LCD Sealant Pre-Curing for Reactive Monomer Stability
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Solution Overview
Problem
The deterioration of reactive monomers during the curing process in liquid crystal display (LCD) manufacturing affects the polymerization and phase separation, leading to mura and instability in the liquid crystal mixture, compromising the quality of the LCD.
Innovation Solution
A method involving a pre-curing process at a lower temperature to cure the sealant, followed by an active curing process at a higher temperature to polymerize the reactive monomer, ensuring the monomer's stability and preventing deterioration, using a reactive monomer with a melting point of 150 to 160°C.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If UV light or thermal energy is applied during the sealant-curing process, then the sealant is cured, but the reactive monomer deteriorates or reacts before the polymer stability alignment process
Solution Approach 1:
The curing process is divided into two distinct stages: a first curing process at a first temperature to cure the sealant, and a second curing process at a second temperature (higher than the first) to cure the reactive monomer. This segmentation prevents the reactive monomer from deteriorating during sealant curing while ensuring both processes are completed effectively.
Solution Approach 2:
The sealant curing is performed as a preliminary action before the reactive monomer curing. By completing the sealant curing first at a lower temperature, the system prepares the structure for the subsequent monomer curing without causing monomer deterioration, thus eliminating the need for sequential temperature changes.
2Ease of manufacture
If the reactive monomer is used in the liquid crystal mixture, then polymerization and phase separation occur to create pre-tilt angle, but the monomer deteriorates during sealant curing, causing mura and instability
Solution Approach 1:
The curing processes are segmented by temperature: the first curing process uses a first temperature suitable for sealant curing but below the monomer's deterioration threshold, while the second curing process uses a higher second temperature to ensure monomer polymerization without deterioration. This segmentation preserves the liquid crystal mixture's composition and eliminates mura.
Solution Approach 2:
The temperature parameter is changed between the two curing processes. The first temperature is selected to cure the sealant without affecting the monomer, while the second temperature is increased to ensure complete monomer curing. This parameter change allows both sealant and monomer to be cured effectively without mutual interference.
3Device complexity
If a single curing process is used for both sealant and reactive monomer, then the process is simplified, but the reactive monomer deteriorates and causes mura in the LCD
Solution Approach 1:
The single curing process is segmented into two distinct curing processes with different temperatures. The first curing process cures the sealant at a lower temperature, while the second curing process cures the reactive monomer at a higher temperature. This segmentation prevents monomer deterioration and ensures LCD reliability.
Solution Approach 2:
The sealant curing is performed as a preliminary action before the monomer curing. This preliminary action completes the sealant curing at a temperature that does not affect the monomer, thereby preventing deterioration and maintaining mixture stability before the second curing process.
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 effectively prevents mura formation by maintaining the reactive monomer's stability throughout the manufacturing process, ensuring proper polymerization and phase separation, thereby enhancing the quality and consistency of the LCD.
Implementation Method 1
a pre-curing process is performed to pre-cure the sealant under a first temperature
Implementation Method 2
an active curing process is performed to polymerize the reactive monomer under a second temperature
Implementation Method 3
a voltage is applied to tilt the liquid crystal molecules to a predetermined angle
Implementation Method 4
an ultraviolet (UV) light is provided to illuminate the LCD, so that polymerization and phase separation of the reactive monomer in the liquid crystal mixture is gradually caused along the aligned direction of the liquid crystal molecules
Data Source
AI summary
A method for manufacturing LCD includes providing a bottom substrate, applying a sealant on its top surface, providing a liquid crystal mixture including a vertical alignment liquid crystal material and at least one reactive monomer which are surrounded by the sealant, providing a top substrate so that its bottom surface covers the sealant and the bottom substrate, performing a pre-curing process to pre-cure the sealant under a first temperature, and performing an active curing process under a second temperature, wherein the second temperature is higher than the first temperature.