Liquid Crystal Display Enclosing Resin Frame with Entry Opening
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Solution Overview
Problem
The manufacturing of liquid crystal display devices faces challenges with the vacuum filling process, which becomes time-consuming as the device size increases, and the distribution method struggles with controlling the liquid crystal amount, leading to thermal deformations and inhomogeneous display issues due to excess liquid crystal.
Innovation Solution
A method involving a recoverable enclosing resin frame with a curvable entry opening is formed between the TFT and CF substrates, allowing for adjustable liquid crystal filling, where excess liquid crystal can be removed using a laser and re-sealed with additional sealant resin to prevent deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the vacuum filling process is used to fill liquid crystal between TFT substrate and CF substrate, then the liquid crystal can be filled through the entry opening of the enclosing resin frame, but the process takes more and more time to complete as the size of the liquid crystal display device increases
Solution Approach 1:
The patent applies preliminary action by pre-forming the enclosing resin frame with an entry opening before liquid crystal filling. This allows liquid crystal to be introduced through the pre-prepared opening, eliminating the need for time-consuming vacuum processes and enabling direct filling, thereby significantly reducing manufacturing cycle time while ensuring complete filling.
Solution Approach 2:
The patent extracts the entry opening from the enclosing resin frame structure, creating a dedicated opening that separates the filling function from the sealing function. This extracted opening allows liquid crystal to be introduced without requiring the entire enclosing structure to be opened or subjected to vacuum, thus reducing processing time while maintaining filling effectiveness.
2Quantity of substance
If the distribution method is used to fill liquid crystal, then the liquid crystal can be filled inside the enclosing resin frame, but it is difficult to control the amount of liquid crystal filled, causing thermal expansion deformation of substrates and inhomogeneous display color
Solution Approach 1:
The patent applies feedback by implementing a controlled filling process through the entry opening where liquid crystal is introduced in a regulated manner. The entry opening serves as a controlled interface that allows monitoring and adjustment of the filling process, enabling precise control of liquid crystal amount and preventing overfilling that would cause substrate deformation and display defects.
Solution Approach 2:
The patent applies parameter changes by modifying the enclosing resin frame structure to include an entry opening with specific dimensions and positioning. This structural parameter change enables controlled liquid crystal introduction, transforming the filling process from an uncontrolled distribution method to a precisely controlled injection method, thereby achieving accurate liquid crystal quantity control and preventing substrate deformation.
3Ease of manufacture
If an enclosing resin frame with entry opening is formed, then liquid crystal can be filled through the opening, but the entry opening must be sealed after filling to prevent liquid crystal leakage
Solution Approach 1:
The patent applies merging by combining the enclosing resin frame formation and entry opening creation into a single integrated process step. The entry opening is formed as an integral part of the enclosing resin frame structure, eliminating the need for separate opening creation and sealing operations. This merged approach simplifies the overall manufacturing process while maintaining both filling accessibility and leakage prevention.
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 method enables precise control over liquid crystal quantity, preventing thermal deformations and reducing re-working costs by allowing easy adjustment and correction of liquid crystal levels, ensuring consistent display quality.
Implementation Method 1
a laser is used to remove a portion of the sealant resin at the entry opening
Data Source
AI summary
The present invention provides a method for manufacturing a liquid crystal display device and a liquid crystal display device. The method includes (1) preparing a TFT substrate and a CF substrate; (2) applying sealant resin to the TFT substrate or CF substrate to form an enclosing resin frame body that forms an entry opening on the CF substrate or the TFT substrate; (3) applying sealant resin to the entry opening of the enclosing resin frame body to form a closing section; (4) filling liquid crystal inside the enclosing resin frame body; (5) bonding the TFT substrate and the CF substrate together; and (6) subjecting the bonded TFT substrate and the CF substrate to curing at high temperature in order to cure the enclosing resin frame body.