Patent ID: 7371590

Claim:
A method of inspection and defect correction for microreplicated display films comprising the steps of: a.) manufacturing a master; b.) inspecting said master for performance and appearance and determining whether the master is acceptable or not acceptable; c.) proceeding to step g, if said master is found to be acceptable, else continuing to step d; d.) storing master failure information related to why the master was not acceptable; e.) adjusting the master manufacturing process based upon the master failure information; f.) proceeding to step a; g.) manufacturing at least one shim from said acceptable master; h.) inspecting for performance and appearance at least one of said shim and determining whether the shim is acceptable or not acceptable; i.) proceeding to step m, if said shim is found to be acceptable, else continuing to step j; j.) storing shim failure information related to why the shim was not acceptable; k.) adjusting the shim manufacturing process based upon the shim failure information; l.) proceeding to step g; m.) manufacturing at least one display film from at least one of said acceptable shim; n.) inspecting for performance and appearance said at least one display film and determining whether the display film is acceptable or not acceptable; o.) proceeding to step s, if said at least one display film is found to be acceptable, else continuing to step p; p.) storing the film failure information related to why the display film was not acceptable; q.) adjusting the film manufacturing process based upon the film failure information; r.) proceeding to step m; s.) determining from a plurality of film failure information whether there is a systemic defect occurring in the manufacturing of said display films, and wherein the inspection and defect correction further comprises of analyzing said systematic defects and determining whether said systematic defects are occurring in the step of manufacturing the display film, the step of manufacturing shim, or the manufacturing of the master; and then adjusting at least one of said steps of manufacturing the display film, the step of manufacturing the shim, or the manufacturing the master based upon said determination.