Vacuum Laminator Periodic Control for Display Panel Alignment

Solution Overview

Problem

During the manufacturing of liquid crystal display panels, low atmospheric pressure can lead to light leakage between substrates, resulting in poor display effects.

Innovation Solution

A method involving a vacuum laminator process where substrates undergo initial rough alignment, followed by controlled vacuumization to stabilize atmospheric pressure, allowing for fine alignment and lamination while preventing excessive suction force, which includes using a control valve to maintain a preset pressure range and employing a calibration camera for precise alignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If vacuumization is continuously applied during the entire lamination process, then lamination quality is improved, but light leakage occurs due to prolonged low atmospheric pressure

Engineering Contradiction:

Improvealignment precisionVSAvoidlight leakage

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The vacuum pump operates periodically rather than continuously. It performs rough vacuumization before alignment, stops during alignment operations, and then resumes for fine vacuumization after alignment. This periodic operation ensures substrates are properly aligned at atmospheric pressure while still achieving necessary vacuum conditions for lamination quality, thereby preventing light leakage caused by prolonged vacuum exposure.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

Rough alignment is performed before vacuumization is applied, and fine alignment is conducted after vacuumization resumes. This preliminary and subsequent alignment strategy ensures that substrates are properly positioned both before and during the vacuum lamination process, achieving high alignment precision without subjecting the substrates to continuous low atmospheric pressure that would cause light leakage.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If vacuumization is stopped during alignment, then alignment precision is improved, but lamination quality may deteriorate

Engineering Contradiction:

Improvealignment precisionVSAvoidlamination quality

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The vacuum pump operates in periodic cycles: rough vacuumization before alignment, stop during alignment, and fine vacuumization after alignment. This periodic operation ensures substrates are properly aligned at atmospheric pressure while still achieving necessary vacuum conditions for lamination quality, thereby preventing light leakage caused by prolonged vacuum exposure.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

Rough alignment is performed before vacuumization is applied, and fine alignment is conducted after vacuumization resumes. This preliminary and subsequent alignment strategy ensures that substrates are properly positioned both before and during the vacuum lamination process, achieving high alignment precision without subjecting the substrates to continuous low atmospheric pressure that would cause light leakage.

Inventive Principle:

Principle #10Preliminary action

3Productivity

If rough alignment is performed before vacuumization, then alignment speed is improved, but alignment precision may be affected by vacuum pressure changes

Engineering Contradiction:

Improvealignment speedVSAvoidalignment precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The alignment process is segmented into two distinct stages: rough alignment performed before vacuumization at atmospheric pressure for high-speed coarse positioning, and fine alignment performed after vacuumization resumes for high-precision adjustment. This segmentation allows each stage to optimize for its specific function without compromising the other, achieving both speed and precision requirements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The vacuum pump operates in periodic cycles: rough vacuumization before alignment, stop during alignment, and fine vacuumization after alignment. This periodic operation ensures substrates are properly aligned at atmospheric pressure while still achieving necessary vacuum conditions for lamination quality, thereby preventing light leakage caused by prolonged vacuum exposure.

Inventive Principle:

Principle #19Periodic 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

This method effectively reduces light leakage and improves display quality by stabilizing the atmospheric pressure and preventing the peel-off of internal structures during the lamination process.

Implementation Method 1

vacuumizing the enclosed cavity by a vacuumizing device; continuing the vacuumization for the enclosed cavity

Methodology Applied

Scientific EffectVacuum: Vacuum

Data Source

PatentUS11604372B2Method and control device for laminating display panel as well as vacuum laminator

Publication Date: 2023.03.14 HKC CORP LTD

AI summary

This application discloses a method for laminating display panel, a control device for laminating display panel, and a vacuum laminator; the method comprising: conducting a vacuumization at the time of a 1st rough alignment for a 1st substrate and a 2nd substrate put into an enclosed cavity; stopping vacuumization at the time of a 2nd rough alignment for the two.