LCD Sealant Hardening via Maskless UV Scanning
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Solution Overview
Problem
Existing sealant hardening methods for LCD panels are inefficient, requiring long tact times and additional masks, which increase fabrication costs and reduce yield, especially when dealing with different LCD panel models.
Innovation Solution
A sealant hardening apparatus and method that uses a scanning UV irradiation method or direct UV ray emission through optical fibers without a mask to harden UV and thermal sealants, reducing tact time and eliminating the need for additional masks by aligning substrates and UV irradiators according to the LCD panel model.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mask is used for UV irradiation to harden sealant, then the sealant can be hardened selectively, but the tact time increases and fabrication cost increases
Solution Approach 1:
The patent removes the mask component from the UV irradiation system, using direct UV irradiation onto the sealant pattern without requiring a mask for selective hardening. This extraction of the mask eliminates the alignment step and reduces tact time while maintaining selective hardening capability through direct patterning.
Solution Approach 2:
The patent replaces the mechanical mask alignment system with a direct UV irradiation system. Instead of using a physical mask that requires precise mechanical alignment, the system directly irradiates UV light onto the sealant pattern, substituting a mechanical alignment process with a more efficient optical process.
2Manufacturing precision
If a mask is used for UV irradiation to harden sealant, then the sealant can be hardened selectively, but the device complexity increases
Solution Approach 1:
The patent extracts and removes the mask and its alignment system from the UV irradiation apparatus. By eliminating the mask component entirely, the system complexity is reduced while maintaining the capability for selective sealant hardening through direct UV irradiation onto the patterned sealant.
Solution Approach 2:
The patent replaces the complex mechanical mask alignment system with a simpler direct UV irradiation system. The complex mechanics of mask positioning, alignment, and securing are substituted with a straightforward optical irradiation process that requires no moving parts or alignment mechanisms.
3Adaptability or versatility
If additional masks are used for different LCD panel models, then selective hardening can be achieved for each model, but the fabrication cost increases
Solution Approach 1:
The patent creates a universal UV irradiation system that can handle different LCD panel models without requiring model-specific masks. The system is designed to accommodate various panel sizes and configurations through a single adaptable apparatus, eliminating the need for multiple specialized masks and reducing fabrication costs.
Solution Approach 2:
The patent enables adaptability to different LCD panel models by changing operational parameters such as UV irradiation intensity, irradiation area, and stage positioning, rather than requiring physical mask changes. This parameter-based adaptability allows the same apparatus to serve multiple model specifications efficiently.
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 approach decreases tact time, enhances yield, and lowers fabrication costs by eliminating the need for complex mask alignment and additional masks, allowing for efficient sealant hardening across various LCD panel models.
Implementation Method 1
a sealant hardening apparatus for an LCD panel includes a stage on which substrates bonded by a sealant are loaded, for being moved in an in-line method; a mask provided above the bonded substrates, having an open part corresponding to a sealant portion to transmit the light, and a closed part corresponding to the remaining portions to prevent the light; at least two align cameras for aligning the mask and the bonded substrates; a lamp for irradiating UV rays of high energy; a plurality of optical fibers for transmitting UV rays of the lamp; and a UV irradiation part for irradiating the UV rays from the optical fibers to the bonded substrates through the mask by arranging and supporting the optical fibers at one line
Implementation Method 2
a plurality of optical fibers for transmitting UV rays of the lamp; and a UV irradiation part for irradiating the UV rays from the optical fibers to the bonded substrates through the mask
Data Source
AI summary
A sealant hardening apparatus of an LCD panel and a sealant hardening method is disclosed, being suitable for decreasing a tact time, and for being easily applied to LCD panels of the different models, by irradiating UV rays in a scanning method, or by directly irradiating UV rays to a sealant pattern without using a mask, which includes a stage on which substrates bonded by a sealant are loaded, for being moved in an in-line method; a mask provided above the bonded substrates, having an open part corresponding to a sealant portion to transmit the light, and a closed part corresponding to the remaining portions to prevent the light; at least two align cameras for aligning the mask and the bonded substrates; a lamp for irradiating UV rays of high energy; a plurality of optical fibers for transmitting UV rays of the lamp; and a UV irradiation part for irradiating the UV rays from the optical fibers to the bonded substrates through the mask by arranging and supporting the optical fibers at one line.