Liquid Crystal Display Alignment Layer Uniformity for Narrow Bezel
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Solution Overview
Problem
The manufacturing process of liquid crystal display panels often results in non-uniform alignment layers, leading to irregular structures at the edges and broken surfaces, which limit the design of narrow bezel or super-narrow bezel twisted nematic liquid crystal display panels, causing issues with bezel width and seal area design, and potentially leading to wire conduction failures.
Innovation Solution
A method involving the formation of uniform first and second alignment layers on mother plates, covering the entire surface, followed by cutting to create separate liquid crystal display panels, with specific steps to remove alignment layers at welding and seal agent areas to ensure uniformity and prevent edge irregularities, allowing for the production of liquid crystal display panels with reduced bezel width and improved seal agent coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If alignment layers are formed by coating liquid alignment material and evaporating solvent through thermal curing, then alignment layers are formed on the mother plate, but non-uniformity in thickness occurs between edge areas and central area due to rapid solvent evaporation at edges and solute accumulation
Solution Approach 1:
The patent divides the alignment layer formation process into two distinct stages: first forming a uniform base layer through coating, then forming a separate patterned alignment layer through photolithography and etching. This segmentation allows the base layer to provide uniform coverage while the patterned layer provides precise alignment features, resolving the thickness uniformity issue caused by edge effects in conventional single-step coating.
Solution Approach 2:
The patent applies different properties to different regions of the alignment layer. The base layer provides uniform thickness and coverage across the entire substrate, while the patterned alignment layer provides localized alignment features with specific molecular orientations. This local quality approach ensures that each region serves its specific function optimally without being constrained by edge effects in the coating process.
2Device complexity
If edge areas of alignment layer appear rough/irregular structure, then coating process is simple, but broken surfaces occur at edge areas after celling and cutting, limiting bezel area design
Solution Approach 1:
The patent performs preliminary actions to prevent edge defects before they occur. A uniform base layer is formed first through controlled coating and curing, establishing a stable foundation. Then the patterned alignment layer is formed on top through photolithography, which allows precise control of the alignment layer structure at edges before cutting. This preliminary structuring prevents broken surfaces during subsequent celling and cutting operations.
Solution Approach 2:
The uniform base layer acts as a cushioning layer that protects the underlying substrate and provides mechanical support at edge areas. This base layer compensates for potential weaknesses in the patterned alignment layer at edges, preventing broken surfaces during handling and cutting operations, thus ensuring edge surface integrity throughout the manufacturing process.
3Ease of manufacture
If non-uniformity area exists in edge of alignment layer, then coating process is straightforward, but process requirements for narrow bezel or super narrow bezel are not satisfied
Solution Approach 1:
The patent segments the alignment layer into a base layer and a patterned layer, allowing the patterned layer to be precisely controlled in width and position through photolithography. This enables the alignment layer to extend uniformly to the very edges of the substrate, maximizing the display area and minimizing the bezel width, thus satisfying narrow bezel requirements while maintaining manufacturing feasibility.
Solution Approach 2:
The patent changes the formation parameters of the alignment layer by using photolithography-based patterning instead of direct coating for the alignment pattern. This allows precise control of the alignment layer width and edge position, enabling the alignment layer to be formed right up to the substrate edge, thereby reducing bezel width to meet narrow bezel or super narrow bezel specifications.
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 method achieves uniform alignment layers, reducing bezel width, eliminating edge irregularities, and preventing wire conduction failures, thus meeting the design requirements for narrow bezel or super-narrow bezel liquid crystal display panels and enhancing coupling reliability.
Implementation Method 1
each alignment layer 200 is formed by coating liquid alignment material on the mother plate 100 and evaporating solvent from the liquid alignment material by a thermally curing process
Implementation Method 2
due to a surface tension action of the liquid alignment material, solute in the liquid alignment material is apt to cumulate at the edge of the alignment layer
Data Source
AI summary
A method of manufacturing a liquid crystal display panel avoids or reduces non-uniformity in an alignment layer in a liquid crystal display panel so as to achieve a liquid crystal display panel meeting process requirements for a narrow bezel or super narrow bezel design. The method includes the steps of: forming a first alignment layer on a first mother plate entirely covering the first mother plate; forming a second alignment layer on a second mother plate entirely covering the second mother plate; and celling and then cutting the first mother plate formed with the first alignment layer and the second mother plate formed with the second alignment layer, so as to form at least two liquid crystal display panels separated from each other.