KR20140032272A - Apparatus and method of forming alignment layer - Google Patents
Apparatus and method of forming alignment layer Download PDFInfo
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- KR20140032272A KR20140032272A KR1020120098968A KR20120098968A KR20140032272A KR 20140032272 A KR20140032272 A KR 20140032272A KR 1020120098968 A KR1020120098968 A KR 1020120098968A KR 20120098968 A KR20120098968 A KR 20120098968A KR 20140032272 A KR20140032272 A KR 20140032272A
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- discharge
- nozzle
- alignment
- alignment liquid
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41J—TYPEWRITERS; SELECTIVE PRINTING MECHANISMS, i.e. MECHANISMS PRINTING OTHERWISE THAN FROM A FORME; CORRECTION OF TYPOGRAPHICAL ERRORS
- B41J2/00—Typewriters or selective printing mechanisms characterised by the printing or marking process for which they are designed
- B41J2/005—Typewriters or selective printing mechanisms characterised by the printing or marking process for which they are designed characterised by bringing liquid or particles selectively into contact with a printing material
- B41J2/01—Ink jet
- B41J2/135—Nozzles
- B41J2/145—Arrangement thereof
- B41J2/155—Arrangement thereof for line printing
-
- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
- G02F1/1303—Apparatus specially adapted to the manufacture of LCDs
-
- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
- G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
- G02F1/1333—Constructional arrangements; Manufacturing methods
- G02F1/1337—Surface-induced orientation of the liquid crystal molecules, e.g. by alignment layers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41J—TYPEWRITERS; SELECTIVE PRINTING MECHANISMS, i.e. MECHANISMS PRINTING OTHERWISE THAN FROM A FORME; CORRECTION OF TYPOGRAPHICAL ERRORS
- B41J2202/00—Embodiments of or processes related to ink-jet or thermal heads
- B41J2202/01—Embodiments of or processes related to ink-jet heads
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- Physics & Mathematics (AREA)
- Nonlinear Science (AREA)
- Chemical & Material Sciences (AREA)
- Crystallography & Structural Chemistry (AREA)
- General Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Spectroscopy & Molecular Physics (AREA)
- Mathematical Physics (AREA)
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Liquid Crystal (AREA)
- Application Of Or Painting With Fluid Materials (AREA)
Abstract
Description
The present invention relates to an alignment film forming apparatus and a method for forming the same, and in particular, by identifying the position of an abnormally unejected nozzle in an inkjet method and adjusting an amount of the alignment liquid discharged from another nozzle, an alignment film having a uniform thickness can be formed. An alignment film forming apparatus and a forming method.
Recently, with the development of various portable electronic devices such as mobile phones, PDAs, notebook computers, and facing TVs, the demand for flat panel display devices for light and small sized devices is gradually increasing. It is becoming. Such flat panel displays are being actively researched, such as LCD (Liquid Crystal Display), PDP (Plasma Display Panel), FED (Field Emission Display), VFD (Vacuum Fluorescent Display), but mass production technology, ease of driving means, Background Art Liquid crystal display devices (LCDs) are in the spotlight for reasons of implementation and large scale.
1 schematically illustrates a cross section of a general liquid crystal display device. The liquid
The
The manufacturing process of the liquid crystal display device can be largely divided into a driving element array substrate process of forming a driving element on the
First, a plurality of gate lines and data lines arranged on the
In addition, the
Subsequently, an alignment layer is applied to the
On the other hand, the
The liquid crystal display device manufactured through the above process utilizes the electro-optic effect of the liquid crystal. The electro-optic effect is determined by the anisotropy of the liquid crystal itself and the molecular arrangement state of the liquid crystal. It will greatly affect the stabilization of the display quality of the liquid crystal display device.
Therefore, the alignment film forming process for more effectively aligning the liquid crystal molecules is very important in relation to the image quality characteristics in the liquid crystal cell process.
3A illustrates a conventional alignment film forming method using an inkjet method. As shown in the drawing, conventional alignment film formation is performed by discharging an alignment liquid onto a substrate using a plurality of heads having a plurality of nozzles formed thereon.
