LCD production process can be described as follows: (1) the orientation layer on the lower and upper plate is formed; (2) the layer is properly positioned so that the liquid crystal can properly align; (3) the spacer is dispensed, the seal is printed, and the two plates are assembled; (4) the liquid crystal is injected into the cell through the capillary effect; and (5) the injection hole is sealed.
1. Printing
the Orientation Layer
The orientation layer is evenly spread
on the pixel area of the upper and
lower plate. The polyimide is spread
on the drum thinly and evenly and
is coated on the rubber plate, which
has been patterned in advance. In
turn, the polyimide is printed on
the upper color filter or the lower
TFT-array plate. After printing, the
polyimide is hardened through the
process of annealing.
2. Rubbing
Rubbing is the process that forms
the straight groove on the hardened
polyimide in a fixed direction in
order to make the liquid crystal orient
in a fixed direction. The straight
groove can be formed by rubbing the
panel in a certain direction with
the rubbing velvet attached to the
rotating drum.
3. Dispensing Spacers
The spacers are dispensed evenly in
order to secure the fixed cell gap
when assembling the upper and lower
plate. After the spacers are mixed
in the liquid with the proper concentration,
they are then transported to the spray
nozzle through the pump, and subsequently
sprayed on the surface of the plate
from the nozzle with high pressure.
Heating dries the liquid, and the
density of the spacer is adjusted
between 100 ea/ and 200 ea/ according
to the display size. The spacer shape
is like a ball with a diameter size
between 4 and 5 which determines
the cell gap between the plates.
4. Injecting the Liquid Crystal
The liquid crystal is injected between
the upper and lower plate using capillary
action and pressure differences after
the upper and lower plate are assembled.
The process system consists of a vacuum
pump, vacuum chamber, an up/down moving
device, a jig, which contains the
liquid crystal, and, an N system.
At first, the internal cell vacuum
level is maintained at about 10-3
Torr from the original vacuum state.
The liquid crystal is then pulled
into the cell by the capillary effect.
When the cell is filled with liquid
crystal up to about 80 percent , N??s
then purged into the vacuum chamber
slowly and the liquid crystal fills
the remaining space in the cell as
a result of the difference in pressure
from inside and outside the cell.
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