Closed Roll Stocker Layout for Clean LCD Rubbing Roll Storage
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Solution Overview
Problem
The existing methods for manufacturing liquid crystal display (LCD) devices face challenges in managing and storing rubbing rolls, leading to issues such as limited space, potential eccentricity, and contamination, which affect the uniformity and quality of the alignment film and ultimately the LCD panel.
Innovation Solution
A roll stocker system that rotates and stores multiple rubbing rolls in a compact, closed space, preventing sagging and eccentricity, and allowing for easy access and replacement of rolls, while maintaining a clean environment to prevent contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If rubbing rolls are stored in a limited clean room space, then space utilization is improved, but the number of available rubbing rolls is reduced
Solution Approach 1:
The patent implements a multi-level rack structure where rubbing rolls are stored horizontally on multiple tiers. The rack includes a bottom rack and an upper rack positioned above it, allowing vertical stacking of storage levels. This nesting approach in the vertical dimension enables storing multiple rubbing rolls within a compact footprint, directly resolving the contradiction between limited storage area and the need to maintain sufficient inventory of rubbing rolls.
2Area of stationary object
If rubbing rolls are kept standing vertically, then space is saved, but eccentricity deviation occurs
Solution Approach 1:
The patent inverts the conventional vertical storage orientation by storing rubbing rolls horizontally instead. The rolls are positioned with their cylindrical axes horizontal, resting on support surfaces of the rack structure. This inversion of storage orientation eliminates the eccentricity deviation problem that occurs with vertical storage, while the multi-level rack design compensates for space consumption by utilizing vertical stacking.
Solution Approach 2:
The patent transitions from one-dimensional vertical storage to three-dimensional storage by utilizing horizontal positioning combined with vertical multi-level stacking. The rack structure incorporates both horizontal extension (multiple rolls per level) and vertical extension (multiple levels), creating a two-dimensional array of storage positions that optimizes space utilization while maintaining roll precision.
3Adaptability or versatility
If multiple rubbing rolls are stored for various LCD models, then adaptability is improved, but device complexity increases
Solution Approach 1:
The patent designs a universal rack structure that can accommodate rubbing rolls of different specifications through adjustable and standardized components. The rack includes adjustable support positions and a modular design that allows the same storage system to hold rolls for various LCD panel sizes (e.g., 15-inch, 17-inch, 19-inch models). This universality enables the system to handle multiple roll types without requiring separate specialized storage systems for each model.
Solution Approach 2:
The storage system is divided into segmented, modular units including separate bottom racks and upper racks, each capable of independently holding multiple rolls. This segmentation allows flexible configuration and easy adjustment of storage capacity based on specific needs, while maintaining a relatively simple basic structure that can be expanded or modified without redesigning the entire system.
Data Source
AI summary
A roll stocker includes a plurality of roll fixing units for fixing a plurality of rubbing rolls; shaft connection parts having a plurality of radially extended end portions connected with each roll fixing unit; and a rotational shaft for fixing the center of the shaft connection parts and rotating the shaft connection parts. A plurality of rubbing rolls can be rotated, and by keeping the plurality of rubbing rolls in storage in the closed roll stocker, contamination of a rubbing cloth due to external particles can be prevented, space utilization can be enhanced, and deviation of eccentricity of the rubbing rolls kept in storage can be prevented.