LCD Sealant Dispensing with Dummy Patterns
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Solution Overview
Problem
The existing sealant dispensing methods for liquid crystal display (LCD) devices face issues with sealant coagulation and disconnection, leading to contamination and reduced production efficiency, particularly in large-sized LCD manufacturing.
Innovation Solution
A method involving the sequential dispensing of dummy sealant patterns around the main sealant pattern to prevent coagulation and disconnection, where the first dummy sealant is dispensed peripherally before and after the main sealant, and the second dummy sealant is dispensed perpendicularly, ensuring continuous sealant flow and preventing contamination of the liquid crystal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the dispenser returns to the starting point to continue dispensing sealant, then the sealant path is completed, but the sealant coagulates in the nozzle causing excessive dispensing and contamination
Solution Approach 1:
The method dispenses a first dummy sealant pattern before the main sealant pattern to prepare the nozzle and ensure smooth sealant flow. This preliminary action prevents coagulation at the starting point and ensures consistent dispensing quality throughout the sealant path.
Solution Approach 2:
The dummy sealant patterns act as intermediaries between the sealant supply system and the main dispensing operation. These dummy patterns absorb the abrupt changes in flow direction and pressure, preventing coagulation and ensuring smooth transition to the main sealant dispensing.
2Ease of manufacture
If the screen printing method is used to dispense sealant, then the dispensing process is simplified, but the screen contacts the substrate damaging the alignment layer
Solution Approach 1:
The patent replaces the mechanical screen printing system with a non-contact dispenser system. The dispenser uses a nozzle to deposit sealant without physical contact with the substrate, thereby eliminating damage to the alignment layer while maintaining dispensing effectiveness.
Solution Approach 2:
The dispenser nozzle serves as an intermediary that transfers sealant to the substrate without direct mechanical contact. This intermediary approach allows the sealant to be deposited precisely while the substrate and its alignment layers remain undisturbed.
3Productivity
If the dispenser moves quickly to maintain production speed, then productivity increases, but sealant distribution uniformity decreases
Solution Approach 1:
The dummy sealant patterns are dispensed before the main sealant pattern to pre-condition the dispensing system. This preliminary action ensures that when the main dispensing occurs at high speed, the sealant flow is already optimized for uniform distribution.
Solution Approach 2:
The method uses different dispensing parameters for the dummy sealant patterns compared to the main sealant pattern. The dummy patterns are dispensed with parameters optimized for flow stabilization, while the main pattern uses parameters optimized for speed and uniformity, allowing both high productivity and precision.
Data Source
AI summary
An LCD device and a method for manufacturing the same is disclosed, to prevent a sealant from being coagulated or disconnected at a predetermined portion, the method comprising preparing lower and upper substrates; dispensing a sealant on any one of the lower and upper substrates by a dispenser; dispensing liquid crystal on any one of the lower and upper substrates; and bonding the lower and upper substrates to each other, wherein the process of dispensing the sealant includes sequential steps of dispensing a first dummy sealant in the periphery of a main sealant pattern, dispensing the main sealant pattern after forming the first dummy sealant, and dispensing a second dummy sealant pattern in the periphery of the main sealant pattern after forming the main sealant pattern.