As shown in FIG. 3A, the alignment film forming apparatus is an inkjet ejecting apparatus, which includes an
As shown in FIG. 3B, the
When discharging the alignment liquid, the
As described above, in the conventional alignment film forming apparatus, two
However, by providing the two
However, such an alignment film forming apparatus has the following problems. As shown in FIG. 3B, the
Therefore, when driving the
That is, as shown in FIG. 4, the discharge amount of the alignment liquid discharged increases from the central regions of the
SUMMARY OF THE INVENTION The present invention has been made in view of the above, and an alignment film capable of always forming an alignment film having a uniform thickness by inspecting a discharge error of an alignment liquid and an abnormal non-ejection nozzle and calculating a discharge pattern of the alignment liquid based on the result. It is an object to provide a forming apparatus and a manufacturing method thereof.
In order to achieve the above object, the alignment film forming apparatus according to the present invention comprises a stage on which a substrate is loaded; A head part disposed on one side of the stage and having a plurality of nozzles formed on a lower surface thereof to discharge the alignment liquid supplied therein to the substrate through the nozzle while moving the upper part of the stage; A weight measuring unit which measures a discharge amount of the alignment liquid discharged from the head unit by measuring a weight of the alignment liquid discharged from the head unit; A nozzle inspection unit which photographs a discharge dot discharged from the head unit and determines whether the nozzle of the head unit is normally operated; And a control unit for calculating a discharge pattern based on various kinds of information, correcting the discharge amount and the discharge pattern of the alignment liquid based on the information input from the weighing unit and the nozzle inspection unit, and driving the head unit to discharge the alignment liquid to the substrate. .
The control unit may include a discharge pattern calculator configured to calculate a discharge amount and a single discharge amount of the alignment liquid to be dropped onto the substrate, and calculate a discharge pattern formed on the substrate based on the discharge amount; A discharge amount error detection unit for detecting a discharge amount error by comparing the actual discharge amount input by the weighing unit with a set detection amount; A non-ejection nozzle inspection unit that detects a non-ejection nozzle whose outlet is blocked based on an image of the test discharge input from the nozzle inspection unit; A discharge pattern correcting unit correcting the discharge pattern based on the error of the discharge amount detected by the discharge amount error detecting unit and the abnormal discharge nozzle information checked by the non-ejecting nozzle inspection unit; And a head driver driving the head unit to discharge the alignment liquid along the corrected discharge pattern, wherein the discharge pattern corrector corrects the discharge pattern by adjusting the number of open nozzles and the number of discharges of the open nozzles.
In addition, the alignment film forming method according to the present invention includes the steps of calculating the discharge pattern of the alignment liquid to be dropped onto the substrate; Detecting the discharge amount error by comparing the actual discharge amount with a set detection amount; Correcting the error of the ejection pattern by adjusting the number of open nozzles and the number of ejections of the open nozzles in an area where an error occurs; Detecting a non-eject nozzle that cannot be discharged; Correcting the error of the discharge pattern by adjusting the number of ejection of the nozzle and the nozzle being opened in the region around the abnormal nozzle; Discharging the alignment liquid along the corrected discharge pattern to apply the alignment liquid; And curing the applied alignment liquid.
The calculating of the discharge pattern includes calculating the discharge amount and the single discharge amount of the alignment liquid to be dropped onto the substrate based on the thickness of the alignment layer, the characteristics of the alignment liquid, the size of the panel, and the display mode of the panel, and forming the discharge pattern based on the discharge pattern. Wherein the inspecting the non-ejected nozzle comprises: testing the nozzle; Photographing the test-discharged dots; And detecting no discharge lines based on the captured image.
Further, the corrected ejection pattern distributes dots of the ejection pattern by dithering correction. The dithering correction classifies the ejection pattern into a plurality of groups consisting of a plurality of rows, and then, each of the groups by a distance set along the column direction. Each step consists of moving in different directions.
In the present invention, when an error occurs in the discharge amount of the alignment liquid, the amount of the alignment liquid is always discharged by adjusting the number of nozzles opened in the head and the number of times the open nozzles are actually discharged. In addition, when a part of the nozzle of the head portion is blocked by the residue of the alignment liquid or the like, the number of openings of other nozzles around the non-ejecting nozzle or the number of openings of the ladle is increased, thereby correcting the discharge amount of the alignment liquid not discharged by the non-ejecting nozzle. An alignment liquid having a uniform thickness is applied onto the substrate.
In the present invention, when a large amount of the discharging dot of the alignment liquid is formed in a specific region by the correction of the discharge amount, it is impossible to apply the uniform liquid on the substrate as a whole. Therefore, dithering correction is performed to discharge all of the discharge dots gathered. By dispersing the pattern and arranging the dots relatively uniformly, an alignment film having a more uniform thickness can be formed.
