U.S. patent application number 16/497798 was filed with the patent office on 2021-04-08 for stretched display panel and method for manufacturing same.
This patent application is currently assigned to TOVIS CO., LTD.. The applicant listed for this patent is TOVIS CO., LTD.. Invention is credited to Young Tae JEONG, Kyung Ha LEE, Won Gyu LEE, Kyoung Hun YANG.
Application Number | 20210104183 16/497798 |
Document ID | / |
Family ID | 1000005292452 |
Filed Date | 2021-04-08 |
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United States Patent
Application |
20210104183 |
Kind Code |
A1 |
LEE; Kyung Ha ; et
al. |
April 8, 2021 |
STRETCHED DISPLAY PANEL AND METHOD FOR MANUFACTURING SAME
Abstract
A method of manufacturing a stretched display panel includes:
cutting the TFT substrate to a desired size; cutting the color
filter substrate; forming an open-circuit line for open-circuiting
a portion defined between a horizontal pixel line that is located
at an end of the TFT substrate and another horizontal pixel line
adjacent thereto in order to prevent electrical noise due to the
horizontal pixel lines being introduced into the end of the TFT
substrate exposed from the pixel exposure portion; and forming a
reinforcement seal for covering the pixel exposure portion using a
reinforcement material in order to prevent occurrence of short
circuit due to introduction of foreign matter into a gap defined
between the horizontal pixel line and the other horizontal pixel
line and at the same time to increase rigidity of the pixel
exposure portion.
Inventors: |
LEE; Kyung Ha; (Changwon-si,
Gyeongsangnam-do, KR) ; YANG; Kyoung Hun; (Incheon,
KR) ; JEONG; Young Tae; (Seoul, KR) ; LEE; Won
Gyu; (Incheon, KR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
TOVIS CO., LTD. |
Incheon |
|
KR |
|
|
Assignee: |
TOVIS CO., LTD.
Incheon
KR
|
Family ID: |
1000005292452 |
Appl. No.: |
16/497798 |
Filed: |
March 26, 2018 |
PCT Filed: |
March 26, 2018 |
PCT NO: |
PCT/KR2018/003517 |
371 Date: |
September 26, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G02F 1/1339 20130101;
G02F 1/1368 20130101; G02F 1/1303 20130101; G09F 9/301 20130101;
G02F 1/136222 20210101; G02F 1/136204 20130101 |
International
Class: |
G09F 9/30 20060101
G09F009/30; G02F 1/1368 20060101 G02F001/1368; G02F 1/1362 20060101
G02F001/1362; G02F 1/1339 20060101 G02F001/1339; G02F 1/13 20060101
G02F001/13 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 31, 2017 |
KR |
10-2017-0042245 |
Claims
1. A method of manufacturing a stretched display panel by cutting a
ready-made display panel comprising a color filter substrate and a
thin film transistor (TFT) substrate to a desired size, the method
comprising: cutting the TFT substrate to a desired size; cutting
the color filter substrate so as to have a length smaller than a
length of the TFT substrate such that a pixel exposure portion,
from which one or more horizontal pixel lines are exposed, is
formed at the TFT substrate; forming an open-circuit line for
open-circuiting a portion defined between a horizontal pixel line
that is located at an end of the TFT substrate and another
horizontal pixel line adjacent thereto in order to prevent
electrical noise due to the horizontal pixel lines being introduced
into the end of the TFT substrate exposed from the pixel exposure
portion; and forming a reinforcement seal for covering the pixel
exposure portion using a reinforcement material in order to prevent
occurrence of short circuit due to introduction of foreign matter
into a gap defined between the horizontal pixel line and the other
horizontal pixel line and at the same time to increase rigidity of
the pixel exposure portion, wherein the step of forming the
reinforcement seal comprises applying the reinforcement material
through an application nozzle for applying the reinforcement
material, the application nozzle being disposed at an end of the
color filter substrate so as to be inclined toward the end of the
TFT substrate in order to spray the reinforcement material, such
that foreign matter on the pixel exposure portion is pushed by the
reinforcement material that is applied and is thus removed.
2. The method according to claim 1, further comprising: applying a
sealing material for preventing foreign matter from flowing into a
gap defined between the color filter substrate and the TFT
substrate when the open-circuit line is formed in order to form a
hermetically sealing seal, wherein the step of forming the
hermetically sealing seal is performed between the step of cutting
the color filter substrate so as to have the smaller length and the
step of forming the open-circuit line.
