LCD Automatic Bonding System Gap Control
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Solution Overview
Problem
The existing bonding methods for liquid crystal display (LCD) devices, particularly the use of adhesives like double-sided tape, result in air gaps between the touch panel and the liquid crystal panel, leading to image degradation due to optical refractive index deviations and reduced structural integrity, making the touch panel prone to damage from external forces.
Innovation Solution
An automatic bonding system that includes a bonding unit for substrates, an adhesive resin coating unit, a pre-hardening unit using UV, and a hardening unit, which controls the bonding gap and uses optical adhesive resin to ensure a high-quality, robust bond between the touch panel and the liquid crystal panel, minimizing air bubbles and maintaining image quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a double-sided tape adhesive is used to bond the touch panel to the liquid crystal panel, then the bonding process is simple and quick, but air gaps are formed between the panels causing image degradation and reduced structural intensity
Solution Approach 1:
The invention changes the bonding parameters by controlling the gap distance between the touch panel and liquid crystal panel to be 0.5mm or less, and by controlling the adhesive resin coating thickness to be 50µm or less. These parameter changes enable elimination of air gaps while maintaining efficient bonding process
Solution Approach 2:
The invention replaces the simple mechanical adhesive bonding method with an automated system that includes adhesive resin coating units, pre-hardening units, and hardening units. This substitution enables precise control of bonding parameters while maintaining productivity
2Ease of manufacture
If a double-sided tape adhesive is used to bond the touch panel to the liquid crystal panel, then the bonding process is simple, but the structural intensity is weakened making the touch panel prone to damage
Solution Approach 1:
The invention replaces simple mechanical adhesive application with an automated bonding system that includes controlled adhesive resin coating, pre-hardening, and hardening processes. This substitution maintains ease of manufacture through automation while significantly improving structural intensity by eliminating air gaps
Solution Approach 2:
The invention uses a composite bonding approach combining adhesive resin material with precise mechanical positioning and UV hardening. This composite method maintains simplicity of process while achieving superior bonding strength that prevents touch panel damage
3Manufacturing precision
If adhesive resin is used with automated bonding system, then bonding precision and image quality are improved, but the device complexity increases
Solution Approach 1:
The bonding unit is designed to perform multiple functions: adhesive resin coating, gap control, pre-hardening, and hardening. This multi-functionality reduces the need for separate devices for each bonding step, thereby reducing overall system complexity while maintaining high bonding precision
Solution Approach 2:
The invention merges the adhesive resin coating unit, pre-hardening unit, and hardening unit into an integrated automated bonding system. This merging consolidates multiple functions into a single coordinated system, reducing device complexity while achieving precise bonding gap control
4Device complexity
If manual bonding method is used, then the system structure is simple, but productivity and bonding quality consistency are reduced
Solution Approach 1:
The automated bonding system performs self-service by automatically coating adhesive resin, controlling bonding gap, pre-hardening, and hardening without manual intervention. This self-service capability significantly improves productivity while maintaining consistent bonding quality
Solution Approach 2:
The invention replaces manual bonding operations with an automated bonding system that uses mechanical arms, adhesive resin coating units, and UV hardening units. This substitution eliminates manual labor limitations, improving both productivity and bonding quality consistency
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 system enhances the quality and durability of the LCD device by eliminating air gaps, ensuring a high-quality image and improved structural integrity, while automating the bonding process to increase productivity and reliability.
Implementation Method 1
a pre-hardening unit configured to perform a process of pre-hardening an adhesive resin that adheres the first and second substrates
Implementation Method 2
a hardening unit configured to perform a process of hardening the adhesive resin that adheres the first and second substrates
Data Source
AI summary
Disclosed is an automatic bonding system for an LCD device. The automatic bonding system includes a bonding unit configured to perform a process of bonding a first substrate to a second substrate, a first substrate supply unit configured to include an inverting arm and supply the first substrate to the bonding unit, a second substrate supply unit configured to include an adhesive resin coating unit and supply the second substrate to the bonding unit, a pre-hardening unit configured to perform a process of pre-hardening an adhesive resin that adheres the first and second substrates, and a hardening unit configured to perform a process of hardening the adhesive resin that adheres the first and second substrates. A gap between the first and second substrates bonded to each other by the bonding unit is a bonding gap controlled by a gap variable control stage.