Film layer coating apparatus and method of operation thereof

Abstract

The present application provides a film layer coating device and an operating method thereof. The film layer coating device comprises a base, a first coating wheel arranged on the base and continuously rotating in a first direction, a second coating wheel arranged on the base, an origin marking unit arranged on the first coating wheel and used for marking a first origin of the first coating wheel, a detection unit arranged on the base and used for detecting the first origin, and a control unit arranged on the base and connected to the second coating wheel and the detection unit; wherein when the detection unit detects the first origin, the control unit controls the second coating wheel to be close to the first coating wheel and rotate in a second direction opposite to the first direction, so that a second origin of the second coating wheel is aligned with a preset position of the first coating wheel.

Description

Technical Field

[0001] This invention relates to a film coating apparatus, and more particularly to a film coating apparatus for an alignment membrane and its operating method. Background Technology

[0002] With the development of technology, display devices are widely used in many electronic products, such as mobile phones, tablets, watches, and automobiles.

[0003] In the production process of liquid crystal display panels, alignment film printing is a critical step in the manufacturing process. When using an alignment film printing machine with an existing design, the asynchronous rotation between the transfer roller and the coating roller can cause virtual patterns to be transferred onto the alignment film coated on the display panel, resulting in the production of unqualified display panels, reducing product yield, and leading to product scrap.

[0004] Therefore, how to provide a film coating device and its operation method that can make the transfer wheel and coating wheel rotate synchronously, avoid the virtual pattern transfer situation, and improve the product yield is one of the problems that needs to be solved. Summary of the Invention

[0005] The embodiments of the present invention provide a film coating apparatus and its operating method, which enables synchronous rotation between the transfer wheel and the coating wheel, avoids virtual graphic transfer, and improves product yield.

[0006] A film coating apparatus according to one embodiment of the present invention includes a base; a first coating wheel disposed on the base and continuously rotating along a first direction; a second coating wheel disposed on the base; an origin marking unit disposed on the first coating wheel for marking a first origin of the first coating wheel; a detection unit disposed on the base for detecting the first origin; and a control unit disposed on the base and connected to the second coating wheel and the detection unit; wherein when the detection unit detects the first origin, the control unit controls the second coating wheel to move closer to the first coating wheel and rotate along a second direction, the first direction being opposite to the second direction, so that the second origin of the second coating wheel aligns with a preset position of the first coating wheel.

[0007] In the above-mentioned film coating apparatus, the origin marking unit is a notch or a protrusion, the origin marking unit is disposed on a baffle, and the baffle is disposed on the first coating wheel and rotates synchronously with the first coating wheel.

[0008] In the above-described film coating apparatus, in a first state, the origin marking unit and the first coating wheel have a first relative position; in a second state, the first coating wheel has a defect, and the baffle is adjusted so that the origin marking unit and the first coating wheel have a second relative position. At this time, along the first direction, the distance between the origin marking unit and the defect exceeds a preset distance, and the preset distance is the first cycle coating distance of the first coating wheel.

[0009] In the above-described film coating apparatus, the first coating wheel further includes a plurality of scales arranged along the first direction. In the first state, the first origin corresponds to a first scale among the plurality of scales; in the second state, the first origin corresponds to a second scale among the plurality of scales, and the interval between the first scale and the second scale exceeds the preset distance along the first direction.

[0010] In the above-described film coating apparatus, the plurality of scales are uniformly or discretely arranged.

[0011] An operating method for a film coating apparatus according to an embodiment of the present invention, wherein the film coating apparatus includes a base, a first coating wheel, a second coating wheel, an origin marking unit, a detection unit, and a control unit. The first coating wheel, the second coating wheel, the detection unit, and the control unit are disposed on the base, and the origin marking unit is disposed on the first coating wheel and used to mark the first origin of the first coating wheel. The operating method includes: step A, controlling the first coating wheel to continuously rotate along a first direction; step B, determining whether the detection unit detects the first origin of the first coating wheel; if so, executing step C; and step C, the control unit controls the second coating wheel to move closer to the first coating wheel and rotate along a second direction, wherein the first direction is opposite to the second direction, so that the second origin of the second coating wheel is aligned with a preset position of the first coating wheel.

[0012] In the above-mentioned operation method of the film coating device, the origin marking unit is a notch or a protrusion, the origin marking unit is disposed on a baffle, and the baffle is disposed on the first coating wheel and rotates synchronously with the first coating wheel.

