Ultrathin Glass LCD Cutting Stability via Support Patterns

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Solution Overview

Problem

The manufacturing of liquid crystal display devices using ultrathin glass substrates faces challenges such as unstable scribe line formation, distortion, and reduced yield due to the repulsive force variations and inaccuracies in cutting, leading to potential cracks and breakage during the cutting process.

Innovation Solution

The implementation of a liquid crystal display device design that includes a seal pattern between glass substrates, with columnar spacers in the display region and gap holding members along the outer circumference of the seal pattern, where the area share of gap holding members is larger than columnar spacers, allowing for stable scribe line formation and improved durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a scribe cutter is used to form a scribe line on ultrathin glass, then cutting can be performed, but the ultrathin glass is distorted largely and repulsive force becomes unstable

Engineering Contradiction:

Improvecutting processVSAvoidscribe line formation

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

A support pattern is formed on the glass substrate before the scribe line formation. This preliminary action provides structural support to the ultrathin glass during the cutting process, preventing distortion and stabilizing the scribe line formation. The support pattern is created in advance at positions that will help maintain glass stability when the scribe cutter applies load.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The support pattern acts as an intermediary structure between the scribe cutter and the ultrathin glass. It mediates the cutting process by providing mechanical support to the glass substrate, allowing the scribe cutter to form scribe lines without causing large distortions or instability in the repulsive force.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If the scribe line is formed closer to the seal pattern, then cutting can be performed, but the distance between scribe line and seal pattern varies due to seal position fluctuations

Engineering Contradiction:

Improvecutting processVSAvoiddistance control

Core Design Contradiction:

Ease of manufactureVSMeasurement precision

Solution Approach 1:

The support pattern is formed in advance at specific positions relative to the seal pattern. This preliminary positioning ensures that even when seal positions fluctuate, the scribe line can be formed at a controlled and consistent distance from the seal pattern, maintaining measurement precision throughout the cutting process.

Inventive Principle:

Principle #10Preliminary action

3Stability of the object's composition

If supporting member is placed near scribe line, then glass distortion is avoided, but the supporting member becomes obstacle to rubbing process

Engineering Contradiction:

Improveglass substrate stabilityVSAvoidrubbing process

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The support pattern is designed with specific local characteristics - it provides support only where needed near the scribe line while maintaining compatibility with the rubbing process. The pattern's local structure allows it to prevent glass distortion at critical cutting areas without interfering with the rubbing process in the display region.

Inventive Principle:

Principle #3Local quality

4Length of stationary object

If ultrathin glass is used to reduce device thickness, then display can be made thinner, but cutting damage and breakage increase during manufacturing

Engineering Contradiction:

Improveglass substrate thicknessVSAvoidcutting process reliability

Core Design Contradiction:

Length of stationary objectVSReliability

Solution Approach 1:

The support pattern is formed on the ultrathin glass substrate before the cutting process. This preliminary structural reinforcement allows the extremely thin glass (0.01 to 0.15 mm) to withstand the cutting process without suffering damage or breakage, thereby maintaining high reliability during manufacturing while preserving the ultra-thin characteristic.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The support pattern provides beforehand cushioning to the ultrathin glass during cutting. By establishing this support structure in advance, the glass is cushioned against the mechanical stresses of cutting, preventing cracks and breakages that would otherwise occur in such thin substrates.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS8873017B2Liquid crystal display device and method of manufacturing the same

Publication Date: 2014.10.28 TRIVALE TECHNOLOGIES LLC

AI summary

A liquid crystal display device includes: first and second glass substrates; a seal pattern placed between the first and second glass substrates to bond the first and second glass substrates together, the seal pattern sealing a liquid crystal material in between the first and second glass substrates and holding the liquid crystal material in a liquid crystal layer; a plurality of columnar spacers placed between the first and second glass substrates in a display region surrounded by the seal pattern and corresponding to a display surface appearing when the liquid crystal display device is in operation, the columnar spacers holding a distance between the first and second glass substrates; and a plurality of gap holding members. The area share of the gap holding members indicating the ratio of a sectional area per unit area is larger than the area share of the columnar spacers.