Gradient Shading Mask for LCD Frame Sealant Curing
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Solution Overview
Problem
The current LCD manufacturing process using UV irradiation for frame sealant curing causes polymerization reactions in the liquid crystal layer edges, leading to disordered pre-tilt angles and affected display quality due to inadequate UV blocking by conventional masks.
Innovation Solution
A mask with a gradient shading region is introduced, featuring a transparent substrate with shading and transparent regions, where the gradient shading region has a lower irradiation transmittance than the transparent region but higher than the shading region, allowing controlled UV exposure to cure the frame sealant while minimizing irradiation to the liquid crystal layer, thereby preventing pre-polymerization reactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional mask with sharp shading regions is used for UV irradiation, then the frame sealant curing process is simplified, but UV rays diffract into the display regions causing pre-polymerization reactions in the liquid crystal layer
Solution Approach 1:
The mask employs a gradient shading region with varying optical densities instead of uniform shading. The optical density gradually transitions from the shading region (higher density) to the transparent region (lower density), creating different levels of UV attenuation across the mask surface. This local variation in shading density effectively blocks UV diffration into the display region while maintaining adequate curing in the non-display region.
Solution Approach 2:
The gradient shading region acts as an intermediary zone between the opaque shading region and the fully transparent region. This intermediate region with moderate optical density serves as a transition buffer that gradually reduces UV intensity, preventing sharp UV cutoff and diffration into the liquid crystal layer while still allowing controlled UV transmission for sealant curing.
2Strength
If UV irradiation is applied to cure the frame sealant, then the TFT substrate and CF substrate are bonded together, but monomers in the liquid crystal layer undergo pre-polymerization reactions affecting display quality
Solution Approach 1:
The gradient shading region creates spatially varying UV transmission characteristics. The optical density gradually changes from the shading region toward the transparent region, ensuring adequate UV intensity for sealant curing in non-display areas while progressively reducing UV intensity near the display region boundaries. This prevents pre-polymerization reactions that would disrupt liquid crystal alignment and pre-tilt angle uniformity.
Solution Approach 2:
The gradient shading region serves as a protective buffer zone that anticipates and mitigates UV diffration before it reaches the liquid crystal layer. By gradually attenuating UV intensity in the transition region, the mask prevents harmful UV exposure to monomers beforehand, avoiding pre-polymerization reactions that would compromise display quality and alignment precision.
3Object-affected harmful factors
If the shading regions adequately block UV rays, then pre-polymerization reactions are prevented, but the frame sealant curing efficiency is reduced
Solution Approach 1:
The mask design implements spatially differentiated UV transmission: the shading regions maintain high optical density to effectively block UV rays and prevent pre-polymerization reactions, while the gradient shading region provides gradual attenuation, and the transparent region allows sufficient UV transmission. This local optimization ensures both protection of the liquid crystal layer and efficient curing of the frame sealant.
Solution Approach 2:
The gradient shading region provides partial UV attenuation rather than complete blocking. By using a transition zone with moderate optical density, the mask allows sufficient UV intensity to reach the frame sealant for effective curing while still reducing diffration into the display region. This partial action balances protection needs with curing efficiency requirements.
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
The mask effectively prevents pre-polymerization reactions in the liquid crystal layer, ensuring consistent pre-tilt angles and improved display quality by reducing UV transmission to the liquid crystal layer, thus enhancing the manufacturing process of liquid crystal display panels.
Implementation Method 1
a gradient shading region is formed in a joining area between the shading region and the transparent region... the irradiation transmittance in the gradient shading region is smaller than the irradiation transmittance in the transparent region, but the irradiation transmittance in the gradient shading region is higher than the irradiation transmittance in the shading region
Implementation Method 2
an ultraviolet (UV) ray is used to irradiate the frame sealant 13' so that the frame sealant 13' is cured to bond the TFT substrate 10' and the CF substrate 20' together
Implementation Method 3
a pre-polymerization reaction of the monomers occurs when the monomers within the LC layer 40' are irradiated by the UV ray since the LC molecules of the LC layer 40' are blended with the monomers
Data Source
AI summary
A mask for curing frame sealant and a liquid crystal display (LCD) panel manufacturing method are provided in the present invention. A gradient shading region is formed in a joining area between a shading region and a transparent region, such that the gradient shading region is integrally formed. When the mask is utilized for exposure, the irradiation transmittance in the gradient shading region is smaller than the irradiation transmittance in the transparent region, but the irradiation transmittance in the gradient shading region is higher than the irradiation transmittance in the shading region. The pre-polymerization reaction of the irradiated monomers occurrence can be avoided in the present invention, and the pre-tilt angles in the liquid crystal layer are kept to be all the same during the alignment process.