Liquid Crystal Display Alignment Layer Sealant Separation
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Solution Overview
Problem
In liquid crystal displays, the non-uniformity of the alignment layer and the potential contact between the sealant and alignment layer lead to display defects, and the existing manufacturing methods are time-consuming due to the extensive patterning process required for the alignment layer.
Innovation Solution
A liquid crystal display design featuring a lower panel with a first alignment layer and an upper panel, where specific removed regions are patterned using a laser beam to prevent contact with the sealant, and a manufacturing method that includes coating and patterning the alignment layers using a laser to reduce the patterning process time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the alignment layer is coated with a large margin to ensure uniformity and prevent contact with the sealant, then the alignment uniformity is improved, but the width of the non-display area is increased
Solution Approach 1:
The alignment layer is segmented into different regions: a first alignment layer in the display area and a second alignment layer in the peripheral area, with a removed region separating them. This segmentation allows each region to have optimized characteristics - the first alignment layer ensures display uniformity while the second alignment layer prevents sealant contact, eliminating the need for excessive margin.
Solution Approach 2:
A specific region of the alignment layer is removed (the removed region) to create a separation between the first and second alignment layers. This extraction eliminates the harmful contact between the sealant and alignment layer while maintaining the necessary margin for sealant placement, thereby reducing the non-display area width.
2Area of stationary object
If the alignment layer is coated close to the sealant to reduce non-display area, then the non-display area width is reduced, but the sealant may contact the alignment layer causing display defects
Solution Approach 1:
The alignment layer is divided into distinct segments with a gap. The second alignment layer is positioned in the peripheral area but separated from the first alignment layer by the removed region, allowing the sealant to be placed in the gap without contacting the alignment layer, thus preventing display defects.
Solution Approach 2:
The removed region acts as an intermediary space between the first and second alignment layers, allowing the sealant to be positioned without直接接触 the alignment layer. This intermediary gap prevents the harmful contact that would cause display defects while maintaining compact design.
3Manufacturing precision
If extensive patterning process is used to create removed regions, then the alignment layer uniformity and sealant separation are improved, but the manufacturing time is increased
Solution Approach 1:
The mechanical patterning process is replaced with laser beam irradiation. The laser selectively removes portions of the alignment layer through photodecomposition, achieving precise patterning of the removed regions without the time-consuming mechanical steps of coating, drying, and etching multiple layers.
Solution Approach 2:
The alignment layer material is selected with specific photodecomposition characteristics that allow selective removal by laser beam. By changing the material parameters to be laser-responsive, the patterning process is simplified and accelerated, reducing manufacturing time while maintaining precision.
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 enhances the uniformity of the alignment layer, prevents defects by avoiding contact with the sealant, and significantly reduces the manufacturing time by minimizing the laser irradiation area and energy used in patterning.
Implementation Method 1
specific removed regions are patterned using a laser beam to prevent contact with the sealant
Implementation Method 2
The alignment layer may include a coated region positioned between a first removed region overlapping the end portion of the signal line and a second removed region overlapping the sealant
Data Source
AI summary
Embodiments relate to a liquid crystal display and a manufacturing method thereof, and more particularly, to a liquid crystal display including an alignment layer pattern and a manufacturing method thereof. The liquid crystal display includes a lower panel including a first alignment layer and a signal line. An upper panel faces the lower panel and uncovers an end portion of the signal line of the lower panel. A sealant is positioned between the lower panel and the upper panel and couples the lower panel and the upper panel with each other. The first alignment layer includes a first portion and a second portion that are separated from each other in a first direction, and the sealant is disposed between the first portion and the second portion and separated from the first portion and the second portion in the first direction.