Method for manufacturing rectangular pieces with high cutting efficiency

Abstract

Disclosed herein is a method of manufacturing two kinds of rectangular unit pieces having different optical properties from a base material sheet through cutting using a cutting frame including a cutter, the method including preparing a base material sheet having a large length to width ratio, the base material sheet exhibiting optical directivity in a longitudinal direction or in a lateral direction, preparing a cutting frame including at least on first cutter for cutting a first unit piece exhibiting optical directivity parallel to that of the base material sheet and at least one second cutter for cutting a second unit piece exhibiting optical directivity perpendicular to that of the base material sheet, the first cutter and the second cutter being arranged adjacent to each other in the lateral direction of the base material sheet, and sequentially cutting the base material sheet using the cutting frame in the longitudinal direction of the base material sheet to simultaneously manufacture the first unit piece and the second unit piece.

Claims

1. A method of manufacturing two kinds of rectangular unit pieces having different optical properties from a base material sheet through cutting using a cutting frame comprising a cutter, the method comprising: preparing a base material sheet having a large length to width ratio, the base material sheet exhibiting one optical directivity in a longitudinal direction or in a lateral direction; preparing a cutting frame comprising at least one first cutter for cutting a first unit piece exhibiting optical directivity parallel to that of the base material sheet and at least one second cutter for cutting a second unit piece exhibiting optical directivity perpendicular to that of the base material sheet, the first cutter and the second cutter being arranged adjacent to each other in the lateral direction of the base material sheet; and sequentially cutting the base material sheet using the cutting frame in the longitudinal direction of the base material sheet to simultaneously manufacture the first unit piece and the second unit piece, wherein the cutting frame comprises two or more first cutters sequentially arranged while being adjacent to each other in the longitudinal direction of the base material sheet and two or more second cutters sequentially arranged while being adjacent to each other in the longitudinal direction of the base material sheet, sides of the first cutters adjacent to each other are coincided and sides of the second cutters adjacent to each other are coincided, the first cutters and the second cutters have the same array length, and the first unit piece and the second unit piece have the same length and width when the first unit piece and the second unit piece are arranged such that the optical directivities of the first unit piece and the second unit piece are perpendicular to each other.

2. The method according to claim 1, wherein the base material sheet is a laminate sheet comprising a selective absorption/transmission layer comprising a layer for absorbing or transmitting only a specific-direction wave motion of light or an electromagnetic wave in the longitudinal direction or in the lateral direction.

3. The method according to claim 2, wherein the laminate sheet is manufactured by coupling separately manufactured unit sheets by adhesive or thermal welding or by co-extrusion.

4. The method according to claim 1, wherein each cutter of the cutting frame is a knife for cutting or a light source for cutting.

5. The method according to claim 4, wherein the knife for cutting is a metal knife or a jet water knife, and the light source for cutting is laser.

6. The method according to claim 4, wherein the knife for cutting is mounted or formed in the cutting frame while having a shape corresponding to each rectangular unit piece.

7. The method according to claim 1, wherein the first cutters and the second cutters are arranged adjacent to each other such that the first cutters and the second cutters are spaced apart from each other by a distance corresponding to a cutting margin.

8. Rectangular unit pieces manufactured using a method according to claim 1.

9. An optical device comprising rectangular unit pieces according to claim 8 as an optical part.

10. The optical device according to claim 9, wherein the optical device comprises a first unit piece and a second unit piece, the first unit piece and a second unit piece being arranged such that optical directivities of the first unit piece and the second unit piece are perpendicular to each other.

11. The optical device according to claim 9, wherein the optical device is a liquid crystal display (LCD), an organic light emitting diode (OLED), an LCD television (TV), a light emitting diode (LED) TV, an LCD monitor, an LED monitor, or a display device.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) The above and other objects, features and other advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:

(2) FIG. 1 is a typical view showing that rectangular unit pieces, manufactured using a conventional cutting frame, are applied to a real product;

(3) FIGS. 2 and 3 are partial typical views showing the array structure of rectangular unit pieces corresponding to cutters of the conventional cutting frame.

(4) FIG. 4 is a partial typical view showing the array structure of rectangular unit pieces corresponding to cutters of a cutting frame according to an embodiment of the present invention;

(5) FIG. 5 is a typical view showing that the cutters are formed in the cutting frame according to the embodiment of the present invention; and

(6) FIG. 6 is a view showing a series of steps of a method of manufacturing rectangular unit pieces according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

(7) Now, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. It should be noted, however, that the scope of the present invention is not limited by the illustrated embodiments.

