Electromagnetic Adsorption Bar for TFT-LCD Substrate Flatness
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Solution Overview
Problem
In the manufacturing of thin film transistor-liquid crystal displays (TFT-LCDs), the vacuum aligning process faces challenges in maintaining the flatness and precision of substrates due to bending deformations and length differences among adsorption bars, leading to reduced production efficiency and increased defective products.
Innovation Solution
The introduction of an electromagnetic adsorption bar with a coil and movable magnet component, where current is applied to generate a magnetic field, allowing the magnet to slide and adjust its position, and a control method using pressure sensors to ensure uniform adsorption forces across adsorption bars, maintaining consistent lengths and improving flatness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional adsorption bars are used for substrate adsorption, then the structure is simple and easy to manufacture, but the adsorption bars exhibit bending deformations and length differences leading to poor flatness and alignment precision
Solution Approach 1:
The patent replaces the traditional mechanical screw-adjustment system with an electromagnetic control system. Coils are wound around the adsorption bar, and by applying current to these coils, magnetic fields are generated that can precisely control the position and flatness of the adsorption bar without mechanical contact, thereby improving alignment precision while avoiding the complexity of mechanical adjustment mechanisms.
Solution Approach 2:
The patent changes the physical state or parameters of the adsorption bar by introducing electromagnetic fields. By controlling the current applied to the coils, the magnetic field strength is adjusted, which in turn controls the position and flatness of the adsorption bar, enabling precise adjustment of alignment parameters without mechanical intervention.
2Productivity
If manual adjustment of adsorption bar lengths is performed, then the device structure remains simple, but the time consumption increases and production efficiency decreases
Solution Approach 1:
The adsorption bar system performs self-adjustment through electromagnetic control. The control system automatically detects position deviations and adjusts the adsorption bar lengths by controlling the electromagnetic coils, eliminating the need for manual intervention and significantly reducing adjustment time, thereby improving production efficiency.
Solution Approach 2:
The patent incorporates a feedback mechanism where the system detects the actual position and flatness of adsorption bars and automatically adjusts the electromagnetic coil currents to correct any deviations. This closed-loop control eliminates manual measurement and adjustment time, enabling rapid positioning and improving overall productivity.
3Manufacturing precision
If uniform adsorption forces are not maintained across adsorption bars, then the control system remains simple, but substrate flatness deteriorates and defective products increase
Solution Approach 1:
The control system continuously monitors the position and flatness of each adsorption bar and adjusts the current applied to individual coils to maintain uniform adsorption forces. This feedback control ensures that all adsorption bars exert equal force on the substrate, maintaining flatness and reducing defects, while the automated nature of the control minimizes the perceived complexity for the operator.
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 solution enhances the precision and consistency of substrate alignment, reducing defective products and improving production efficiency by maintaining uniform adsorption forces and flatness across the substrates.
Implementation Method 1
Current is applied to the coil to generate a magnetic field, and the magnet longitudinally slides along the slide bar under a repulsive force of the magnetic field
Implementation Method 2
The movable part includes an elastic element and a magnet. One end of the elastic element is a fixed end, and the other end thereof is a free end. The fixed end is fixedly connected to the slide bar, and the free end is connected to the magnet
Implementation Method 3
In the industry of manufacturing thin film transistor-liquid crystal displays (TFT-LCDs), vacuum aligning process refers to a technology in which in a closed vacuum environment, a color filter substrate and an array substrate are respectively adsorbed by an upper base platform and a lower base platform
Data Source
AI summary
The present disclosure provides an adsorption bar, a vacuum aligner system, and a control method of the vacuum aligner system. The adsorption bar includes an electromagnetic component and an adsorption member. The electromagnetic component includes a slide bar, a coil and a movable part. The coil is fixedly arranged on the slide bar. The movable part includes an elastic element and a magnet. One end of the elastic element is a fixed end which is fixedly connected to the slide bar, and the other end thereof is a free end which is connected to the magnet. The adsorption member is fixedly connected to the magnet and is exposed at one end, of the magnet, away from the coil. Current is applied to the coil to generate a magnetic field. The magnet longitudinally slides along the slide bar under a repulsive force of the magnetic field.