LCD Seal Line Protrusions for Substrate Yield
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Solution Overview
Problem
The existing methods for manufacturing liquid crystal display (LCD) apparatuses face challenges in maximizing production yields and reducing process time due to limitations in the design of seal lines, which affect the distance between adjacent substrates and the efficiency of the breaking process.
Innovation Solution
The proposed solution involves forming a seal line with protrusions and a dummy pattern on one side and an end seal to fill the opening, allowing for a more efficient drawing process that increases the number of products obtained from a mother substrate by creating closed loops with points of contact between adjacent substrates, enabling easier separation and liquid crystal injection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the distance between adjacent sticks is increased to facilitate the breaking process, then the ease of manufacture is improved, but the productivity decreases due to reduced yield per mother substrate
Solution Approach 1:
The seal line is divided into multiple segments including protrusions and dummy patterns. The protrusions create natural separation points that facilitate breaking while the dummy patterns maintain proper spacing. This segmentation allows the breaking process to occur at specific predetermined locations without requiring excessive distance between adjacent sticks, thereby maintaining high yield per mother substrate.
Solution Approach 2:
The seal line is pre-designed with protrusions and dummy patterns that create predetermined breaking points before the actual breaking process. This preliminary structuring of the seal line ensures that breaking occurs at the intended locations with minimal distance between sticks, optimizing both ease of manufacture and productivity.
2Reliability
If the seal line is drawn continuously without breaks to ensure reliability, then the reliability is improved, but the manufacturing precision deteriorates due to difficulty in controlling breaking positions
Solution Approach 1:
The continuous seal line is segmented into multiple sections with protrusions at specific intervals. These protrusions create natural breaking points that maintain the overall continuity and reliability of the seal line while enabling precise control over where breaking occurs. The segmentation allows reliable sealing along the entire perimeter while providing controlled weak points for separation.
Solution Approach 2:
The protrusions and dummy patterns act as intermediaries between the continuous seal line and the breaking process. They maintain the reliability of the continuous seal line while mediating the breaking process at predetermined locations, thus resolving the conflict between continuity and precise breaking control.
3Productivity
If the distance between dummy line and adjacent stick is reduced to increase yield, then the productivity is improved, but the reliability worsens due to potential interference during breaking process
Solution Approach 1:
The seal line is segmented with protrusions that create clear separation zones between adjacent sticks. This segmentation allows the distance between dummy lines and adjacent sticks to be minimized for high yield, while the protrusions ensure reliable breaking by providing distinct separation points that prevent interference during the breaking process.
Solution Approach 2:
Different regions of the seal line have different properties: protrusions provide breaking points with specific geometric features, while dummy patterns provide spacing control. This local differentiation of quality allows minimal spacing between sticks for high productivity while maintaining breaking process integrity through specially designed protrusion structures.
Data Source
AI summary
A liquid crystal display (LCD) apparatus and a method of manufacturing the same include a seal line having two protrusions, one of the protrusions having a liquid crystal (LC) injection hole. Moreover, the LCD apparatus having the seal line constitutes a closed loop. The display apparatus and the manufacturing method thereof increase production yields because the number of apparatus substrates for the display apparatus obtained from a mother substrate is increased by minimizing a distance between two adjacent apparatus substrates on the mother substrate. The method of manufacturing an exemplary LCD apparatus includes a one drop filling method or a vacuum injection method.