KR100779668B1 - Method for Manufacturing Back Light Unit - Google Patents

Abstract

The present invention relates to a method for manufacturing a backlight unit, the main process of the upper and lower plate forming step (S1); Discharge gas and mercury getter injection tube forming step (S2); Alignment and clipping of the upper and lower plates (S3); An exhaust and sealing step (S4) of putting the panel clipped in the step (S3) into a vacuum chamber, then exhausting the gas inside the panel while heating the panel under vacuum, and then pressure-sealing the panel; Transferring the panel sealed in the step (S4) to an atmospheric pressure furnace (S5); By discharging the mercury getter by heating the mercury getter by a heating apparatus attached to the outer circumference of the discharge gas and the mercury getter injection tube, the discharge gas injection and mercury getter activates the mercury getter while discharging the gas into the panel. Activation process (S6); Mercury diffusion process (S7); And a tip-off process (S8) of the discharge gas and the mercury getter injection tube. The backlight unit may be manufactured to significantly shorten the time required for the entire process while simplifying the process by the above process. can do.

Backlight, discharge gas, mercury getter, vacuum chamber, atmospheric pressure furnace

Description

Manufacturing Method for Backlight Unit {Method for Manufacturing Back Light Unit}

1 is a view showing a process of a method for manufacturing a backlight unit according to the present invention,

2 to 12 are diagrams showing a process model for explaining each process according to the manufacturing method of the present invention.

<Description of the symbols for the main parts of the drawings>

10: vacuum chamber 11: top plate

12: bottom 13: clip

20: discharge gas and mercury getter injection tube 21: tube body

22: blocking film 23: discharge gas

24: mercury getter 40: exhaust pipe

41: through 42: frit glass

44: sealing heater 45: piston

The present invention relates to a method for manufacturing a backlight unit, and more particularly, a backlight unit that can significantly reduce the time required for the entire process while simplifying the process by allowing the discharge gas and the mercury getter to be simultaneously injected into the panel. It relates to a manufacturing method of.

A backlight unit is used to illuminate a display unit such as a liquid crystal display (LCD), which is widely used at present.

Referring to the general manufacturing method of the backlight unit as described above, as follows.

First, the upper and lower plates to be used as the BLU is aligned and clipped, and the upper and lower plates are integrally formed by heating and sealing them under normal pressure, thereby forming a tubular discharge passage between the upper and lower plates. In addition, the mercury getter injection tube and the upper and lower mercury getter tubes can be injected into the upper and lower plates which are integrally sealed by heating and sealing the exhaust pipe / mercury getter injection tube at the bottom of the lower plate using a frit glass under normal pressure. An exhaust pipe for exhausting the impurity gas inside the plate and injecting the discharge gas is integrally formed with the upper and lower plates.

Next, the mercury getter is injected into the integrally formed mercury getter injection tube, the tip of the mercury getter injection tube is first tip-off, the sealed upper and lower panels are transferred to the exhaust system, and the exhaust pipe is evacuated using an exhaust pipe. Tip off first.

Subsequently, the mercury getter is heated to be activated to allow the activated mercury gas to diffuse into the sealed vacuum panel, and then tip off the exhaust pipe / mercury getter tube respectively to finally complete the backlight unit.

In the conventional method of manufacturing a backlight unit through the above process, first, the gas inside the panel is evacuated after sealing the upper plate and the lower plate under normal pressure, so that exhausting takes a long time, which causes a stagnation in the flow of the whole process. It has been pointed out as the biggest obstacle to increase the productivity of the backlight unit, and secondly, in the above process to inject the discharge gas into the panel, and to diffuse the mercury inside the panel in a later process, First, the panel temperature is cooled to room temperature, and then the panel is heated to about 300 to 350 ° C. to facilitate mercury diffusion. Therefore, a large amount of time must be secured during this cooling and reheating process, which delays the entire process. And in that process a separate mercury diffusion path has to be established. The enlargement process and had become a complex issue.

