Dual-Stage Light Exposure System for LCD Manufacturing
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Solution Overview
Problem
The existing light exposure systems for LCD manufacturing are inefficient, leading to high manufacturing costs and reduced competitiveness due to idle time during preparatory processes like cell replacement, alignment, and electric field application, which wastes the light exposure system's capacity.
Innovation Solution
A light exposure system with a transmission device and two moving stages that carry assembly cells, allowing the light source module to emit light to the cells while moving, thereby reducing idle time and enhancing the system's utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single cell stage is used for light exposure operation, then the light exposure system is simple in structure, but the tact time is wasted on non-exposure time such as panel exchange, cell alignment, or electric field application
Solution Approach 1:
The system divides the cell processing into multiple stages: one stage undergoes light exposure while another stage simultaneously undergoes preparatory operations (panel exchange, alignment, electric field application). This segmentation allows parallel processing and eliminates idle time in the light exposure system.
Solution Approach 2:
The light exposure system maintains continuous operation by having multiple stages working in parallel. While one stage is exposed to light, another stage prepares the next cell, ensuring the light exposure system never remains idle and tact time is minimized.
2Productivity
If multiple light exposure systems are established to increase production capacity, then the production capacity increases, but the manufacturing cost increases and competitiveness decreases
Solution Approach 1:
The patent combines multiple cell processing functions into a single light exposure system by implementing multi-stage parallel processing. This allows one system to handle multiple cells simultaneously through different operational stages, achieving increased production capacity without requiring multiple separate light exposure systems.
Solution Approach 2:
The system dynamically assigns different operational states to different stages: one stage is in light exposure mode while another is in preparatory mode. This dynamic allocation allows a single system to effectively manage multiple cells at different processing stages, increasing productivity without additional equipment investment.
3Reliability
If the light exposure system waits for preparatory processes to complete, then the cell alignment and electric field application are ensured, but the light exposure system is not used effectively and adequately
Solution Approach 1:
The preparatory processes (panel exchange, alignment, electric field application) are performed in advance on one stage while light exposure is simultaneously performed on another stage. This preliminary action ensures that when a cell reaches the light exposure stage, it is already prepared, eliminating waiting time and maximizing system utilization.
Solution Approach 2:
The system adds a temporal dimension to the processing by implementing overlapping operation cycles. While one cell undergoes light exposure (first dimension), another cell undergoes preparatory processes (second dimension), effectively utilizing the light exposure system across different time dimensions and maximizing its productivity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces the tact time of the light exposure process, lowers manufacturing costs, and improves product competitiveness by ensuring continuous use of the light exposure system, while also minimizing issues with uneven illumination.
Implementation Method 1
the photosensitive monomer within the LC molecules is photo-cured
Data Source
AI summary
A light exposure system executing a light exposure process to a plurality of assembly cells, each of which includes a first substrate, a second substrate and a liquid crystal layer disposed between the first and second substrates, comprises: a transmission device; two moving stages disposed on the transmission device and carrying the assembly cells; and a light source module including at least a light emitting element, wherein the transmission device moves at least one of the moving stages carrying the assembly cell or the light source module, and the light emitting element emits the light to the assembly cell, wherein the assembly cells include a first assembly cell and a second assembly cell, the moving stages carry the first assembly cell and the second assembly cell, respectively, wherein when the light exposure process is executed to the first assembly cell, the second assembly cell receives the work of cell replacement and alignment, electrode contact and application of electric field, wherein when the light exposure process is executed to the second assembly cell, the first assembly cell receives the work of cell replacement and alignment, electrode contact and application of electric field. A light exposure process applied to the light exposure system is also disclosed.