Liquid Crystal Display Panel Size Conversion via Cutting and Refilling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing manufacturing processes for liquid crystal display panels are labor-intensive, time-consuming, and costly when producing panels with uncommon display sizes, as they require redesigning masks and redeveloping processes for new product lines.
Innovation Solution
A method for manufacturing liquid crystal display panels that involves providing a first panel with a specific size, cutting it to adjust the display area using a squeezing device and cutting tool to avoid liquid crystal leakage, followed by squeezing out gas, compensating for liquid crystal loss, and sealing to achieve a new display size, allowing for efficient conversion of display sizes without extensive retooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a mask is redesigned and manufacturing process is re-developed for new product line to produce uncommon display sizes, then the display size adaptability is improved, but the manufacturing complexity and production cost increase
Solution Approach 1:
The display panel manufacturing process is segmented into two independent stages: first, manufacturing a large-size panel with complete liquid crystal filling; second, cutting the panel to the required smaller size and refilling liquid crystal. This segmentation allows the same manufacturing line to produce different display sizes without complete process redesign, reducing manufacturing complexity while maintaining adaptability.
Solution Approach 2:
The patent performs preliminary action by manufacturing a large-size display panel that exceeds the final required size, filling it with liquid crystal in advance, and then cutting it to the exact dimensions needed. This preliminary over-production approach eliminates the need for separate mask redesign and process development for each display size, reducing both manufacturing complexity and production cost.
2Manufacturing precision
If cutting is performed to adjust display area, then the display size precision is improved, but liquid crystal leakage may occur
Solution Approach 1:
The patent performs the cutting operation before the liquid crystal refilling step. By cutting the panel to the exact final dimensions before adding liquid crystal, the display area precision is ensured without the risk of liquid crystal leakage during cutting, as the liquid crystal is contained within the larger panel structure during the cutting process.
3Adaptability or versatility
If manual operations are used for cutting and liquid crystal refilling, then the manufacturing flexibility is improved, but the production time and labor cost increase
Solution Approach 1:
The patent develops a universal manufacturing process that can handle multiple display sizes using the same equipment and procedures. The cutting device and liquid crystal refilling system are designed to be multi-functional, accommodating different panel sizes and configurations. This universality maintains manufacturing flexibility while enabling automated high-volume production, thereby improving productivity without sacrificing adaptability.
Data Source
AI summary
A method for fast and convenient manufacture of liquid crystal display panels of different and uncommon sizes without retooling provides a first liquid crystal display panel having a first display area of a large first size. The color filter substrate is cut to make the first liquid crystal display panel into a vacuum-broken state. A sealant is coated onto the array substrate, wherein the sealant seals the liquid crystal layer and extends to a side of the color filter substrate away from the array substrate to cover part of the first display area, thereby obtaining a second liquid crystal display panel with a second display area of a second size.