Laser Cutting LCD Substrates to Eliminate Particle Contamination
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Solution Overview
Problem
Conventional liquid crystal display (LCD) manufacturing processes are inefficient and costly due to the generation of particles, powders, and foreign matters during substrate cutting and grinding, leading to defects and increased manufacturing complexity, particularly when adhering polarizers and testing panels.
Innovation Solution
Adhering polarizers to substrates before separating LCD panels and using lasers for cutting and beveling to avoid particle generation, thereby simplifying the process and reducing equipment costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wheel cutter is used for cutting substrates, then cutting can be performed, but particles and powders are generated causing defects
Solution Approach 1:
The patent replaces the mechanical wheel cutter system with a laser cutting system. The laser beam cuts the substrate without physical contact, eliminating the generation of particles and powders that contaminate the liquid crystal panels. This substitution of mechanical cutting with optical cutting resolves the contradiction between manufacturing capability and contamination prevention.
2Manufacturing precision
If grinding wheel is used for grinding and beveling TFT substrate, then sharp edges are avoided, but many particles and powders are generated
Solution Approach 1:
The patent replaces the mechanical grinding wheel with a laser processing system for grinding and beveling operations. The laser ablates the glass material precisely without mechanical contact, achieving smooth edges and rounded corners while eliminating the generation of grinding particles and powders that would otherwise contaminate the panel interior.
3Ease of operation
If polarizers are adhered after panel separation, then each panel can be processed individually, but time and complexity increase
Solution Approach 1:
The patent performs the polarizer adherence operation before the liquid crystal panels are separated into individual units. By adhering polarizers to the stacked panels in advance, the manufacturing process eliminates the need to handle and process each panel individually later, significantly reducing the time and operational complexity of polarizer application while maintaining proper alignment through the stack.
4Object-affected harmful factors
If conventional cleaning process is used after grinding, then particles can be removed, but manufacturing complexity and cost increase
Solution Approach 1:
The patent replaces the mechanical cleaning system (grinding wheel followed by cleaning equipment) with a laser processing system. Since the laser does not generate particles during grinding and beveling operations, the subsequent cleaning step becomes unnecessary. This eliminates the need for complex cleaning equipment and associated manufacturing complexity while still achieving particle-free panels.
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 time and complexity of polarizer adherence and testing, increases yield, and prevents defects caused by particle adherence, resulting in a more efficient and economic manufacturing process for LCDs.
Implementation Method 1
cutting the first substrate and the second substrate by using lasers
Implementation Method 2
ground and beveled by using a grinding wheel
Data Source
AI summary
In a method of manufacturing a liquid crystal display, first, a panel assembly structure including a first substrate, a second substrate and several sealants connecting inner surfaces of the first and second substrate is provided. The first substrate includes several third substrates. The second substrate includes several fourth substrates corresponding to the third substrates, respectively. Each third substrate, the corresponding fourth substrate and the corresponding sealant form a panel. First and second polarizers are adhered correspondingly to outer surfaces of the third and fourth substrates. The panels are separated after the adherence of the first and second polarizers.