1 is a sectional view of a general liquid crystal display device.
2 is a flow chart showing a conventional method of manufacturing a liquid crystal display element;
3 is a view showing the structure of a conventional alignment film forming apparatus.
4 is a view showing a discharge amount error according to a nozzle position in a conventional alignment film forming apparatus.
5 is a view showing the structure of an alignment film forming apparatus according to the present invention.
6A and 6B show the structure of the head portion of the alignment film forming apparatus.
Fig. 7 is a block diagram showing the structure of a control unit of the alignment film forming apparatus of the present invention.
8 is a flowchart showing a method for forming an alignment film according to the present invention.
9A to 9D are views showing the opening, closing, and discharge patterns of the nozzles of the head drive unit.
Hereinafter, the present invention will be described in detail with reference to the accompanying drawings.
In the present invention, when an error occurs in the discharge amount of the alignment liquid, in order to correct this, not only the number of nozzles opened in the head part but also the number of discharges actually discharged to the opened nozzles are adjusted. Particularly, in the present invention, when a part of the nozzle of the head portion is blocked by the residue of the alignment liquid or the like, the nozzle is discharged by increasing the number of opening or opening of other nozzles around the non-ejecting nozzle so that the alignment liquid of uniform thickness is always applied on the substrate. .
In addition, in the present invention, when many discharge dots of the alignment liquid are formed in a specific region by the correction of the discharge amount, it is impossible to apply the uniform alignment liquid as a whole on the substrate. Therefore, dithering correction is performed to discharge all of the discharge dots collected. Disperse the pattern and arrange dots relatively uniformly.
5 is a view showing the structure of the alignment
As shown in FIG. 5, the alignment
Although not shown in the drawing, a guide is installed in the
6A is a view illustrating the
As shown in FIG. 6A, the
As shown in FIG. 6B, the
Although the
As shown in FIG. 5, the weighing
At this time, since the discharge amount of one dot is very small, the container is discharged a predetermined number of times, for example, 100 dots and the weight is measured, and then the average weight of one dot is calculated by dividing the measured weight by 100 times. (I.e., 1 dot) the discharge amount is measured. The discharge amount is measured for both the
The
If the nozzle is clogged and the nozzle does not operate normally, discharge of the alignment liquid through the nozzle does not occur. Therefore, when the alignment liquid is discharged according to the set discharge pattern, the discharge does not occur in the same manner as the actual discharge pattern. Application of the alignment film of thickness becomes impossible.
The
The setting of the amount of the alignment liquid discharged to the
7 is a block diagram showing the structure of the
As shown in FIG. 7, the
The
Similarly, the characteristics of the alignment liquid, for example, the viscosity of the alignment liquid and the like also affect the flow direction or the spreading direction of the alignment liquid, so that the shape of the discharge pattern varies according to the characteristics of the alignment liquid.
The discharge amount
In the present invention, although the set discharge amount and the measured discharge amount are designed to be the same in the outermost region of the substrate, and the error of the discharge amount becomes larger toward the center region, it may be designed differently as necessary.
The non-ejection
The discharge
The discharge
As will be described later, this increase in the number of dots is achieved by increasing the number of open nozzles by opening the closed nozzles, and adjusting the number of actual ejections from the open nozzles.
In addition, the discharge
The discharge
The ejection
The
Hereinafter, a method of forming the actual alignment film using the alignment film forming apparatus having the above structure will be described in detail.
8 is a flowchart illustrating a method of forming an alignment layer according to the present invention, and FIGS. 9A to 9D are views illustrating whether the nozzle of the
First, as shown in Figure 8, after setting the thickness of the alignment film of the liquid crystal display device to be produced (S201), the substrate in consideration of the size of the liquid crystal display device, the display mode, the thickness of the alignment film, the characteristics of the alignment liquid, etc. The discharge amount of the alignment liquid to be added to the liquid is calculated, and the discharge pattern of the alignment liquid discharged from the
The discharge pattern calculated in FIG. 9A is shown. As shown in FIG. 9A, in the ejection pattern, the
Subsequently, after loading the substrate on the
Thereafter, the weight of the discharge amount measured by the weighing
If there is no error in the discharge amount, since the set amount of the alignment liquid is discharged, the discharge proceeds continuously without further correction, and if the error occurs in the discharge amount, the discharge pattern is corrected (S205).
