week 4). ), at least part of the production volume of the next cycle (week 2 to week 4) can be produced together in that cycle.

At this time, at least a part of the production amount of the next cycle (week 2) may be determined as less than or equal to the difference between the total amount of the available production amount of the production line and the required amount for each optical film.

In week 1, the P08 product should be produced with the highest priority, and at this time, the P08 product can be produced so that all raw materials 1 (15,000m) are exhausted. Since the available production remaining in week 1 is 12,000m, production of products P02 to P04 can be considered. In this way, the product production order can be arranged, and the product production order can be selected so that the sum of the replacement time such as the width and thickness of raw material 1, the adhesive, and the path is minimized.

On the other hand, for the P02 product, the required amount for the second week is 4,587, and the required amount for the fourth week is 8,000. At this time, the P02 product can be produced at the 1st, 2nd and 4th week requirements together.

Preferred embodiments of the present invention described above are disclosed for the purpose of illustration, and those skilled in the art who have ordinary knowledge of the present invention will be able to make various modifications, changes, and additions within the spirit and scope of the present invention. And additions will be seen as falling within the scope of the following claims.

Claims (8)

1. In the same production line, while changing the production pattern according to the combination of raw materials 2 and 3, each of which is attached to a plurality of raw materials 1 having various widths and one kind of raw material 1 through a predetermined adhesive, In the production method of an optical film to be sequentially produced,
   Calculate the sum of the raw material replacement time and the adhesive replacement time according to the production sequence for each optical film,
   When a specific kind of raw material 1 is selected, the remaining amount of the raw material 1 is minimized, and the production sequence for each optical film is selected to minimize the sum of the raw material replacement time and the adhesive replacement time, and
   The type of raw material varies depending on the thickness and width of the raw material,
   A method of producing an optical film in which raw material replacement time occurs when at least one of the raw material thickness and width is changed.
2. The method of claim 1,
   In the captain's stage, the remaining amount of raw material 1 becomes 0, and the production order for each optical film is selected to minimize the sum of raw material replacement time and adhesive replacement time.
3. delete
4. The method of claim 1,
   In the selection step, a production method of an optical film in which a production sequence for each optical film in which the sum of the number of replacements of raw materials and replacement of adhesives is minimum is selected.
5. The method of claim 1,
   An optical film production method further comprising a production step of sequentially producing each optical film according to the selected production sequence.
6. The method of claim 5,
   An optical film production method that determines the amount of production for each optical film in the production stage based on the total amount of optical film required for each cycle and the available production amount of the production line.
7. The method of claim 6,
   When the total required amount for each optical film in the corresponding cycle is smaller than the available production amount of the production line, and a predetermined optical film is to be produced in the corresponding cycle and the next cycle, at least a part of the production quantity of the next cycle is produced in the corresponding cycle. Production method.
8. The method of claim 7,
   At least a part of the production amount of the next cycle is determined by less than or equal to the difference between the available production amount of the production line and the total amount required for each optical film.
   

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