Central Alignment Material Supply System for LCD Manufacturing
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Solution Overview
Problem
The existing alignment material supply systems for LCD devices are inefficient, leading to process delays and increased costs due to manual replacement of alignment material containers, which requires significant time and labor, and results in unnecessary consumption of alignment material.
Innovation Solution
A central supplying unit automatically manages and replenishes alignment material across multiple alignment layer forming lines, using a controller to monitor and refill alignment material containers, ensuring continuous supply and minimizing waste through real-time weight measurements and automated valve control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual replacement of alignment material containers is used, then device complexity is reduced, but productivity decreases and loss of time increases
Solution Approach 1:
Multiple alignment material containers are merged into a single central supply unit that serves multiple coating devices. The central supply unit integrates storage, monitoring, and distribution functions, allowing one centralized system to replace what would otherwise require multiple separate supply systems, thereby improving productivity without proportionally increasing device complexity
Solution Approach 2:
The central supply unit pre-stores alignment material in large containers before it is needed. The system monitors material levels in advance and automatically replenishes coating devices before they run out, preventing process delays and maintaining continuous production without requiring manual intervention at critical moments
2Loss of time
If manual monitoring and replacement of alignment material is performed, then measurement precision requirements are reduced, but loss of time increases
Solution Approach 1:
The system implements continuous feedback through weight sensors that monitor the alignment material levels in real-time. The controller receives constant updates on material quantities and automatically triggers replenishment when thresholds are reached, eliminating the need for manual checking and ensuring timely replacement without requiring high-precision measurement systems
Solution Approach 2:
Manual visual inspection and physical replacement of alignment material containers are replaced by an automated electronic monitoring and control system. Weight sensors and controllers automatically detect material levels and manage replenishment, significantly reducing replacement time while using simple weight-based measurement rather than complex precision measurement
3Loss of substance
If alignment material is supplied to multiple coating devices independently, then adaptability is improved, but loss of substance increases
Solution Approach 1:
The central supply unit maintains continuous supply of alignment material to multiple coating devices through a coordinated distribution system. Material is transferred continuously from the central reservoir to individual coating devices as needed, preventing interruptions and ensuring that each device receives material at the optimal moment without excess waste or depletion
Solution Approach 2:
A single central supply unit serves multiple different coating devices with potentially different requirements. The system can adaptively distribute material to various devices based on their individual needs while maintaining a unified control architecture, achieving versatility without requiring separate independent supply systems for each device
Data Source
AI summary
An apparatus for forming an alignment layer comprising: at least one alignment layer forming line having a plurality of alignment layer forming units; a plurality of alignment material coating devices disposed at each alignment layer forming unit and configured to coat an alignment material on a substrate of the corresponding alignment layer forming units; at lest one alignment material supplying unit having a plurality of second alignment material containers for supplying the alignment material to each alignment material coating device; a central supplying unit connected to the at least alignment material supplying unit and having at least one first alignment material container for supplying the alignment material to the at least one alignment material supplying unit; a supplying pipe configured to connect the at least one alignment material supplying unit to the central supplying unit; and a controller configured to measure the remnant amount of alignment material of the at least one alignment material supplying unit so as to supply the alignment material in the first alignment material container to the plurality of second alignment material containers via the supplying pipe when the measured remnant amount of the alignment material is smaller than a minimum amount thereof, and to measure the remnant amount of the alignment material in the central supplying unit so as to replace the first alignment material container with a new first alignment material container fully filled with the alignment material when the remnant amount of the alignment material in the central supplying unit is smaller than the minimum amount thereof.