Liquid Crystal Display Manufacturing Alignment Process
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Solution Overview
Problem
The existing methods for manufacturing liquid crystal displays face challenges in achieving sufficient light penetration to the liquid crystal layer for initial alignment, leading to decreased response speed and uniformity, particularly due to the time-consuming and equipment-intensive process of applying voltage and ultraviolet irradiation to each cut cell.
Innovation Solution
The method ensures that light, such as ultraviolet rays, effectively reaches the liquid crystal layer by optimizing the alignment of the lower and upper substrates during the manufacturing process, allowing for efficient curing of alignment supporting agents and pretilt angle formation across multiple directions, thereby improving response speed and alignment uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If voltage is applied to each cut cell and ultraviolet ray is irradiated separately, then alignment precision is improved, but productivity is degraded
Solution Approach 1:
The patent combines multiple cut cells into a single mother substrate, allowing voltage application and ultraviolet irradiation to be performed simultaneously across all cells rather than individually. This merging approach maintains alignment precision while significantly improving productivity by reducing the number of separate processing steps.
Solution Approach 2:
The patent applies voltage and irradiates ultraviolet rays to the entire mother substrate before cutting into individual cells. This preliminary action ensures that alignment is established in advance, and the same alignment conditions are maintained across all subsequent cells, eliminating the need for repeated alignment operations on each cut cell.
2Speed
If ultraviolet ray is irradiated during alignment process, then alignment speed is improved, but light penetration becomes insufficient
Solution Approach 1:
The patent introduces a transparent substrate as a new dimensional element that allows ultraviolet light to penetrate through it and reach the liquid crystal layer effectively. This transparent substrate acts as a window for light transmission, solving the light penetration problem while maintaining the speed benefits of ultraviolet irradiation during the alignment process.
3Speed
If alignment supporting material is added to liquid crystal, then response speed is improved, but manufacturing complexity increases
Solution Approach 1:
The patent combines the liquid crystal and alignment supporting material into a single integrated composition. This merging eliminates the need for separate application steps for the alignment material, reducing manufacturing complexity while maintaining the response speed improvements provided by the alignment supporting material.
Solution Approach 2:
The liquid crystal composition is designed to serve multiple functions simultaneously: it provides both the liquid crystal properties for display operation and the alignment supporting properties for initial orientation. This multi-functionality eliminates the need for separate alignment material layers, simplifying the manufacturing process while maintaining response speed performance.
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 significantly enhances the response speed of the liquid crystal display by ensuring thorough alignment and curing, simplifying the manufacturing process while maintaining high uniformity and image quality.
Implementation Method 1
The alignment supporting material cured by heat or light, such as ultraviolet ray, such that the liquid crystal may have the pretilt angle in a specific direction
Implementation Method 2
The liquid crystal display generates an electric field in a liquid crystal layer by applying a voltage to the electric field generating electrode, determines a direction of liquid crystal molecules of the liquid crystal layer through the generated electric field
Data Source
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AI summary
A method of manufacturing a liquid crystal display includes: preparing a lower mother substrate (1), where lower cells, each including a thin film transistor, are provided on the lower mother substrate, and a lower alignment layer (11) is disposed on the lower cells; preparing an upper mother substrate (2), where upper cells corresponding to the lower cells are provided on the upper mother substrate, and an upper alignment layer (21) is disposed on the upper cells; providing a mother substrate assembly by providing a liquid crystal mixture layer (3) between the lower and upper mother substrates (1, 2) and combining the lower and upper mother substrates; providing a pretilt of the liquid crystals (31) by applying a voltage to a voltage application unit of the lower mother substrate; and curing an alignment supporting agents in the liquid crystal mixture layer or the lower and upper alignment layers by irradiating light to a side of the mother substrate assembly.