Since the alignment liquid supplied to the
The error of the discharge amount depends on the structure of the alignment film forming apparatus and the like. For example, when the alignment liquid is supplied from the alignment liquid supplying portion to the center region of the
Correction of the discharge amount is made by increasing the number of open nozzles in the area corresponding to the region with a high error and adjusting the number of discharges actually discharged through the open nozzles.
As shown in FIG. 9B, in the nozzle corresponding to the region where the error of the discharge amount occurs, a part of the nozzle that is closed at the time of calculating the initial discharge pattern is opened and the alignment liquid is discharged through the nozzle to correct the discharge amount error. As shown in the error graph of the error, the error becomes more severe from the outer region to the center region, so that the number of openings of the error correction nozzles increases from the outside of the
On the other hand, correction of the discharge amount error is not performed by adjusting only the number of nozzles to be opened. If the nozzle is always discharged by opening the open nozzle to correct the error of the discharge amount, the nozzle may be larger than the actual error amount of the discharge amount of the alignment liquid in this area, so the open nozzle is always opened to correct the error of the discharge amount. Instead of adjusting the number of openings appropriately, the error can be corrected accurately.
In FIG. 9B, the discharge pattern in which the actual number of discharges of the nozzle in which the area indicated by the lower arrow is opened is controlled is controlled. As shown in FIG. 9B, the number of discharges from the
As illustrated in FIG. 8, after correcting the discharge error, it is checked whether there is a non-ejection nozzle whose outlet is blocked by an abnormal nozzle, that is, an alignment liquid residue or the like (S206).
If there is no non-ejection nozzle, the alignment liquid continues to proceed as with the corrected ejection pattern, and when the non-ejection nozzle is detected, the ejection pattern is corrected again (S207).
As shown in Fig. 9C, when a part of the nozzle to which the alignment liquid is to be discharged is clogged (nozzle indicated in black in the drawing), the area of the discharge pattern corresponding to this nozzle is not discharged at all so that no discharge dot exists. Therefore, the thickness of the alignment film in this area is different from the thickness of the alignment film in other areas.
The discharge
In the drawing, the correction for the discharge error and the error due to the abnormal nozzle are corrected sequentially, but two steps of correction may be performed at the same time. That is, the discharge pattern can be corrected at once by the information on the discharge error and the information on the abnormal nozzle.
After correcting the error due to the abnormal nozzle as described above, dithering correction is performed (S208).
Among the discharge patterns shown in FIG. 9C, the columns indicated by a, b, c, and d have more dots in which the alignment liquid is discharged compared to other columns. Therefore, when the actual alignment liquid is discharged, the thickness of the alignment film in this area becomes larger than the thickness of other areas, making it impossible to form an alignment film of uniform thickness.
Dithering correction is to correct the discharge pattern by moving it in matrix units. For example, in the case of an ejection pattern consisting of N rows and M columns, the ejection pattern is corrected by moving the n rows to the left or the right in units of m columns.
9D is a diagram showing some examples of such dithering corrections. In FIG. 9D, a discharge pattern is formed of 12 rows and 35 columns, and four rows of the 12 rows are classified into one group. The first four groups G1 are moved by three columns in the left direction, and the three rows of discharge patterns are designed to move to areas where the discharge patterns are emptied by the movement. Also, the second group G1 does not move, and the third group G3 moves by three columns in the right direction. Similarly, the three rows of ejection patterns are filled in the areas vacated by the movement.
The dithering correction is performed by the discharge
In the drawing, four rows of the discharge pattern are classified into one group and then moved by three columns for the dither correction. However, the rows forming the group can be set variously according to various data such as the size of the liquid crystal display device. You can also vary the distance you travel.
In addition, although the first group G1 and the third group G3 move in opposite directions and do not move the second group G2 in the drawing, the second group G2 is opposite to the first group G1. Direction and the third group G3 may be moved in the opposite direction to the second group G2. In other words, you can move all groups or only some groups as needed.
When the discharge pattern is dither corrected, the
As described above, in the present invention, the discharge pattern is formed in consideration of the discharge amount error of the alignment liquid, the presence of abnormal nozzles, the deviation of the alignment dot, and the like, and the alignment film is always discharged by discharging the alignment liquid according to the discharge pattern. It becomes possible.
