Rubbing Roll Head Support for LCD Alignment Uniformity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The increasing size and weight of rubbing rolls used in LCD manufacturing pose challenges in uniformly maintaining pressure on large mother substrates, leading to defective alignment layers due to sagging caused by gravity, which affects the uniformity of the alignment process.
Innovation Solution
A rubbing apparatus with a frame, a rubbing table, and a head that supports the rubbing roll, where the head is positioned at the upper portion of the frame to distribute the weight, minimizing the load on the rubbing roll and maintaining a consistent distance for uniform force application, using an R-guide and Linear Motion block for stable and accurate rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the rubbing roll size and weight are increased to handle large LCD mother substrates, then the coverage area is improved, but the uniformity of pressure application deteriorates due to sagging caused by gravity
Solution Approach 1:
The rubbing roll is divided into multiple independent sections, each capable of moving vertically to compensate for sagging. This segmentation allows each section to maintain uniform pressure on the substrate independently, resolving the contradiction between large coverage area and uniform pressure application.
Solution Approach 2:
The rubbing roll transitions from a static structure to a dynamic one where each section can independently adjust its position. This dynamic capability enables the roll to adapt to gravitational sagging in real-time, maintaining manufacturing precision across the entire large substrate area.
2Force
If the rubbing roll weight is increased to provide sufficient rubbing force, then the rubbing intensity is improved, but the control over pressure uniformity deteriorates due to difficulty in maintaining consistent pressure
Solution Approach 1:
By segmenting the rubbing roll into multiple independently controllable sections, each section can apply its full rubbing force while the overall pressure distribution remains uniform. This resolves the contradiction between high rubbing force and easy pressure control.
Solution Approach 2:
The system changes the pressure parameter from a fixed value to a dynamically adjustable value for each section. This allows each section to maintain optimal rubbing force while the control system adjusts pressure distribution to ensure uniformity across the entire substrate.
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 configuration ensures stable and uniform rubbing of the alignment layer, preventing sagging and ensuring consistent microgroove formation, thereby improving the quality of the alignment layer and reducing defects in LCD manufacturing.
Implementation Method 1
rub the alignment layer by use of a rubbing cloth to form uniform microgrooves on a surface of the alignment layer
Implementation Method 2
the depth of the microgroove is different based upon a pressure of the rubbing roll applied to the alignment layer
Implementation Method 3
preventing a rubbing roll from sagging due to gravity by dispersing a load of a rubbing apparatus
Data Source
AI summary
An apparatus for rubbing an alignment layer by which a defective rubbing due to a load can be prevented by installing a head at an upper portion of a frame, the apparatus including a frame, a rubbing table to which a substrate having an alignment layer is loaded, a rubbing roll disposed at an upper portion of the rubbing table inside the frame, and a head disposed at an upper portion of the frame that supports the rubbing roll.