Gas Injection Bubble Removal for LCD Polarizing Plates
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Solution Overview
Problem
Conventional methods for removing bubbles between substrates and polarizing plates in LCD manufacturing are time-consuming, unsuitable for large panels, and hinder automation due to the use of chamber-based systems, which pose safety concerns and are inefficient for treating large sizes.
Innovation Solution
A method and apparatus that inject preheated compressed gas through nozzles positioned opposite each other, applying pressure to the liquid crystal panel to dislodge bubbles without the need for a chamber, using a gas injecting part that can be exposed to atmospheric conditions, with adjustable temperature and pressure to optimize bubble removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a chamber-based system is used to remove bubbles by increasing temperature and pressure, then bubbles can be removed from the liquid crystal panel, but the process becomes time-consuming and the system becomes unsuitable for large panels
Solution Approach 1:
The patent extracts the bubble removal function from the enclosed chamber system and implements it through direct gas injection nozzles that contact the panel surface. The nozzles inject gas directly at the attachment sites between substrates and polarizing plates, eliminating the need for chamber-based temperature and pressure cycling while achieving effective bubble removal in a much shorter time
Solution Approach 2:
The patent uses pneumatic injection through nozzles to deliver gas directly to the bubble formation sites. The gas injection creates localized pressure to dislodge bubbles from the attachment interfaces, providing a fast and efficient alternative to the thermal and pressure cycling of chamber systems
2Reliability
If a chamber-based system is used to remove bubbles, then bubbles can be removed from the liquid crystal panel, but the system becomes unsuitable for large panels and automation becomes difficult
Solution Approach 1:
The patent segments the bubble removal process into multiple localized injection points distributed across the panel surface. Multiple nozzles can be positioned at different locations to handle panels of various sizes, making the system adaptable and scalable from small to large panels without requiring a chamber structure
Solution Approach 2:
The patent replaces the mechanical chamber structure with a streamlined gas injection system using nozzles. This substitution eliminates the size constraints of chamber systems and enables easy adaptation to different panel dimensions, while also facilitating automation through precise nozzle positioning and control
3Reliability
If a chamber-based system is used to remove bubbles, then bubbles can be removed from the liquid crystal panel, but the system complexity increases and safety concerns arise
Solution Approach 1:
The patent extracts the essential bubble removal function from the complex chamber system and implements it through simple gas injection nozzles. This extraction eliminates unnecessary chamber components, pressure cycling mechanisms, and thermal control systems, resulting in a much simpler and safer device that maintains effective bubble removal capability
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 allows for efficient bubble removal without the time constraints of temperature and pressure cycling, is scalable for larger panels, and facilitates automation by eliminating the need for a chamber, ensuring safer and more efficient LCD manufacturing processes.
Implementation Method 1
applying a pressure to the plate surface of the liquid crystal panel by injecting gas through the gas injecting part
Implementation Method 2
the injected gas is preheated
Data Source
AI summary
A method of manufacturing an LCD comprising, preparing a liquid crystal panel which comprises a substrate assembly and a polarizing plate, wherein the polarizing plate is attached to the substrate assembly, disposing a gas injecting part towards the plate surface of the liquid crystal panel, while the gas injecting part is exposed to atmospheric conditions, and applying a pressure to the plate surface of the liquid crystal panel by injecting gas through the gas injecting part. With this configuration, the present invention provides a method to remove bubbles between the polarizing plate and liquid crystal panel without the use of a chamber.