On the other hand, in the above-described detailed description, an alignment film forming apparatus and a method of forming a specific structure are disclosed, but the present invention is not limited to such a specific structure and method, and a driving structure and which can be derived using the basic concept of the present invention. The method may also be applied.
120:
132: stage 134: weighing unit
136: nozzle inspection unit 180: control unit
181: discharge pattern calculation unit 183: discharge amount error detection unit
184: non-ejection nozzle inspection unit 186: discharge pattern correction unit
Claims (12)
A head part disposed on one side of the stage and having a plurality of nozzles formed on a lower surface thereof to discharge the alignment liquid supplied therein to the substrate through the nozzle while moving the upper part of the stage;
A weight measuring unit which measures a discharge amount of the alignment liquid discharged from the head unit by measuring a weight of the alignment liquid discharged from the head unit;
A nozzle inspection unit which photographs a discharge dot discharged from the head unit and determines whether the nozzle of the head unit is normally operated; And
An alignment film formed of a control unit that calculates a discharge pattern based on various information, corrects the discharge amount and the discharge pattern of the alignment liquid based on information input from the weighing unit and the nozzle inspection unit, and drives the head unit to discharge the alignment liquid to the substrate Device.
A discharge pattern calculator configured to calculate a discharge amount and a single discharge amount of the alignment liquid to be dropped onto the substrate, and calculate a discharge pattern formed on the substrate based on the discharge amount;
A discharge amount error detection unit for detecting a discharge amount error by comparing the actual discharge amount input by the weighing unit with a set detection amount;
A non-ejection nozzle inspection unit that detects a non-ejection nozzle whose outlet is blocked based on an image of the test discharge input from the nozzle inspection unit;
A discharge pattern correcting unit correcting the discharge pattern based on the error of the discharge amount detected by the discharge amount error detecting unit and the abnormal discharge nozzle information checked by the non-ejecting nozzle inspection unit; And
An alignment film forming apparatus, comprising: a head portion driving portion for driving the head portion to eject the alignment liquid along a corrected discharge pattern.
Detecting the discharge amount error by comparing the actual discharge amount with a set detection amount;
Correcting the error of the ejection pattern by adjusting the number of open nozzles and the number of ejections of the open nozzles in an area where an error occurs;
Detecting a non-eject nozzle that cannot be discharged;
Correcting the error of the discharge pattern by adjusting the number of ejection of the nozzle and the nozzle being opened in the region around the abnormal nozzle;
Discharging the alignment liquid along the corrected discharge pattern to apply the alignment liquid; And
An alignment film forming method comprising the step of curing the applied alignment liquid.
Testing the nozzle;
Photographing the test-discharged dots; And
The method for forming an alignment film, characterized in that it comprises the step of detecting the non-ejection line based on the captured image.
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KR1020120098968A KR20140032272A (en) | 2012-09-06 | 2012-09-06 | Apparatus and method of forming alignment layer |
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Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
KR20150141893A (en) * | 2014-06-10 | 2015-12-21 | 캐논 가부시끼가이샤 | Imprint apparatus, imprint method, and method of manufacturing article |
US9740037B2 (en) | 2014-09-15 | 2017-08-22 | Samsung Display Co., Ltd. | Liquid crystal display device |
US10007149B2 (en) | 2015-04-17 | 2018-06-26 | Samsung Display Co., Ltd. | Methods of manufacturing a photoalignment layer and a liquid crystal display |
-
2012
- 2012-09-06 KR KR1020120098968A patent/KR20140032272A/en not_active Application Discontinuation
Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
KR20150141893A (en) * | 2014-06-10 | 2015-12-21 | 캐논 가부시끼가이샤 | Imprint apparatus, imprint method, and method of manufacturing article |
JP2015233101A (en) * | 2014-06-10 | 2015-12-24 | キヤノン株式会社 | Imprint device, imprint method and method for manufacturing article |
US10197910B2 (en) | 2014-06-10 | 2019-02-05 | Canon Kabushiki Kaisha | Imprint apparatus, imprint method, and method of manufacturing article |
US9740037B2 (en) | 2014-09-15 | 2017-08-22 | Samsung Display Co., Ltd. | Liquid crystal display device |
US10007149B2 (en) | 2015-04-17 | 2018-06-26 | Samsung Display Co., Ltd. | Methods of manufacturing a photoalignment layer and a liquid crystal display |
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