Rubbing Roller Alignment with Vacuum Suction and Combing

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Solution Overview

Problem

The existing apparatus for rubbing liquid crystal alignment layers in TFT-LCD manufacturing faces issues such as contamination from dust particles, static electricity, and cloth breakage, leading to reduced yield and increased manufacturing costs due to the use of mechanical rollers.

Innovation Solution

An apparatus incorporating a vacuum suction unit to remove dust particles in real time and a combing unit to align fibers of the rubbing cloth, preventing contamination and static electricity, thereby ensuring a smooth rubbing process and enhancing the alignment layer's quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If flannelette rubbing rollers are used for mechanical rubbing, then alignment layer orientation is achieved, but dust particles and contamination occur

Engineering Contradiction:

Improvealignment layer orientationVSAvoiddust particles contamination

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent extracts and removes dust particles from the rubbing system by introducing a suction device that generates negative pressure to suck away dust particles generated during the rubbing process, preventing them from contaminating the alignment layer

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces air flow as an intermediary medium between the rubbing roller and the alignment layer to carry away dust particles, using the air current generated by the suction device to transport contaminants away from the rubbing area

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If rubbing cloth is used for alignment, then pretilt angle is produced, but rubbing scores and contamination occur

Engineering Contradiction:

Improvepretilt angleVSAvoidrubbing scores

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The patent removes the harmful rubbing scores and contamination by using the suction device to extract particles generated during rubbing, preventing their accumulation on the substrate

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent supplements the mechanical rubbing system with a pneumatic system (suction device) to remove harmful byproducts, combining mechanical action with air flow to achieve cleaner rubbing

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If conditioning roller is added to smoothen rubbing cloth, then cloth breakage is reduced, but device complexity increases

Engineering Contradiction:

Improverubbing cloth durabilityVSAvoidapparatus structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the suction device with the existing rubbing roller assembly, making the suction device serve both as a dust removal mechanism and as part of the overall rubbing system integration, reducing the need for separate conditioning components

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Manufacturing precision

If mechanical rubbing is performed, then alignment is achieved, but yield rate decreases

Engineering Contradiction:

Improvealignment qualityVSAvoidyield rate

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent converts the harmful dust particles generated during mechanical rubbing into removable contaminants by using the suction device to capture and remove them, transforming the harmful byproduct into a manageable waste stream that can be easily eliminated

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The suction device operates continuously during the rubbing process to maintain a clean environment throughout the entire alignment operation, ensuring consistent high-quality results without interruption or rework

Inventive Principle:

Principle #20Continuity of useful action

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

The apparatus effectively prevents rubbing scores and improves the alignment layer's uniformity, reducing production costs and increasing the yield of liquid crystal display panels by maintaining a clean and aligned rubbing cloth during the process.

Implementation Method 1

at least one vacuum suction unit located at one side of the platform to suck and remove the particles released from the rubbing

Methodology Applied

Scientific EffectVacuum suction: Suction

Data Source

PatentUS7751023B2Apparatus for rubbing alignment layer on a substrate

Publication Date: 2010.07.06 AU OPTRONICS CORP

AI summary

An apparatus for rubbing an alignment layer on a substrate is disclosed. The apparatus includes a platform to support the substrate; a conveyance unit incorporating the platform to convey the substrate in a predetermined direction; a rubbing roller located above the platform for rubbing the alignment layer on the substrate; a combing unit located at one side of the rubbing roller for contacting with the rubbing roller; and at least one vacuum suction unit located at one side of the platform to suck and remove the particles released from the rubbing. The combing unit serves to smoothen a rubbing cloth on the rubbing roller, with a result of low static electricity accumulation on the substrate and of a better alignment effect on the alignment layer.