The present invention has been made to solve the above problems, the object is to discharge the discharge gas and mercury getter injection tube formed in the discharge gas and mercury getter in one tube near the lower end of the lower plate to the discharge Discharge gas and mercury getters injected into the gas and mercury getters can be injected into the panel at the same time to avoid the complicated process of separately injecting the discharge gas and mercury getters into the panel. Yet, to provide a method of manufacturing a backlight unit that can improve the productivity by significantly reducing the time required for the entire process.

Another object of the present invention is the time and consumption required for reheating the panel by performing the mercury diffusion process without cooling the panel temperature to room temperature in the discharge gas injection process and the mercury diffusion process. It is to provide a method of manufacturing a backlight unit that can save energy.

Another object of the present invention is to provide a manufacturing method of a backlight unit that can improve the quality of the final product by improving the degree of vacuum inside the panel by finally discharging a small amount of impurity gas remaining inside the panel to the outside of the panel. Is in.

Method for manufacturing a backlight unit according to the present invention for achieving the above object is the upper plate and lower plate forming step (S1) for forming the upper and lower plates for the backlight, respectively; A tube body having an outer wall of which the upper part is opened and the lower part of the tube body is closed, a barrier film formed to block the flow of fluid at one point inside the tube body, a discharge gas filled in the lower portion of the barrier film, and A discharge gas and a mercury getter injection tube forming process (S2) including a mercury getter inserted into the center portion; The upper plate and the lower plate formed in the step (S1) are superimposed and aligned under normal pressure, and the edges are pressed and fixed with a clip to be bonded to one panel, and the discharge formed in the step on the through hole formed on one side of the lower plate. Alignment and clipping process of fixing the gas and mercury getter tube (S3); The panel clipped in the step (S3) is introduced into a vacuum chamber, and then while the panel is heated under vacuum, the gas inside the panel is evacuated through a gap of the frit glass for sealing the upper plate and the lower plate, and then pressurized. An exhaust and sealing step of sealing and heating sealing the discharge gas and the mercury getter injection tube by using frit glass on the through hole formed near the lower end of the lower plate (S4); A normal pressure furnace transfer step (S5) of removing the panel sealed in the step (S4) from the vacuum chamber and transferring the normal pressure furnace to the normal pressure furnace; By opening the barrier film by heating the mercury getter using a heating device attached to the outer periphery of the discharge gas and the mercury getter injection tube in an atmospheric pressure state, the discharge gas is injected into the panel while activating the mercury getter Gas injection and mercury getter activation step (S6); A mercury diffusion step (S7) in which mercury diffuses into the vacuum-sealed panel by the mercury getter activated in the step (S6); And a tip off step (S8) of sealing the tip portion of the discharge gas and the mercury getter injection tube.

Here, it is preferable that an atmospheric heating step is further added between the step (S3) and step (S4) to raise the panel to 300 to 350 ° C primarily under normal pressure.

Here, the mercury diffusion step (S7) is preferably carried out in an atmospheric pressure furnace for 2 hours at a temperature of 300 ~ 350 ℃.

In addition, the lower plate of the step (S1) is separated from the through-hole for attaching the discharge gas and the mercury getter injection tube on one side of the upper plate and the lower plate when sealing the frit glass in the process of heating and solidifying the frit glass in the process A through hole for discharging the remaining impurity gas is further formed to prevent a trace amount of the impurity gas generated by the remaining inside of the panel, and in the step (S3), a small amount in the through hole for discharging the remaining impurity gas The exhaust pipe for discharging impurity gas is fixed, and in the step (S4), the exhaust pipe for discharging the trace amount of impurity gas is heat-sealed to the through-hole for discharging the remaining impurity gas, and the inside of the panel in the step (S4). After the gas is exhausted and the sealing is completed, the impurity gas remaining inside the panel loses before being introduced into the atmospheric furnace of the process (S5). That after the discharge from the inside to the outside to complete, further comprising an exhaust tube tip-off process of sealing the opened portion of the exhaust tube tip is preferred.

