Narrow Frame LCD Seal Material Control via Spacer Buffering
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Solution Overview
Problem
The increasing demand for narrow frame liquid crystal display panels leads to variations in seal material formation accuracy, affecting cutting accuracy and yield, as the seal material's width and location become more critical, and the distance between the cut line and seal material outer end varies, causing inconsistencies in the manufacturing process.
Innovation Solution
A method involving a first and second spacer arrangement between organic insulating films, with the seal material extending to overlap substrate ends, and a cutting process that uses spacers to control seal material distribution and reduce spreading resistance, ensuring accurate cutting and improved adhesive strength between substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the frame portion is narrowed to meet market demand, then the display device achieves a more compact and modern appearance, but the accuracy of seal material formation deteriorates, leading to variations in cutting accuracy and manufacturing yield
Solution Approach 1:
A resin layer is introduced as an intermediary element between the seal material and the substrate. This resin layer acts as a buffering medium that compensates for variations in seal material formation, preventing direct transmission of errors to the cutting process. The resin layer's greater width compared to the seal material creates a margin of error that maintains cutting accuracy despite frame narrowing.
Solution Approach 2:
The resin layer is formed in advance before the cutting process, creating a pre-established buffer zone. By preparing this compensating structure beforehand, the system anticipates and prevents potential cutting accuracy issues that would arise from narrow frame dimensions and seal material variations.
2Shape
If the seal material width is reduced to achieve narrow frame, then the frame becomes narrower, but the distance variation between cut line and seal material outer end increases, causing cutting accuracy deterioration
Solution Approach 1:
The resin layer serves as a mediator between the seal material position and the cut line. Even when seal material outer end position varies, the resin layer's extended width ensures that the cut line remains at a consistent distance from the resin layer edge, thereby maintaining cutting accuracy independent of seal material positioning variations.
3Shape
If the frame portion is narrowed, then the display device achieves compact design, but the variation in seal material location increases, affecting manufacturing yield
Solution Approach 1:
The resin layer acts as a buffer that decouples seal material location variations from manufacturing outcomes. By providing this intermediate zone, the system maintains consistent cutting conditions and adhesive performance even when seal material placement varies, thereby preserving manufacturing yield despite frame narrowing.
Solution Approach 2:
The resin layer width is deliberately set greater than the seal material width, creating a parameter difference that provides tolerance for seal material position variations. This parameter change in the resin layer dimensions compensates for the reduced margin for error caused by narrow frame design.
Data Source
AI summary
A first organic insulating film is arranged in a circumference area outside an active area on a first substrate. A circumference color filter is arranged in the circumference area on a second substrate. A second organic insulating film covers the circumference color filter. A seal material is arranged between the first and second organic insulating films to attach the first substrate and the second substrate. The seal material extends up to a position in which end portions of the first and second substrates overlap. A first spacer is arranged between the first and second organic insulating films in the circumference area. The first spacer is arranged on an active area side in the seal material. A second spacer is formed between the first and second organic insulating films in a position in which the end portions of the substrates overlap.