3. The method according to claim 1, further comprising: spraying
carbon dioxide in order to wash the display panel, wherein the step
of spraying the carbon dioxide is performed between the step of
forming the open-circuit line and the step of forming the
reinforcement seal.
4. The method according to claim 3, wherein the step of spraying
carbon dioxide in order to wash the display panel comprises washing
the display panel through a spray nozzle for applying the carbon
dioxide, the spray nozzle being disposed at the end of the color
filter substrate so as to be inclined toward the end of the TFT
substrate.
5. A stretched display panel manufactured using the method of
manufacturing the stretched display panel according to claim 1.
Description
TECHNICAL FIELD
[0001] The present invention relates to a stretched display panel
manufactured by cutting a ready-made display panel for displaying
an image and a method of manufacturing the same.
BACKGROUND ART
[0002] In general, a display panel, which is a device for
displaying an image, includes a thin film transistor (TFT)
substrate, a color filter substrate, and a liquid crystal layer
disposed therebetween.
[0003] In the display panel configured as described above, the
polymer liquid crystal layer blocks or transmits light emitted from
the TFT substrate, and the light is colored through the color
filter substrate, whereby an image is displayed.
[0004] Meanwhile, display panels are manufactured in standardized
sizes. In the case in which a non-standardized display panel is to
be used, therefore, a standardized display panel is cut.
[0005] A conventional method of cutting a display panel is
disclosed in Korean Registered Patent No. 10-0671215 (published on
Jan. 18, 2007) entitled FLAT DISPLAY PANEL AND METHOD OF CUTTING
THE SAME.
[0006] In the conventional flat display panel and the conventional
method of cutting the flat display panel, the flat display panel
includes two fragile material substrates bonded to each other using
a seal excluding openings, the two fragile material substrates and
the seal defining a closed space, one of the two fragile material
substrates has a scribed surface, which constitutes the outer
surface of the closed space, the scribed surface of one of the
fragile material substrates is opposite a non-scribed surface of
the other fragile material substrate, a terminal unit is located at
the scribed surface of one of the fragile material substrates, and
the scribed surface of one of the fragile material substrates is
cut first.
[0007] In the conventional flat display panel described above, the
lower fragile material substrate is cut with a margin in the
direction in which the lower fragile material substrate is bent,
whereby the upper and lower fragile material substrates can be cut
so as to have the same length.
[0008] When the conventional flat display panel is cut, however,
conductive foreign matter separated from circuits printed on the
fragile material substrates may be attached to a circuit substrate,
whereby noise may be generated due to short circuit, and therefore
the defect rate of the flat display panel may be high.
[0009] In addition, it is difficult to restore display panels in
which a noise defect occurs, and all such display panels must
therefore be discarded.
[0010] In addition, the cut portion of the display panel is
hermetically sealed using a seal; however, when the seal is
applied, a spray nozzle applies the seal in the vertical direction
or in the horizontal direction, whereby foreign matter may flow
into a gap between the fragile material substrates or may be fixed
to the fragile material substrates, and therefore a noise defect
may occur.
DISCLOSURE
Technical Problem
[0011] The present invention has been made in view of the above
problems, and it is an object of the present invention to provide a
stretched display panel configured such that the amount of noise
generated in the stretched display panel due to conductive foreign
matter is minimized when a display panel is cut in order to
manufacture the stretched display panel, whereby the defect rate of
the stretched display panel is reduced, such that an existing
display panel in which a noise defect occurs is capable of being
restored, whereby the number of stretched display panels that are
discarded is minimized, and such that foreign matter is removed
when a reinforcement seal is installed, whereby the defect rate of
the stretched display panel is minimized, and a method of
manufacturing the same.