Here, the lower plate of the step (S1) is a frit glass is heated and solidified in the process of sealing the top plate and the lower plate separately from the through hole for attaching the discharge gas and the mercury getter injection tube on one side outside the frit glass The through-holes for discharging the remaining impurity gas is further formed to prevent a small amount of impurity gas generated by the remaining inside the panel, and in the step (S4) the gas inside the panel is exhausted and the sealing is completed It is preferable to further include a step of closing the through-holes after the impurity gas remaining in the panel is discharged from the inside of the panel to the outside before the silver step (S5) is introduced into the atmospheric pressure furnace.

In the step of closing the through hole, the metal having the frit glass coated thereon may be melted by the encapsulation heater so that the metal seals the through hole, and the heater is elevated by the piston.

Hereinafter, a method of manufacturing a backlight unit according to a preferred embodiment of the present invention will be described in detail with reference to the accompanying drawings.

1 is a view showing a process of the manufacturing method of the backlight unit according to the present invention, Figures 2 to 12 is a process model for explaining each process according to the manufacturing method of the present invention shown in FIG. Drawing.

First, the manufacturing method of the backlight unit according to the present invention, as shown in Figure 1 upper and lower plate forming step (S1), discharge gas and mercury getter injection tube forming step (S2), alignment and clipping process (S3), exhaust and Sealing step (S4), atmospheric pressure furnace transfer step (S5), discharge gas injection and mercury getter activation step (S6), mercury diffusion step (S7), and the tip-off step (S8) is composed of each step sequentially.

First, the upper plate and the lower plate forming step (S1), as shown in Figure 2, the upper plate 11 and the lower plate 12 for backlight is formed, respectively, the upper plate 11 and the lower plate (circumference around the edge of the lower plate 12 ( A frit glass (not shown) having a low melting point property for sealing 12) is applied.

In addition, in the discharge gas and mercury getter injection tube forming process (S2), as shown in FIG. 4, the discharge gas and the mercury getter injection tube 20 attached to the through-side formed near the lower end of the lower plate 12 are formed. Is formed.

The discharge gas and the mercury getter injection tube 20 is formed so that the flow of the fluid to the tube body 21 and the inner portion of the tube body 21 having an outer wall of which the top is open and the bottom is closed. The blocking film 22 is formed, the discharge gas 23 filled in the lower portion of the blocking film 22, and the mercury getter 24 is inserted into the central portion of the blocking film 22.

Next, in the alignment and clipping process (S3), as shown in FIG. 3, the upper plate 11 and the lower plate 12 formed in the upper plate and the lower plate forming step S1 overlap and align under normal pressure, and the edges thereof are illustrated. As shown in Fig. 4, the discharge gas and mercury formed in the step (S2) are formed in the through hole formed on one side of the lower plate 12 by being fixed by pressing by a fixing means such as a clip (13). Fix the getter injection tube 20.

As a next step, the evacuation and encapsulation step S4 is carried out by placing the panel clipped in the alignment and clipping process S3 into the vacuum chamber 10 as shown in Fig. 5, and then heating the panel under vacuum. The gas inside the panel is evacuated through a gap of a frit glass (not shown) for sealing the upper plate 11 and the lower plate 12, and then pressurized and sealed, and the discharge gas and the mercury getter injection tube 20 ) Is heat-sealed using a frit glass (not shown) in the through hole formed near the lower end of the lower plate 12.

The heating of the panel in the step (S4) is for melting the frit glass located between the upper plate 11 and the lower plate 12 to fuse the upper plate 11 and the lower plate 12, the exhaust process is completely fusion It proceeds through a minute gap formed between the surface curved surface of the previous frit glass and the upper plate 11 and the lower plate 12 in contact with it, and after the vacuum exhaust process is completed, the upper plate 11 and the lower plate 12 ) Is pressed under vacuum.

