Vacuum Lamination of Glass Panels with UV Curing
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Solution Overview
Problem
Conventional liquid crystal display panel manufacturing processes face challenges such as deformation during UV curing due to substrate handling, contamination from uncured seal resin, and improper UV light alignment, leading to reduced precision and increased product disposal.
Innovation Solution
A method and device for combined glass panel lamination and UV curing in a vacuum environment, using a UV lamp module and prism plate to ensure precise UV light transmission perpendicular to the TFT substrate, eliminating the need for substrate turning and reducing the time between lamination and UV curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If substrates are handled separately for lamination and UV curing, then process flexibility is maintained, but manufacturing time increases and precision decreases
Solution Approach 1:
The patent combines the lamination and UV curing processes into a single integrated vacuum chamber. The substrates remain in the same chamber for both operations, eliminating the need for intermediate handling and turning. The vacuum environment is maintained throughout, and the UV curing is performed through the vacuum chamber window, achieving both lamination and curing in one continuous operation without compromising precision or increasing time.
2Reliability
If substrates are turned over for UV curing, then complete curing is achieved, but substrate deformation occurs and precision is lost
Solution Approach 1:
Instead of turning the substrates over to cure the seal resin from the back side, the patent inverts the approach by curing through the front side using the TFT substrate's transparency to UV light. The UV lamp is positioned on the opposite side of the TFT substrate, and the light passes through the substrate to cure the seal resin from the rear, eliminating the need for substrate turning while achieving complete curing.
3Productivity
If UV light is applied immediately after lamination, then manufacturing time is reduced, but seal resin contamination occurs
Solution Approach 1:
The patent applies preliminary action by performing the lamination process first under vacuum, ensuring the substrates are properly bonded and positioned. Only after successful lamination is achieved does the system proceed to UV curing. The vacuum environment is maintained throughout, and the transition from lamination to curing is controlled sequentially, preventing contamination while maintaining efficient production speed.
4Reliability
If substrates are removed from vacuum for UV curing, then curing can be performed, but vacuum integrity is compromised and re-lamination is required
Solution Approach 1:
The patent uses the vacuum chamber window as an intermediary medium to transmit UV light into the vacuum environment. The window is made of a material transparent to UV light, allowing the UV lamp positioned outside the vacuum chamber to cure the seal resin without breaking the vacuum seal. This intermediary solution enables effective curing while maintaining vacuum integrity and avoiding the need for re-lamination.
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 approach enhances manufacturing efficiency and yield rate by preventing substrate deformation, reducing contamination, and ensuring accurate UV exposure, thereby improving product quality and lowering manufacturing costs.
Implementation Method 1
aligning and laminating the TFT substrate and the CF substrate in a vacuum environment
Implementation Method 2
applying UV (Ultraviolet) light to transmit through the TFT substrate for carrying out UV curing of the seal resin
Implementation Method 3
using a UV lamp module and prism plate to ensure precise UV light transmission perpendicular to the TFT substrate
Implementation Method 4
carrying out UV curing of the seal resin interposed between the laminated CF substrate and TFT substrate
Data Source
AI summary
The present invention provides a method for laminating glass panels and a vacuum lamination device using the method. The method includes (1) providing a TFT substrate (240) and a CF substrate (220) to be laminated, the CF substrate (220) being coated with a seal resin (204), the TFT substrate (240) carrying liquid crystal (402) dropped thereon; (2) aligning and laminating the TFT substrate (240) and the CF substrate (220) in a vacuum environment to complete a lamination process; (3) applying UV light to transmit through the TFT substrate (240) for carrying out UV curing of the seal resin (204) interposed between the CF substrate (220) and the TFT substrate (240) so as to complete a UV curing process; (4) removing the laminated CF substrate (220) and the TFT substrate (240) that have been subjected to the UV curing process out of the vacuum environment.