Multi-Stage Roll Storer for LCD Rubbing Process Space Optimization
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Solution Overview
Problem
The existing methods for manufacturing liquid crystal display (LCD) devices face challenges in managing and storing a sufficient number of rubbing rolls, which are essential for maintaining process stability and uniformity, especially as the size of mother substrates increases, leading to limitations in clean room space and operational efficiency.
Innovation Solution
A two-stage roll stocker system is introduced, featuring upper and lower stages with roll keeping units and a moving unit to manage and replace rubbing rolls, ensuring a sufficient supply of rolls for various models and maintaining operational stability, along with a method for fabricating LCD devices that includes forming alignment films and performing rubbing processes efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the size of mother substrates is increased to improve productivity, then the number of LCD devices that can be produced increases, but the clean room space required increases, limiting the storage of sufficient rubbing rolls
Solution Approach 1:
The patent transitions from horizontal storage arrangement to vertical multi-stage storage arrangement. The roll stocker includes an upper stage and a lower stage, allowing rubbing rolls to be stored in multiple vertical layers. This dimensional change enables sufficient storage capacity within the limited clean room space while supporting increased productivity from larger mother substrates
2Reliability
If the number of rubbing rolls is increased to maintain process stability and uniformity, then the reliability of the rubbing process improves, but the storage space requirement increases, reducing clean room availability
Solution Approach 1:
The patent implements vertical multi-stage storage with upper and lower stages, transforming the storage configuration from single-level horizontal arrangement to multi-level vertical arrangement. This enables storing multiple rubbing rolls for process reliability while minimizing the floor space occupation in the clean room environment
3Productivity
If a sufficient number of rubbing rolls are stored to secure operational margin, then the continuity of production is improved, but the clean room space is consumed, limiting flexibility for other operations
Solution Approach 1:
The patent employs vertical multi-stage storage configuration with upper and lower stages to store multiple rubbing rolls. This dimensional transformation allows maintaining production continuity through adequate roll inventory while preserving clean room floor space for other essential operations and movements
Solution Approach 2:
The roll stocker includes a moving unit that can horizontally transfer roll keeping units between different positions. This dynamic capability enables flexible access to rubbing rolls on different stages and allows the system to adapt to varying production needs while maintaining compact vertical storage
Data Source
AI summary
A roll stocker and a method for fabricating a liquid crystal display device using the same are disclosed. The roll stocker is constructed by multi-stage, of which roll keeping units of an upper stage can be moved left and right so that a rubbing roll at the lower stage can be easily taken out. Thus, space utilization can be enhanced and rolls can be stably kept. The roll stocker formed by two stages includes an upper stage installed at an upper side of a lower stage used as a support; a plurality of roll keeping units positioned at the upper and lower stages and keeping rubbing rolls; and a moving unit installed between the upper and lower stages and moving the roll keeping units of the upper stage.