On the other hand, the heating for sealing the panel in the step (S4) is typically performed until the temperature reaches approximately 450 ℃, in order to shorten the heating time of the panel and to minimize the temperature non-uniformity acting on the panel Some heating sections may be performed at atmospheric pressure instead of inside the vacuum chamber 10, in which case, the heating is performed until the temperature reaches 300 to 350 ° C. The reason why the atmospheric heating process is carried out to 300 to 350 ° C. is because the degassing of moisture and impurity gas adsorbed inside the panel is most smoothly near this temperature range, and the exhaust is concentrated, thereby improving the exhaust characteristics due to the atmospheric pressure environment. This is because the temperature of the panel is increased under normal pressure, where the temperature characteristic of the panel is about 10 ° C./min. Keeping the vacuum in the inside, it is possible to heat up the temperature and high vacuum inside the panel in a short time compared to the past.

Next, the panel in which the sealing is completed in the exhaust and sealing process S4 is taken out of the vacuum chamber 10, and the process proceeds to the normal pressure furnace conveying process S5, which is transferred to the normal pressure furnace.

Next, the discharge gas injection and mercury getter activation step (S6) is performed using the heating device 36 attached to the outer circumference of the discharge gas and mercury getter injection tube 20 at atmospheric pressure as shown in FIG. 6. The mercury getter 24 is heated to open the blocking film 22 as shown in FIG. 7, thereby activating the mercury getter 24 while allowing the discharge gas 23 to be injected into the panel.

The mercury getter 24 inserted into the center portion of the blocking film 22 absorbs residual gas inside the panel when heated and evaporated, and the blocking film 22 is formed of a thin glass film.

Therefore, when the heating device 36 attached to the outer circumference of the discharge gas and the mercury getter injection tube 20, that is, a specific example of the heating device is a high frequency heating source, when a high frequency current flows through the coil of the high frequency heating source, Energy is concentrated on the surface layer of the mercury getter 24 located inside the coil and rapidly heated. Accordingly, the surface layer of the heated mercury getter 24 rapidly melts the surrounding thin glass film. After the glass film no longer supports the mercury getter 24, the mercury getter 24 falls downward due to its own weight, thereby forming a passage for injecting a discharge gas located at a lower portion thereof. ) Is injected into the panel and the mercury getter 24 is activated.

The mercury diffusion step S7 allows mercury to diffuse into the vacuum-sealed panel as shown in FIG. 8 by the mercury getter 24 activated in the step S6, and mercury is evenly distributed inside the panel. In order to diffuse, it is maintained for about 2 hours at a temperature of about 300 ~ 350 ℃.

The mercury diffusion process (S7) as described above is carried out in a normal pressure furnace after the panel is taken out from the vacuum chamber 10, compared to the conventional process, injecting the discharge gas into the interior of the panel, and then In order to perform the mercury diffusion process, it is not necessary to cool the panel temperature to room temperature and then reheat it to a temperature of about 300 to 350 ° C., thereby shortening time and saving energy. The mercury diffusion does not need to be.

Finally, in the tip-off process (S8) after the mercury is diffused into the panel, the tip of the discharge gas and the mercury getter injection tube 20 using a torch or a heating device is melted and cut as shown in FIG. Ensure the panels are sealed.

In the method of manufacturing a backlight according to the present invention through the above process, the discharge gas and the mercury getter injection tube 20 are sealed near the lower end of the lower plate, so that the discharge gas and the mercury getter injection tube 20 are separated from the panel. By simultaneously discharging the discharge gas and mercury inside, it is possible to avoid the process complexity of separately injecting the discharge gas and the mercury getter into the inside of the panel, as in the conventional backlight manufacturing method, the time required is much longer This shortens the time required for the entire backlight manufacturing process to significantly reduce productivity.

On the other hand, Figure 10 is a state that is attached to the through-hole 41 separate from the through-hole 40 for attaching the discharge gas and the mercury getter injection tube 20 to the outside of one side of the lower plate 12 of the open end of the tip portion As shown in the drawings, a method of manufacturing a backlight by attaching the exhaust pipe 40 having the tip portion open to a separate through-hole 41 formed at one outside of the lower plate 12 as described above is compared with the method described above. Except for a few differences due to the attachment (40) is made of the same process, only the differences will be described below.