[0013] The above-described method for operating the film coating apparatus includes the following steps: In a first state, the origin marking unit and the first coating wheel have a first relative position; The method further includes step D, confirming whether there is a defect on the first coating wheel; if so, executing step E; and step E, adjusting the baffle so that the origin marking unit and the first coating wheel have a second relative position, at which point the distance between the origin marking unit and the defect exceeds a preset distance along the first direction, the preset distance being the first cycle coating distance of the first coating wheel.

[0014] The above-described method for operating the film coating apparatus includes a first coating wheel further comprising a plurality of scales arranged along the first direction. In the first state, the origin marking unit aligns with the first scale among the plurality of scales; in the second state, the origin marking unit aligns with the second scale among the plurality of scales, and the distance between the first scale and the second scale along the first direction exceeds the preset distance.

[0015] In the above-described method for operating the film coating apparatus, the plurality of scales are either uniformly or discretely set.

[0016] The present invention will be described in detail below with reference to the accompanying drawings and specific embodiments, but this is not intended to limit the present invention. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the structure of a film coating device according to an embodiment of the present invention.

[0018] Figure 2A This is a schematic diagram of the structure of an origin marking unit according to an embodiment of the present invention.

[0019] Figure 2B This is a schematic diagram of the structure of the origin marking unit according to another embodiment of the present invention.

[0020] Figure 3 This is a schematic diagram of the structure of the origin marking unit in another embodiment of the present invention.

[0021] In the attached figures, the following labels are used:

[0022] 10: Target Coating Area

[0023] 100: Film coating device

[0024] 101: Abutment

[0025] 102: First coating wheel

[0026] 103: Second coating wheel

[0027] 104: Origin Marker Unit

[0028] 105: Detection Unit

[0029] 106: Control Unit

[0030] 107: Baffle

[0031] 1071: Notch

[0032] 1072: Protrusion

[0033] 108: Optical ruler

[0034] 109: Scale

[0035] APR: Alignment film printing plate

[0036] D1: First Direction

[0037] D2: Second Direction

[0038] P1: First Origin Point

[0039] P2: Second Origin

[0040] S: Preset distance Detailed Implementation

[0041] The structural and working principles of the present invention will be described in detail below with reference to the accompanying drawings:

[0042] Please refer to Figure 1 , Figure 1 This is a schematic diagram of a film coating apparatus according to an embodiment of the present invention. Figure 1 As shown, the film coating apparatus 100 of the present invention includes a base 101, a first coating wheel 102, a second coating wheel 103, an origin marking unit 104, a detection unit 105, and a control unit 106. The first coating wheel 102, the second coating wheel 103, the detection unit 105, and the control unit 106 are respectively disposed on the base 101, and the control unit 106 is electrically connected to the detection unit 105 and is used to control the movement of the second coating wheel 103 towards / away from the first coating wheel 102, etc.

[0043] In one embodiment, the first coating wheel 102 may be, for example, a transfer wheel, and the first coating wheel 102 continuously rotates along a first direction D1. The film coating apparatus may further include an alignment liquid injection unit (not shown in the figure) and a doctor blade (not shown in the figure) disposed adjacent to the first coating wheel 102. The alignment liquid injection unit is used to inject alignment liquid onto the first coating wheel 102, and the doctor blade is used to scrape the alignment liquid injected onto the first coating wheel 102 evenly, so that the alignment liquid is uniformly coated on the first coating wheel 102. An origin marking unit 104 is provided on the first coating wheel 102, and the origin marking unit 104 is used to mark the first origin P1 of the first coating wheel 102. A detection unit 105 is used to detect the rotation of the first coating wheel 102 in real time. The second coating wheel 103 may be, for example, a printing wheel, on which an alignment film printing (APR) plate is fixedly disposed. The second coating wheel 102 has a second origin P2, which is, for example, the origin of the alignment film printing plate, and the second coating wheel 102 can rotate along the second direction D2, the first direction D1 and the second direction D2 are opposite to the rotation direction.

