LCD Panel Transfer via Pin Impact and Suction

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Solution Overview

Problem

The existing methods for cutting and transferring liquid crystal display (LCD) panels from substrates face issues such as incomplete separation, dust generation, and potential defects due to misalignment, which can interrupt the manufacturing process.

Innovation Solution

A liquid crystal display panel transferring system that uses a camera to capture alignment marks and a controlling unit to align the panel, combined with pins and suction to apply pressure and separate the panel from the substrate, ensuring accurate alignment and complete separation without defects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a diamond wheel is used to form a scribing line and mechanical force is applied to break the mother substrate, then LCD panels can be cut from the substrate, but incomplete separation and dust generation occur

Engineering Contradiction:

Improvecutting efficiencyVSAvoidseparation completeness

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The cutting process is divided into two distinct stages: first, a diamond wheel forms a scribing line to create a guide groove, and second, a breaking device applies mechanical force to snap the substrate along the scribed line. This segmentation allows each device to perform its specialized function optimally, ensuring complete separation without dust generation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The scribing line acts as an intermediary between the diamond wheel and the breaking force. By first creating a precise groove in the substrate, the scribe provides a controlled path for the subsequent breaking process, ensuring that the mechanical force applies exactly where needed for clean separation.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If the LCD panel is misaligned during separation, then complete separation cannot be achieved, but alignment verification adds process complexity

Engineering Contradiction:

Improvealignment accuracyVSAvoidalignment verification system

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Alignment marks are pre-formed on the substrate at known positions before the cutting process begins. These marks serve as reference points that guide the diamond wheel and breaking device to the correct locations, eliminating the need for complex real-time alignment verification systems.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces complex mechanical alignment verification systems with a simpler optical detection method. A camera captures images of the pre-formed alignment marks, and image processing software automatically determines panel positions and orientations, substituting mechanical complexity with optical simplicity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If alignment marks are formed at the dummy region, then accurate alignment can be achieved, but the dummy region occupies additional substrate area

Engineering Contradiction:

Improvealignment mark detectionVSAvoidsubstrate utilization area

Core Design Contradiction:

Measurement precisionVSArea of stationary object

Solution Approach 1:

The dummy region is designed with specific local qualities: it contains pre-formed alignment marks with high contrast and precise geometry optimized for camera detection, while the rest of the substrate maintains its standard structure for LCD panel production. This localized specialization allows accurate alignment verification without compromising overall substrate utilization.

Inventive Principle:

Principle #3Local quality

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 method enables complete separation and transfer of LCD panels without defects, reduces downtime, and prevents misalignment issues, allowing for continuous processing and improved yield.

Implementation Method 1

a camera (256) formed at the main body (251) for checking the alignment of the liquid crystal display panel (210)

Methodology Applied

Scientific EffectImage capture and processing: Photography

Implementation Method 2

separating the liquid crystal display panel (210) from the substrate (410) by descending a transfer apparatus with pins for impacting at a dummy region (232)

Methodology Applied

Scientific EffectImpact force: Impact Force

Implementation Method 3

sucking and ascending the separated panel from the substrate

Methodology Applied

Scientific EffectSuction: Suction

Data Source

PatentUS7626676B2LCD panel transferring system and method for separating scribed panels from a substrate by descending a transfer apparatus with pins for impacting at a dummy region and then sucking and ascending the separated panel from the substrate

Publication Date: 2009.12.01 LG DISPLAY CO LTD

AI summary

A liquid crystal display (LCD) panel transferring system including a panel transferring apparatus that takes out and transfers a LCD panel formed at a surface of a substrate; a camera installed at the panel transferring apparatus that captures an image of the LCD panel; and a controlling unit that aligns the LCD panel with the panel transferring apparatus based on an image captured using the camera. The panel transferring apparatus includes a main body; a plurality of suction holes formed at the main body that fix an LCD panel to the main body; and a pin formed at the peripheral area of the main body that applies an impact to a dummy region to separate the LCD panel from the substrate.