First, in order to manufacture a backlight using the exhaust pipe 40 having the tip open as described above, the exhaust pipe 40 for discharging a small amount of impurity gas to the through-hole 41 for discharging the remaining impurity gas in the step (S3). ) Is further fixed, and in the step S4, the exhaust pipe 40 is heated and sealed to the through-hole 41 for discharging the remaining impurity gas.

In the step S4, the gas inside the panel is exhausted and the inside of the panel where the sealing is completed is maintained in a sealed state that is blocked from the outside of the panel. However, the frit glass positioned between the upper plate 11 and the lower plate 12 generates a small amount of impurity gas in the process of being heated and solidified to a certain point even after sealing is performed. The generated impurity gas does not affect the degree of vacuum inside the panel. However, when such impurity gas is generated at the inner position of the panel, the impurity gas is not discharged to the outside because the inside of the panel is sealed to the outside. It does not remain inside the panel, which causes a decrease in the degree of vacuum inside the panel.

Therefore, it is possible to externally discharge a small amount of residual impurity gas in the panel generated during heating and solidification of the frit glass through the open tip of the exhaust pipe 40 so as to prevent the vacuum in the panel from being lowered. After exhausting the residual impurity gas, the exhaust pipe 40 is heated by using a heating device such as an encapsulation heater 39 in which a coil is wound around the tip of the exhaust pipe 40 to be isolated from the outside of the panel. After the tip off process of the exhaust pipe 40 which seals the open tip part is made, the panel is taken out of the vacuum chamber 10 and introduced into the normal pressure furnace of step S5.

By manufacturing the backlight using the exhaust pipe 40 with the tip open as described above, the degree of vacuum inside the panel is further improved, thereby improving the quality of the final product.

FIG. 11 is a view showing a state in which only the exhaust hole 41 is simply formed without attaching the exhaust pipe 40 as shown in FIG. 10 in order to discharge the trace amount of impurity gas remaining inside the panel. As the above method, only the difference in the process of closing the through-hole 41 in comparison with the method described above, so only the difference will be described below.

In the process (S4), the gas inside the panel is exhausted and the panel is sealed, and after the impurity gas remaining inside the panel is discharged from the inside of the panel to the outside before being introduced into the atmospheric pressure path of the process (S5), the through hole ( 41 to further include a step of sealing, the process of closing the through-hole 41 as described above, as shown in Figure 12, the heater 43 for sealing the metal 43 coated with frit glass 42 on the upper side By melting the frit glass 42 so that the metal 43 seals the through-hole 41, and the heater 44 is elevated by the piston 45. The same process as that described above is used for the process of.

According to the method of manufacturing a backlight unit according to the present invention, the discharge gas and the mercury getter injection tube formed with the discharge gas and the mercury getter in one tube are sealed near the lower end of the lower plate to the discharge gas and the mercury getter injection tube. By allowing the injected discharge gas and the mercury getter to be injected into the panel at the same time, the time required for the entire process while simplifying the process by avoiding the complicated process of separately injecting the discharge gas and the mercury getter into the panel. Can be significantly reduced to improve productivity.

In addition, according to the method for manufacturing a backlight unit according to the present invention, in the discharge gas injection step and the mercury diffusion step, the mercury diffusion step is performed without lowering the panel temperature to room temperature between the steps and the step. This can reduce the time and energy required for reheating.

In addition, according to the method of manufacturing a backlight unit according to the present invention, a small amount of impurity gas remaining inside the panel is finally discharged to the outside of the panel to improve the degree of vacuum inside the panel to improve the quality of the final product. have.

Although the present invention has been described with reference to the embodiments described above, it can be said that it is exemplary, and those skilled in the art can come up with various modifications and equivalent embodiments therefrom, such an equivalent implementation It is only natural that examples should also be regarded as included within the claims of the present invention.