(8) FIG. 4 is a partial typical view showing the array structure of rectangular unit pieces corresponding to cutters of a cutting frame according to an embodiment of the present invention. In addition, FIG. 5 is a typical view showing that the cutters are formed in the cutting frame according to the embodiment of the present invention.

(9) Referring to these drawings, a plurality of cutters 320 and 330 is mounted or formed in a cutting frame 300. The cutters 320 and 330 cut a base material sheet 100 according to the array shape of the cutters 320 and 330 to manufacture rectangular unit pieces 20 and 30.

(10) The array length of the first cutters 320 is equal to that of the second cutters 330 such that the shape of the upper end of each of the cutters 320 and 330 is identical to that of the lower end of each of the cutters 320 and 330.

(11) Consequently, it is possible to continuously manufacture the rectangular unit pieces 20 and 30 using the cutting frame 300 without an unnecessary cutting margin. As a result, it is possible to improve cutting efficiency and thus to lower manufacturing costs of the rectangular unit pieces.

(12) In addition, the first cutters 320 are arranged to be parallel to optical directivity 15 of the base material sheet 100 and the second cutters 330 are arranged to be perpendicular to the optical directivity 15 of the base material sheet 100.

(13) Consequently, it is possible to cut rectangular unit pieces 20 and 30 having different optical directivities from the same base material sheet 100 using the cutting frame 300.

(14) Specifically, the first cutters for cutting first unit pieces having optical directivity parallel to that of the base material sheet and the second cutters for cutting second unit pieces having optical directivity perpendicular to that of the base material sheet are mounted in the cutting frame 300 according to the present invention, thereby achieving high cutting efficiency.

(15) In addition, it is possible to manufacture the rectangular unit pieces base on the array structure of the rectangular unit pieces having high cutting efficiency, thereby reducing cutting loss and thus lowering manufacturing costs of products.

(16) FIG. 6 is a view showing a series of steps of a method of manufacturing rectangular unit pieces according to an embodiment of the present invention.

(17) Referring to FIG. 5 together with FIG. 5, rectangular unit pieces 400 are manufactured through a step of manufacturing a base material sheet 100 of a laminate sheet structure and winding the base material sheet 100 on a supply roll 200, a step of continuously supplying the base material sheet 100 from the supply roll 200, a step of cutting the base material sheet 100 using the cutting frame 300 to obtain a plurality of rectangular unit pieces 400, a step of winding scrap 101 produced after the cutting of the base material sheet 100 on a winding roll 210, and a step of transferring the rectangular unit pieces 400 to a predetermined position.

(18) The base material sheet 100 is configured to have a laminate structure in which protective sheets 120 are bonded to opposite sides of a sheet 110 including a predetermined absorption layer or transmission layer.

(19) The base material sheet 100, supplied from the supply roll 200, is maintained in a continuous sheet shape even after the base material sheet 100 is cut by the cutting frame 300. Consequently, the base material sheet 100 can be continuously wound on the winding roll 210 in the shape of scrap 101 produced after the cutting of the base material sheet 100, thereby continuously performing the operation. Specifically, during the cutting operation using the cutting frame 300, the operation is continuously performed through intermittent stop processes since the base material sheet 100 does not move.

(20) When the base material sheet 100 is transferred onto a die 301, the cutting frame 300 is lowered and the cutters 320 and 330 cut the base material sheet 100. The rectangular unit pieces 400, dropped under the die 301, are transferred to a predetermined position along a conveyor 500.

(21) Although the preferred embodiments of the present invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims.

Effects of the Invention

(22) As is apparent from the above description, a method of manufacturing rectangular unit pieces according to the present invention has effects in that first cutters for cutting first unit pieces having optical directivity parallel to that of a base material sheet and second cutters for cutting second unit pieces having optical directivity perpendicular to that of the base material sheet are mounted in a cutting frame, thereby achieving high cutting efficiency. In addition, it is possible to manufacture the rectangular unit pieces based on the array structure of the rectangular unit pieces having high cutting efficiency as described above, thereby reducing cutting loss and thus lowering manufacturing costs of products.