Resin Plate Convex-Concave Geometry for LCD Alignment Layer Uniformity
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Solution Overview
Problem
The existing methods for manufacturing alignment layers in liquid crystal display devices often result in defects due to alignment errors and non-uniform thickness, leading to incomplete removal and reformation of the alignment layer, which can cause recurring defects.
Innovation Solution
An apparatus comprising a dispenser, an anilox roll, a printing roll with a resin plate having specific convex and concave portions, and a doctor roll is used to uniformly apply and spread the alignment material on a substrate, ensuring a uniform thickness and preventing excessive material accumulation in peripheral areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional alignment layer formation methods are used, then the alignment layer can be formed on the substrate, but the thickness of the alignment layer is not uniform and defects occur
Solution Approach 1:
The resin plate incorporates convex portions in the display area and concave portions in the peripheral area, creating locally different surface geometries. This local quality variation enables precise control of alignment material distribution: convex portions in the display area ensure sufficient material for uniform coverage, while concave portions in the peripheral area prevent excessive material accumulation, thereby achieving uniform thickness and reducing defects throughout the substrate.
2Reliability
If the alignment layer is removed and reformed due to defects, then defects can be addressed, but incomplete removal occurs due to non-uniform thickness and recurring defects arise
Solution Approach 1:
The resin plate with pre-designed convex and concave portions performs preliminary action by controlling the alignment material distribution before the alignment layer formation is complete. This preliminary geometric control ensures uniform thickness from the outset, preventing defects before they occur and eliminating the need for time-consuming removal and reformation cycles.
3Quantity of substance
If excessive alignment material accumulates in peripheral areas, then the display area can be adequately covered, but non-uniform thickness and defects occur
Solution Approach 1:
The resin plate incorporates convex portions in the display area and concave portions in the peripheral area, creating locally different surface geometries. This local quality variation enables precise control of alignment material distribution: convex portions in the display area ensure sufficient material for uniform coverage, while concave portions in the peripheral area prevent excessive material accumulation, thereby achieving uniform thickness and reducing defects throughout the substrate.
Data Source
AI summary
An apparatus for manufacturing an alignment layer includes: a dispenser which supplies an alignment material; an anilox roll, onto which the alignment material supplied from the dispenser is applied; a printing roll which is engaged and rotated with the anilox roll; and a resin plate attached to an outer peripheral surface of the printing roll, where the resin plate receives the alignment material applied onto the anilox roll and prints the alignment material to a targeted substrate, in which the resin plate comprises a first area and a second area surrounding the first area, first convex portions and first concave portions are disposed in the first area, second convex portions and second concave portions are disposed in the second area, and an area of each second convex portion is larger than an area of each first convex portion.