Technical Solution
[0012] In accordance with an aspect of the present invention, the
above and other objects can be accomplished by the provision of a
method of manufacturing a stretched display panel by cutting a
ready-made display panel including a color filter substrate and a
thin film transistor (TFT) substrate to a desired size, the method
including cutting the TFT substrate to a desired size, cutting the
color filter substrate so as to have a length smaller than the
length of the TFT substrate such that a pixel exposure portion,
from which one or more horizontal pixel lines are exposed, is
formed at the TFT substrate, forming an open-circuit line for
open-circuiting a portion defined between a horizontal pixel line
that is located at the end of the TFT substrate and another
horizontal pixel line adjacent thereto in order to prevent
electrical noise due to the horizontal pixel lines being introduced
into the end of the TFT substrate exposed from the pixel exposure
portion, and forming a reinforcement seal for covering the pixel
exposure portion using a reinforcement material in order to prevent
occurrence of short circuit due to introduction of foreign matter
into a gap defined between the horizontal pixel line and the other
horizontal pixel line and at the same time to increase rigidity of
the pixel exposure portion, wherein the step of forming the
reinforcement seal includes applying the reinforcement material
through an application nozzle for applying the reinforcement
material, the application nozzle being disposed at the end of the
color filter substrate so as to be inclined toward the end of the
TFT substrate in order to spray the reinforcement material, such
that foreign matter on the pixel exposure portion is pushed by the
reinforcement material that is applied and is thus removed.
[0013] The method may further include applying a sealing material
for preventing foreign matter from flowing into a gap defined
between the color filter substrate and the TFT substrate when the
open-circuit line is formed in order to form a hermetically sealing
seal, wherein the step of forming the hermetically sealing seal may
be performed between the step of cutting the color filter substrate
so as to have the smaller length and the step of forming the
open-circuit line.
[0014] The method may further include spraying carbon dioxide in
order to wash the display panel, wherein the step of spraying the
carbon dioxide may be performed between the step of forming the
open-circuit line and the step of forming the reinforcement
seal.
[0015] The step of spraying carbon dioxide in order to wash the
display panel may include washing the display panel through a spray
nozzle for applying the carbon dioxide, the spray nozzle being
disposed at the end of the color filter substrate so as to be
inclined toward the end of the TFT substrate.
[0016] In accordance with another aspect of the present invention,
there is provided a stretched display panel manufactured using the
method of manufacturing the stretched display panel.
Advantageous Effects
[0017] According to the present invention, it is possible to
manufacture a stretched display panel in which the amount of noise
that is generated due to conductive foreign matter is minimized by
cutting a TFT substrate first, cutting a color filter substrate
such that a pixel exposure portion is formed at the TFT substrate,
installing a reinforcement seal at the TFT substrate, and forming
an open-circuit line at the TFT substrate at the time of cutting a
display panel.
[0018] In addition, an existing display panel in which a noise
defect occurs may be restored using the same method, whereby it is
possible to minimize the number of defective stretched display
panels that are discarded.
[0019] In addition, a reinforcement material is applied toward the
end of the TFT substrate in order to form a reinforcement seal,
whereby it is possible to remove foreign matter from the pixel
exposure portion. At the same time, the reinforcement seal is
formed so as to extend to the side surface of the end of the TFT
substrate, whereby it is possible to prevent inflow of foreign
matter.
[0020] In addition, washing is performed using carbon dioxide,
whereby it is possible to easily remove micro-scale conductive
foreign matter.
DESCRIPTION OF DRAWINGS
[0021] FIG. 1 is a plan view showing a stretched display panel
according to an embodiment of the present invention.
[0022] FIG. 2 is a perspective view illustrating a method of
manufacturing a stretched display panel according to an embodiment
of the present invention, showing the state in which a TFT
substrate is cut.
[0023] FIG. 3 is a perspective view illustrating the method of
manufacturing the stretched display panel according to the
embodiment of the present invention, showing the state in which a
color filter substrate is cut.
[0024] FIG. 4 is a perspective view illustrating the method of
manufacturing the stretched display panel according to the
embodiment of the present invention, showing the state in which a
hermetically sealing seal is formed.
[0025] FIG. 5 is a perspective view illustrating the method of
manufacturing the stretched display panel according to the
embodiment of the present invention, showing the state in which an
open-circuit line is formed.
[0026] FIG. 6 is a side sectional view illustrating the method of
manufacturing the stretched display panel according to the
embodiment of the present invention, showing the state in which the
stretched display panel is washed through a spray nozzle.
[0027] FIG. 7 is a side sectional view illustrating the method of
manufacturing the stretched display panel according to the
embodiment of the present invention, showing the state in which a
reinforcement material is applied through an application
nozzle.
[0028] FIG. 8 is a partial side sectional view showing a stretched
display panel manufactured using the method of manufacturing the
stretched display panel according to the embodiment of the present
invention.