[0044] When the detection unit 105 detects the origin marking unit 104 of the first coating wheel 102, that is, when the first origin P1 of the first coating wheel 102 rotates into the detection range of the detection unit 105, the control unit 106 controls the second coating wheel 103 to approach and contact the first coating wheel 102, so that the second origin P2 of the second coating wheel 103 is aligned with the preset position on the first coating wheel 102. At the same time, the control unit 106 controls the second coating wheel 103 to rotate along the second direction D2. Thus, the alignment liquid on the first coating wheel 102 can be transferred to the APR plate on the second coating wheel 103, and then the alignment liquid is printed onto each target coating area 10 of the display substrate by the second coating wheel 103. In one embodiment, the display substrate is an uncut mother board, which is cut after each process is completed. Each target coating area 10 is located on a cut display panel, but this is not a limitation. In one embodiment, the detection unit 105 is an optical sensor, but this is not a limitation.

[0045] In this invention, the preset position on the first coating wheel 102 can be the position of the first origin P1, or it can be another preset position on the first coating wheel 102. For example, the rotation distance of the first coating wheel 102 / second coating wheel 103 during the process of the second coating wheel 102 completing the approach, contact, and rotation when the detection unit 105 detects the origin mark unit 104 can be determined in advance to determine the first origin P1, so that the second origin P2 can be aligned with the first origin P1 during use. In addition, the second origin P2 can also be another preset position on the second coating wheel 103, and this invention is not limited to this.

[0046] In the prior art, after the coating roller and transfer roller cooperate to print with the alignment liquid, the surface of the coating roller will retain the dummy pattern of the previous APR plate. In the prior art, because the rotation of the coating roller and transfer roller is asynchronous each time, their alignment positions are different each time. If the dummy pattern of the previous APR plate remaining on the coating roller does not overlap with the APR plate on the transfer roller, then during the next alignment liquid printing, the dummy pattern of the APR plate on the coating roller will be transferred to the effective display area (AA) of the display panel, causing problems such as horizontal belt mura (HBM) in the display area (AA).

[0047] In this invention, an origin marking unit 104 is provided on the first coating wheel 102. Each time the second coating wheel 103 approaches and contacts the first coating wheel 102 for alignment liquid printing, the second origin P2 on it can be aligned with the preset position of the first coating wheel 102. That is, the alignment position of the second coating wheel 103 and the first coating wheel 102 is consistent each time. This ensures that the APR plate on the second coating wheel 103 will overlap with the pattern trace (dummy pattern) of the previous coating APR plate left on the first coating wheel 102. This prevents the pattern trace (dummy pattern) of the APR plate on the first coating wheel 102 from being transferred to the effective display area (AA) of each target coating area 10 on the display substrate, thus avoiding the adverse effects caused by the pattern trace of the APR plate on the first coating wheel 102 and improving product quality.

[0048] Figure 2A This is a schematic diagram of the structure of an origin marking unit according to an embodiment of the present invention. Figure 2B This is a schematic diagram of the structure of the origin marking unit according to another embodiment of the present invention. (Combined with...) Figure 1 and Figure 2A , Figure 2B As shown, the origin marking unit 104 of the present invention is disposed on the baffle 107. The origin marking unit 104 may be, for example, a... Figure 2A The notch 1071 shown or Figure 2B The protrusion 1072 shown is accompanied by a baffle 107 which can be axially disposed on one side (e.g., the outer side) of the first coating wheel 102 and rotate synchronously with the first coating wheel 102. In one embodiment, the baffle 107 is detachably fixed to the first coating wheel 102, and before being fixed, it can rotate axially along the first coating wheel 102 to adjust the relative position of the notch 1071 or the protrusion 1072 with the first coating wheel 102. In this invention, the origin marking unit 104 can also be disposed on the baffle 107 in other ways, and this invention is not limited thereto.

[0049] In one embodiment, in the first state, the origin marking unit 104 and the first coating wheel 102 have a first relative position, and the first coating wheel 102 and the second coating wheel 103 can normally print the alignment liquid. Due to the use of the film coating apparatus 100 or the influence of the working environment, the first coating wheel 102 may develop defects. In the second state, when there are defects on the first coating wheel 102, such as pits or scratches, the relative position between the baffle 107 and the first coating wheel 102 can be adjusted to adjust the origin marking unit 104 (notch 1071 or protrusion 1072) to have a second relative position with the first coating wheel 102. At this time, along the first direction D1, the distance between the origin marking unit 104 and the defect of the first coating wheel 102 exceeds a preset distance S, which is the first cycle coating distance of the first coating wheel 102. The first cycle coating distance can be the entire cycle coating distance of the APR plate on the second coating roller 103, which for example covers one or more target coating areas 10. Taking the entire cycle coating distance of the APR plate covering one target coating area 10 as an example, the first cycle coating distance can be, for example, the sum of the length of the target coating area 10 and the interval between two adjacent target coating areas 10, that is, the distance between one side of one target coating area 10 and one side of the next target coating area 10, but is not limited to this. By adjusting the relative position between the baffle 107 and the first coating roller 102, the first coating roller 102 can still participate in the alignment liquid coating after defects occur, extending the service life of the first coating roller 102, while avoiding the transfer of defects to each target coating area 10 of the display substrate, thus ensuring product quality.

