Movable Press-Block Pressure Control for Liquid Crystal Panel Yield
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Solution Overview
Problem
The existing pressing apparatus for liquid crystal panels experiences uneven pressure distribution due to wear and aging of components, leading to deficiencies such as uneven thickness of frame-sealing adhesive lines and cell gaps, resulting in reduced yield.
Innovation Solution
A pressing apparatus with a movable pressing plate comprising multiple press-blocks, each equipped with a pressure sensor and drive unit, controlled by a unit to adjust pressure uniformly across the panel, ensuring equal pressure application by moving the press-blocks upward or downward based on detected pressure values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single movable pressing plate is used, then the structure is simple, but the pressure distribution becomes uneven due to wear and aging
Solution Approach 1:
The movable pressing plate is divided into multiple independent movable press-blocks (first, second, third, and fourth press-blocks). Each press-block can be independently adjusted to compensate for wear and aging, ensuring uniform pressure distribution across different regions of the liquid crystal panel without requiring complete replacement of the entire pressing plate.
Solution Approach 2:
Each movable press-block is equipped with its own drive unit and pressure sensor, allowing local adjustment of pressure in specific regions. This enables targeted compensation for wear in different areas of the pressing plate, maintaining uniform pressure distribution while preserving the overall simplicity of the pressing apparatus structure.
2Manufacturing precision
If multiple movable press-blocks with individual control are used, then pressure distribution uniformity is improved, but device complexity increases
Solution Approach 1:
The control unit serves multiple functions: it receives pressure values from all pressure sensors, compares each against the target pressure, and controls all drive units based on the comparison results. This centralized control approach manages the complexity of multiple press-blocks through a single multi-functional controller, avoiding the need for separate control systems for each press-block.
Solution Approach 2:
Multiple drive units are merged under a single control unit that processes pressure data from all sensors and coordinates all drive units simultaneously. This consolidation reduces the overall system complexity by using shared control logic and a unified control architecture, making the system manageable despite having multiple independently controlled press-blocks.
3Productivity
If pressure is not adjusted uniformly, then the pressing process is fast, but product quality decreases due to uneven thickness and cell gaps
Solution Approach 1:
Pressure sensors in each movable press-block continuously detect the actual pressure applied to the liquid crystal panel. The control unit receives these feedback signals, compares them with the target pressure value, and automatically adjusts each press-block's position through its drive unit. This closed-loop feedback control ensures uniform pressure distribution and consistent frame-sealing adhesive line thickness while maintaining efficient pressing operation.
Solution Approach 2:
The system pre-establishes a target pressure value for uniform pressure distribution. Before the pressing process begins, the control unit is configured with this target value, and during pressing, it automatically compares actual pressure readings against this predetermined target, making real-time adjustments to maintain the desired pressure uniformity without manual intervention.
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 solution ensures consistent pressure distribution, reducing the likelihood of uneven thickness and cell gaps, thereby increasing the yield of liquid crystal panels during the pressing process.
Implementation Method 1
a pressure sensor provided in each movable press-block, each of the pressure sensors being used to detect a pressure value between the corresponding movable press-block and the static pressing plate
Implementation Method 2
the drive unit is a motor drive device, comprising an electrical motor and a transmission mechanism; wherein the electrical motor drives the transmission mechanism so as to move the movable press-blocks toward or away from the static pressing plate
Implementation Method 3
the transmission mechanism comprises a lead screw and a screw nut cooperating with the lead screw; wherein one end of the lead screw is drivingly connected with the electrical motor, and the screw nut is fixedly connected with the movable press-block
Data Source
AI summary
A pressing apparatus is disclosed. The pressing apparatus includes: a static pressing plate; a movable pressing plate opposing the static pressing plate and including a plurality of movable press-blocks; a pressure sensor provided in each respective movable press-blocks; a plurality of drive units provided corresponding to the plurality of movable press-blocks, each drive unit being connected with one movable press-block for driving the corresponding movable press-block; a control unit electrically connected with each drive unit and each pressure sensor, the control unit being configured to compare the detected pressure value from each pressure sensor with a predefined pressure value, and adjust the pressure value between the corresponding movable press-block and the static pressing plate by means of the corresponding drive unit based on the comparison result.