Claims (6)

An upper plate and a lower plate forming process (S1) for forming the backlight upper plate 11 and lower plate 12, respectively; A tube body 21 having an outer wall of which an upper part is opened and a lower part thereof is closed, a blocking film 22 formed to block flow of a fluid at a point inside the tube body 21, and the blocking film 22. A discharge gas and mercury getter injection tube forming process (S2) including a discharge gas 23 filled in a lower portion of the discharge gas and a mercury getter 24 inserted into a central portion of the blocking film 22; The upper plate 11 and the lower plate 12 formed in the step (S1) are superimposed and aligned under normal pressure, and the edges are pressed and fixed with a clip 13 to be bonded to one panel, and the lower plate 12 is An alignment and clipping process (S3) for fixing the discharge gas and the mercury getter injection tube 20 formed in the step (S2) to the through-hole formed on one side; The panel clipped in the step (S3) is introduced into the vacuum chamber 10, and then the gas inside the panel is filled with frit glass for sealing the upper plate 11 and the lower plate 12 while heating the panel under vacuum. After exhausting the vacuum through the gap and pressurized sealing, the exhaust gas and the mercury getter injection tube 20 is heat-sealed using frit glass on the through hole formed near the lower end of the lower plate 12 and Sealing process (S4); A normal pressure furnace transferring step (S5) of taking out the panel sealed in the step (S4) from the vacuum chamber (10) and transferring it to the normal pressure furnace; The discharge gas 23 is opened by heating the mercury getter 24 using the heating device 36 attached to the outer circumference of the discharge gas and the mercury getter injection tube 20 at an atmospheric pressure to open the blocking film 22. A discharge gas injection and mercury getter activating step (S6) for activating the mercury getter 24 while allowing the injection into the panel; A mercury diffusion step (S7) in which mercury diffuses into the vacuum-sealed panel by the mercury getter 24 activated in the step (S6); And And a tip off step (S8) of sealing the tip of the discharge gas and the mercury getter injection tube (20). The method of claim 1, A method of manufacturing a backlight unit further comprising an atmospheric pressure heating step of heating the panel to 300 to 350 ° C. first under normal pressure between the step (S3) and the step (S4). The method of claim 1, The mercury diffusion step (S7) is a manufacturing method of the backlight unit, characterized in that carried out in a normal pressure furnace for 2 hours at a temperature of 300 ~ 350 ℃. The method of claim 1, The lower plate 12 of the step (S1) is the frit glass is heated when sealing the upper plate 11 and the lower plate 12 separately from the through-hole for attaching the discharge gas and the mercury getter injection pipe 20 on one side outside A through-hole is further formed to discharge the remaining impurity gas so as to prevent the trace impurities generated by the frit glass from remaining inside the panel during the solidification process. In the step (S3), an exhaust pipe for discharging a small amount of impurity gas is fixed to the through-hole for discharging the remaining impurity gas, In the step (S4), the exhaust pipe for discharging the trace amount of impurity gas is heated and sealed to the through side for discharging the remaining impurity gas, In the step S4, the gas inside the panel is exhausted and the sealed panel is exhausted after the impurity gas remaining inside the panel is discharged from the inside of the panel to the outside before being introduced into the atmospheric pressure path of the step S5. Method of manufacturing a backlight unit characterized in that it further comprises a tip off process of the exhaust pipe for sealing the open tip of the). The method of claim 1, The lower plate 12 of the step (S1) is the frit glass is heated when sealing the upper plate 11 and the lower plate 12 separately from the through hole for attaching the discharge gas and the mercury getter injection tube 20 to one side outside And a through hole 41 for discharging the remaining impurity gas to prevent the trace impurities generated by the frit glass from remaining in the panel during the solidification process. In the step (S4), the gas inside the panel is exhausted and the sealing is completed, the panel after the impurity gas remaining inside the panel is discharged from the inside of the panel to the outside before being introduced into the normal pressure path of the step (S5) 41) The method of manufacturing a backlight unit, characterized in that it further comprises a step of sealing. The method of claim 5, In the step of closing the through hole 41, the metal 42 having the frit glass 42 coated thereon is melted by the encapsulation heater 44 to melt the frit glass 42 to allow the metal 42 to pass through. (41) to be sealed, and the heater (44) is lifted by the piston (45) manufacturing method of the backlight unit.

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