[0050] Figure 3 This is a schematic diagram of the structure of the origin marking unit in another embodiment of the present invention. (Combined with...) Figure 1 and Figure 3 As shown, the origin marking unit 104 may also include an optical scale 108 disposed on the first coating wheel 102 along the first direction D1. The optical scale 108 has multiple graduations 109, such as 0, 90, 180, 270, or other graduation methods. The multiple graduations 109 may be uniformly or discretely arranged, and the present invention is not limited thereto. In other embodiments, the multiple graduations 109 may also be directly disposed on the surface of the baffle 107. By setting the multiple graduations 109, the origin marking unit 104 can be accurately adjusted. For example, when a defect occurs in the first coating wheel 102, the multiple graduations 109 can be used to ensure that the adjusted origin marking unit 104 is more than a preset distance S from the defect.

[0051] In one embodiment, in a first state, the first origin P1 corresponds to a first scale among the plurality of scales; in a second state, when there are defects on the first coating wheel 102, such as pits or scratches, the first origin P1 is adjusted from corresponding to the first scale to corresponding to the second scale, and the interval between the first scale and the second scale exceeds the preset distance S along the first direction D1.

[0052] This invention also provides an operating method for a film coating apparatus. (Combined with...) Figures 1 to 3 As shown, the operation method of the present invention includes:

[0053] Step A: Control the first coating wheel 102 to continuously rotate along the first direction D1.

[0054] Step B: Determine whether the detection unit 105 has detected the first origin P1 of the first coating wheel 102.

[0055] If the detection unit 105 detects the first origin P1, then step C is executed. The control unit 106 controls the second coating wheel 103 to move closer to the first coating wheel 102 and rotate along the second direction D2, with the first direction D1 and the second direction D2 rotating in opposite directions, so that the second origin P2 of the second coating wheel 103 is aligned with the preset position of the first coating wheel 102. The preset position on the first coating wheel 102 can be the position of the first origin P1, or other preset positions on the first coating wheel 102. Similarly, the second origin P2 can be the starting position of the APR plate, or other preset positions on the second coating wheel 103; this invention is not limited to these limitations.

[0056] Step D: Confirm whether there are defects on the first coating wheel 102. If there are no defects on the first coating wheel 102, the origin marking unit 104 and the first coating wheel 102 continue to maintain a first relative position. At this time, the film coating apparatus 100 is in the first state, and the above steps A-C are repeatedly executed to coat the alignment liquid onto each target coating area 10 of the display substrate.

[0057] When a defect is confirmed on the first coating wheel 102, the film coating apparatus 100 is in a second state. The relative position between the baffle 107 and the first coating wheel 102 can be adjusted, and the origin marking unit 104 (notch 1071 or protrusion 1072) is adjusted to have a second relative position with the first coating wheel 102. At this time, along the first direction D1, the distance between the origin marking unit 104 and the defect on the first coating wheel 102 exceeds a preset distance S. The preset distance is the first cycle coating distance of the first coating wheel 102. The first cycle coating distance can, for example, be the entire cycle coating distance of the APR plate on the second coating wheel 103. By adjusting the relative position between the baffle 107 and the first coating wheel 102, the defect can be prevented from being transferred to the target coating area 10.

[0058] In another embodiment, in the first state, the first origin P1 corresponds to a first scale among the plurality of scales; in the second state, when there are defects on the first coating wheel 102, such as pits or scratches, the first origin P1 is adjusted from corresponding to the first scale to corresponding to the second scale, and the interval between the first scale and the second scale exceeds the preset distance S along the first direction D1.