DESCRIPTION OF REFERENCE NUMERALS
[0029] 100: Stretched display panel 110: TFT substrate [0030] 111:
Pixel exposure portion 113: Horizontal pixel lines [0031] 130:
Polymer liquid crystal layer 150: Color filter substrate [0032]
160: Hermetically sealing seal 170: Open-circuit line [0033] 180:
Reinforcement seal 190: Drive circuit substrate [0034] 200:
Ready-made display panel 210: Spray nozzle [0035] 230: Application
nozzle
BEST MODE
[0036] Hereinafter, embodiments of the present invention will be
described with reference to the accompanying drawings.
[0037] A stretched display panel 100 according to the present
invention may be a display panel that is manufactured by cutting a
ready-made display panel 200 into a desired shape, or may be a
stretched display panel that is manufactured in advance and is
defective.
[0038] As shown in FIG. 1, the portion of a ready-made display
panel 200 that is opposite the portion of the ready-made display
panel to which a drive circuit is attached is cut in the horizontal
direction such that only the portion of the ready-made display
panel to which a tab of a drive circuit substrate 190 is attached
is used as a stretched display panel 100, and the remaining portion
of the ready-made display panel is discarded without being
used.
[0039] The stretched display panel 100, which is manufactured by
cutting the ready-made display panel in the horizontal direction,
as described above, has an aspect ratio of, for example, 2 or
more:1, rather than a general aspect ratio of 16:9, 16:10, or 4:3.
For this reason, the display panel manufactured as described above
is called a stretched display panel 100.
[0040] Here, the display panel 200, from which the stretched
display panel 100 is manufactured, may be a liquid crystal display
(LCD).
[0041] First, a method of manufacturing a stretched display panel
100 according to an embodiment of the present invention will be
described.
[0042] As shown in FIG. 2, the stretched display panel 100
according to the embodiment of the present invention is
manufactured by cutting only a thin film transistor (TFT) substrate
110 of a ready-made display panel 200 to a desired size first.
[0043] At this time, the TFT substrate 110 may be cut using any
cutting means, such as a diamond wheel, a laser, a water jet, or
chemical etching.
[0044] When the TFT substrate 110 is cut, pixels or gate lines in
the cut portion of the TFT substrate are damaged by the cutting
means. In this embodiment, therefore, the TFT substrate 110 is cut
with a margin equivalent to about three horizontal pixel lines 113
in consideration of the pixels that are damaged. Alternatively, one
or more horizontal pixel lines 113 may be left.
[0045] Each of the horizontal pixel lines 113 is a line in which
electrical pixels are arranged horizontally on the TFT substrate
110, and gate lines for electrically connecting the horizontal
pixel lines may be included.
[0046] As shown in FIG. 3, the display panel 200 is turned upside
down after the TFT substrate 110 is cut, and then a color filter
substrate 150 is cut.
[0047] Meanwhile, the color filter substrate 150 is cut so as to
have a length smaller than the length of the TFT substrate 110 such
that a pixel exposure portion 111, from which a plurality of
horizontal pixel lines 113 is exposed, is formed at the TFT
substrate 110.
[0048] In the same manner as when cutting the TFT substrate 110,
the color filter substrate 150 may be cut using any of cutting
means, such as a diamond wheel, a laser, or chemical etching.
[0049] At least two horizontal pixel lines 113, which are left in
consideration of the pixels that are damaged when the TFT substrate
110 is cut, may be exposed from the TFT substrate 110.
[0050] Meanwhile, the pixel exposure portion 111 of the TFT
substrate 110, from which the horizontal pixel lines 113 are
exposed, may function to support the lower end of a hermetically
sealing seal 160, which will be described below, in order to form
the hermetically sealing seal 160.
[0051] In the case in which the color filter substrate 150 and the
TFT substrate 110 are cut so as to have the same length, a gel-type
sealing material runs down when the hermetically sealing seal 160
is installed between the color filter substrate 150 and the TFT
substrate 110, whereby it is difficult to form the hermetically
sealing seal 160.
[0052] In addition, it is necessary to use a gel-type hermetically
sealing seal 160 having high viscosity in order to easily fix the
gel-type hermetically sealing seal 160, whereby the thickness of
the hermetically sealing seal 160 may be increased, and the amount
of material that is used to form the hermetically sealing seal 160
may be increased.
