Ink Jet Spacer Formation for Liquid Crystal Panel Gaps
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The ink jetting method for forming spacers in liquid crystal panels faces issues with positional accuracy, leading to uneven spacer distribution and display quality deterioration due to nozzle clogging and abnormal jetting, which increases production costs and reduces productivity.
Innovation Solution
The method involves jetting multiple drops of ink containing spacers onto predetermined positions using an ink jet head with multiple nozzle openings, allowing for precise placement even when some nozzles are clogged, and includes a nozzle judging system to ensure only normal nozzles are used for spacer formation, maintaining a constant gap between substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If one drop of ink is jetted onto spacer forming position, then the amount of ink is reduced, but the spacer may not be securely formed or may spread too wide
Solution Approach 1:
The ink jetting process is divided into multiple sequential drops (first drop, second drop, etc.) rather than using a single large drop. Each drop is jetted from a different nozzle or at different timing, allowing the spacer to be securely formed within a confined area while ensuring sufficient spacer material is deposited.
Solution Approach 2:
The solution transitions from a single-drop approach to a multi-drop approach, adding the dimension of time and sequence to the ink jetting process. This allows precise control over spacer formation by jetting drops at different times from different nozzles, achieving both security of formation and limited spread.
2Reliability
If nozzle cleaning operation is performed to solve abnormal jetting, then the display quality is maintained, but the productivity is reduced and running cost increases
Solution Approach 1:
The system performs preliminary detection of nozzle status before ink jetting begins. By detecting abnormal nozzles in advance and excluding them from the jetting process, the system prevents defective spacer formation without requiring interruption for cleaning operations, thereby maintaining both quality and productivity.
Solution Approach 2:
The system incorporates a detection mechanism that provides feedback on nozzle status. Based on this feedback, the control system automatically adjusts the jetting process by excluding abnormal nozzles, creating a closed-loop system that maintains quality without manual intervention or productivity loss.
3Ease of manufacture
If ink is jetted onto black matrix region, then spacer formation is simplified, but the jetting position error may invade the pixel region causing display quality deterioration
Solution Approach 1:
The system applies different strategies to different regions: ink is jetted onto the black matrix region (non-pixel region) where spacers are needed, while carefully controlling the jetting parameters and nozzle positioning to prevent ink spread into the pixel region. This local differentiation allows simplified spacer formation without compromising display quality.
4Quantity of substance
If dispersion density of spacer is increased to ensure spacer inclusion, then one drop surely includes spacer, but the fluidity varies and granular spacers aggregate together
Solution Approach 1:
Instead of using one drop with high spacer concentration that causes aggregation, the system segments the spacer deposition into multiple drops with lower individual concentrations. This ensures each drop remains fluid and jettable while collectively delivering sufficient spacer material to the target position.
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 ensures secure formation of spacers within a predetermined range, maintaining constant liquid crystal layer thickness and improving display quality while reducing production costs by avoiding nozzle cleaning operations.
Implementation Method 1
plural drops of ink are jetted on each of the spacer forming positions for maintaining a constant gap to be filled with liquid crystal, between opposite substrates, granular spacers being dispersed in the ink
Implementation Method 2
The solvent is evaporated and the spacers remain on the black matrix
Data Source
AI summary
Providing a spacer forming method by which spacers can be securely formed in a predetermined region on a substrate. Ink containing granular spacers is jetted onto a crossing portion of a black matrix 5 in the shape of a lattice. Red pixel R, green pixel G and blue pixel B are formed in the openings of the lattice. The spacer containing ink is jetted onto the spacer forming positions from the nozzle by the ink jetting method. Plural drops of ink 7 are jetted onto each of the spacer forming positions on one of the opposite substrates E. The gap between the opposite substrates E can be securely maintained at a constant for filling with liquid crystal.