Mother Substrate Layout for LCD Panel Arrangement Efficiency
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Solution Overview
Problem
The existing methods for manufacturing liquid crystal display (LCD) devices face inefficiencies in substrate utilization, particularly in arranging multiple LCD panels on a mother substrate, which limits the size and efficiency of the substrate, especially as panel sizes increase.
Innovation Solution
A layout and size optimization for the mother substrate that includes a dummy region of 15 mm or less and specific margin percentages for each LCD panel, allowing for efficient arrangement of multiple panels, such as six or eight 26-inch models, to maximize substrate efficiency, with equations defining the optimal substrate size based on panel size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple LCD panels are arranged on a mother substrate using conventional methods, then the substrate can be manufactured, but the substrate efficiency is low and manufacturing costs increase
Solution Approach 1:
The invention divides the mother substrate into multiple LCD panel regions with optimized dimensions. By segmenting the substrate into specific configurations (e.g., 2×2, 2×3, or 3×3 arrangements), each panel is precisely positioned to maximize space utilization. The dummy region is segmented and minimized to 15mm or less, allowing more effective use of the substrate area while maintaining manufacturing feasibility.
Solution Approach 2:
The invention changes the dimensional parameters of the mother substrate and LCD panels to achieve optimal packing. Specific equations are provided that relate the mother substrate dimensions (L1, L2) to the LCD panel dimensions (l1, l2) and the number of panels (m, n). By adjusting these parameters according to the formulas, substrate efficiency reaches 90% or more, significantly reducing material waste.
2Productivity
If the dummy region size is reduced to maximize substrate efficiency, then more panels can be arranged, but manufacturing precision requirements increase
Solution Approach 1:
Instead of minimizing the dummy region to the absolute theoretical limit, the invention sets it at 15mm or less, which is a practical value that provides sufficient buffer for manufacturing variations. This partial action approach ensures that the dummy region is small enough to maintain high substrate efficiency while large enough to accommodate normal manufacturing tolerances and process variations.
3Area of moving object
If larger LCD panels are manufactured, then product size increases, but substrate efficiency decreases due to arrangement limitations
Solution Approach 1:
The invention provides dynamic layout solutions that adapt to different LCD panel sizes. The equations and methods allow flexible adjustment of the mother substrate dimensions and panel arrangements based on the specific size requirements. Whether producing 26-inch, 32-inch, or other sizes, the system dynamically optimizes the arrangement configuration to maintain high substrate efficiency.
Solution Approach 2:
The invention creates a universal methodology that can handle various LCD panel sizes and configurations. The same basic principles and equations apply regardless of the specific panel dimensions, making the solution broadly applicable. The method supports different arrangement patterns (2×2, 2×3, 3×3, etc.) and can be adapted to various product requirements.
Data Source
AI summary
A layout of LCD panels and a size of the mother substrate are disclosed, to improve the efficiency in arrangement of the LCD panels, and to maximize the substrate efficiency, the layout comprising a mother substrate; a dummy region of 15 mm or less in a periphery of the mother substrate; and six LCD panels of the 26-inch model in a matrix of 2×3 on the mother substrate excluding the dummy region with a margin corresponding to 2 ˜4% of a length of the LCD panel.