Liquid Crystal Dispensing and Cell Gap Pressing for LCD Manufacturing
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Solution Overview
Problem
The manufacturing of liquid crystal display (LCD) devices faces challenges with gravity and touch defects due to inappropriate dispensing amounts of liquid crystal, particularly in large-sized devices, where the trade-off between these defects makes it difficult to determine the optimal dispensing amount.
Innovation Solution
A method involving the preparation of first and second substrates with liquid crystal applied on one substrate and spacers formed on the other, followed by bonding and applying pressure to adjust the cell gap to ensure the appropriate filling of liquid crystal, using column spacers slightly higher than standard to allow for precise control of the liquid crystal amount and distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large amount of liquid crystal is dispensed to ensure complete filling of the cell gap, then the risk of touch defects is reduced, but gravity defects occur due to liquid crystal flowing downward
Solution Approach 1:
The invention applies a preliminary pressing action during the bonding process to pre-distribute the liquid crystal uniformly before the device is subjected to gravitational forces during operation. This preliminary distribution prevents both touch defects (by ensuring complete filling) and gravity defects (by establishing uniform distribution that resists downward flow)
2Object-affected harmful factors
If a small amount of liquid crystal is dispensed to prevent gravity defects, then liquid crystal flow is controlled, but touch defects occur due to insufficient filling
Solution Approach 1:
The bonding pressing action serves as a preliminary distribution step that ensures complete and uniform filling of the cell gap before the device enters service. This preliminary action allows using a smaller initial dispensing amount while still achieving complete filling, thus preventing both gravity defects and touch defects
3Ease of manufacture
If the cell gap is made larger to facilitate liquid crystal dispensing, then dispensing process is simplified, but the amount of liquid crystal required increases leading to potential gravity defects
Solution Approach 1:
The invention applies pressing during bonding as a preliminary action to distribute the liquid crystal uniformly throughout the cell gap. This allows using a smaller cell gap dimension while still achieving complete and uniform filling, thus simplifying the dispensing process without increasing the risk of gravity defects
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 effectively prevents gravity and touch defects by ensuring uniform cell gap filling, improving picture quality and reducing manufacturing time by allowing for precise control of liquid crystal distribution.
Implementation Method 1
Pressure is applied to the first or second substrates so as to change the cell gap to a second height smaller than the first height
Data Source
AI summary
A method for manufacturing an LCD device includes preparing first and second substrates and dispensing liquid crystal on the first substrate. A plurality of column spacers are formed on the second substrate, and a seal pattern is formed on the second substrate. The second substrate is inversed and the first and second substrates are bonded to each other to form an LCD panel having a first height (h1) corresponding to a cell gap between the first and second substrates. Pressure is applied to the rear surfaces of the first or second substrates so as to change the cell gap to a second height (h2) smaller than the first height (h2<h1).