[0059] In this invention, by setting an origin marking unit 104 on the first coating wheel 102, the second origin P2 on the second coating wheel 103 can be aligned with a preset position on the first coating wheel 102, such as the first origin P1, each time the alignment liquid is coated on the display substrate. Thus, after detecting the first origin P1 of the first coating wheel 102, the second coating wheel 103 can be controlled to move closer to and contact the first coating wheel 102 to transfer the alignment liquid to the APR plate for printing, avoiding the occurrence of virtual graphic transfer. It can also continue to participate in the alignment liquid printing when there are defects on the first coating wheel 102 and ensure that the defects on the first coating wheel 102 do not affect the printing of the alignment film, thereby improving the product yield.

[0060] Of course, the present invention may have other various embodiments. Without departing from the spirit and essence of the present invention, those skilled in the art can make various corresponding changes and modifications according to the present invention, but these corresponding changes and modifications should all fall within the protection scope of the appended claims.

Claims

1. A film coating apparatus, characterized in that, include: A base; A first coating wheel is disposed on the base and continuously rotates along a first direction; A second coating wheel is disposed on the base; An origin marking unit is disposed on the first coating wheel to mark the first origin of the first coating wheel; A detection unit is disposed on the base and used to detect the first origin; and A control unit is disposed on the base and connected to the second coating wheel and the detection unit; in When the detection unit detects the first origin, the control unit controls the second coating wheel to move closer to the first coating wheel and rotate in a second direction, the first direction being opposite to the second direction, so that the second origin of the second coating wheel aligns with a preset position of the first coating wheel; wherein, The origin marking unit is disposed on a baffle, and the baffle is disposed on the first coating wheel and rotates synchronously with the first coating wheel; In the first state, the origin marking unit and the first coating wheel have a first relative position; in the second state, the first coating wheel has a defect, and the baffle is adjusted so that the origin marking unit and the first coating wheel have a second relative position. At this time, along the first direction, the distance between the origin marking unit and the defect exceeds a preset distance, and the preset distance is the first cycle coating distance of the first coating wheel.

2. The film coating apparatus as described in claim 1, characterized in that, The origin marking unit is a notch or a protrusion.

3. The film coating apparatus as described in claim 1, characterized in that, The first coating wheel further includes a plurality of scales arranged along the first direction. In the first state, the first origin corresponds to a first scale among the plurality of scales. In the second state, the first origin corresponds to a second scale among the plurality of scales. The interval between the first scale and the second scale exceeds the preset distance along the first direction.

4. The film coating apparatus as described in claim 3, characterized in that, The multiple scales are set uniformly or discretely.

5. An operating method for a film coating apparatus, characterized in that, The film coating apparatus includes a base, a first coating wheel, a second coating wheel, an origin marking unit, a detection unit, and a control unit. The first coating wheel, the second coating wheel, the detection unit, and the control unit are disposed on the base. The origin marking unit is disposed on the first coating wheel and is used to mark the first origin of the first coating wheel. The origin marking unit is disposed on a baffle, and the baffle is disposed on the first coating wheel and rotates synchronously with the first coating wheel. In the first state, the origin marking unit and the first coating wheel have a first relative position; the operation method includes: Step A: Control the first coating wheel to continuously rotate along a first direction; Step B: Determine whether the detection unit has detected the first origin of the first coating wheel; if yes, proceed to step C; and Step C, the control unit controls the second coating wheel to move closer to the first coating wheel and rotate in a second direction, wherein the first direction is opposite to the second direction, so that the second origin of the second coating wheel is aligned with the preset position of the first coating wheel; Step D: Confirm whether there are defects on the first coating wheel; if so, proceed to step E; and Step E: Adjust the baffle so that the origin marking unit and the first coating wheel have a second relative position. At this time, along the first direction, the distance between the origin marking unit and the defect exceeds a preset distance, which is the first cycle coating distance of the first coating wheel.

6. The operation method of the film coating apparatus as described in claim 5, characterized in that, The origin marking unit is a notch or a protrusion.

7. The operating method of the film coating apparatus as described in claim 5, characterized in that, The first coating wheel also includes a plurality of scales arranged along the first direction. In the first state, the first origin is aligned with the first scale among the plurality of scales. In the second state, the first origin is aligned with the second scale among the plurality of scales. The distance between the first scale and the second scale along the first direction exceeds the preset distance.

8. The operation method of the film coating apparatus as described in claim 7, characterized in that, The multiple scales are set uniformly or discretely.

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