[0053] After the color filter substrate 150 is cut, the portion of
a polymer liquid crystal layer 130 that is located above the pixel
exposure portion 111 may be removed.
[0054] As shown in FIG. 4, after both the color filter substrate
150 and the TFT substrate 110 are cut, the hermetically sealing
seal 160 may be formed in order to prevent foreign matter from
flowing into a gap between the color filter substrate 150 and the
TFT substrate 110, and at the same time to protect the polymer
liquid crystal layer 130, which is located between the color filter
substrate 150 and the TFT substrate 110, from being discharged
therefrom.
[0055] Meanwhile, the portion at which the hermetically sealing
seal 160 will be formed may be washed in order to remove foreign
matter therefrom, and then the hermetically sealing seal 160 may be
formed by applying a sealing material to the circumference of the
end of the color filter substrate 150.
[0056] At this time, the hermetically sealing seal 160 may be
installed such that at least one horizontal pixel line 113 that is
adjacent to the end of the color filter substrate 150 is also
hermetically sealed.
[0057] Here, the hermetically sealing seal 160 may perform both a
function of preventing outflow of the polymer liquid crystal layer
130 and a function of preventing foreign matter from flowing into
horizontal pixel lines 113 that are not damaged.
[0058] The hermetically sealing seal 160 may be formed by applying
a hardenable resin in order to prevent the color filter substrate
and the TFT substrate 110 from being damaged by heat and then
performing hardening treatment on the hardenable resin such that
the hardenable resin is hardened.
[0059] Here, the hardening treatment may be performed differently
depending on kind of the hardenable resin. For example, a natural
hardenable resin may be left at a normal temperature for a
predetermined amount of time, a thermosetting resin may be
thermally treated, and ultraviolet light may be applied to an
ultraviolet (UV)-curable resin.
[0060] As shown in FIG. 5, after the hermetically sealing seal 160
is installed at the end of the color filter substrate 150, an
open-circuit line 170 is formed in order to electrically open the
horizontal pixel lines 113 that are exposed from the pixel exposure
portion 111 such that noise is prevented from being generated by
possible conductive foreign matter.
[0061] Meanwhile, the open-circuit line 170 may be formed between a
horizontal pixel line 113 that is located at the end of the TFT
substrate 110 and another horizontal pixel line 113 adjacent
thereto, or may be formed between a horizontal pixel line 113 that
is covered by the hermetically sealing seal 160 and an adjacent
horizontal pixel line 113 that is not covered by the hermetically
sealing seal 160.
[0062] In addition, the open-circuit line 170 may be formed on a
horizontal pixel line 113 that is located between horizontal pixel
lines 113, or may be formed on a conductor for electrically
connecting the horizontal pixel lines 113 to each other.
Alternatively, the open-circuit line 170 may be formed by applying
a laser to the electrical connection portion in order to remove the
electrical connection portion through incineration.
[0063] In the case in which the open-circuit line 170 is formed
through incineration using the laser, it is possible to minimize
the amount of conductive foreign matter that is separated from the
horizontal pixel lines 113, whereby it is possible to prevent
generation of noise due to short circuit.
[0064] In addition, the horizontal pixel line 113 that is located
at the end of the TFT substrate 110 as the result of being cut by
the open-circuit line 170 may perform a function of extinguishing
overcurrent/overvoltage generated due to static electricity, etc.
and thus inhibiting generation of noise.
[0065] Meanwhile, after the open-circuit line 170 is formed on the
horizontal pixel line 113, a preliminary inspection may be carried
out.
[0066] The preliminary inspection is carried out as follows. The
drive circuit is powered on in order to temporarily drive the
stretched display panel 100, and then inspection is performed in
order to determine whether noise is generated in the stretched
display panel 100.
[0067] When the color filter substrate 150 or the TFT substrate 110
is cut, foreign matter is generated therefrom. In particular,
conductive foreign matter is generated from the TFT substrate 110
due to the characteristics thereof. The generated conductive
foreign matter flows into the exposed pixels, whereby a short
circuit occurs. When the short-circuited display panel 200 is
driven, noise is generated, whereby a horizontally striped pattern
image is not displayed.
[0068] As shown in FIG. 6, in the case in which noise is generated
when the preliminary inspection is carried out, the portion of the
display panel in which the noise is generated may be inspected
intensively in order to remove foreign matter, or the pixel
exposure portion 111, from which the horizontal pixel lines 113 are
exposed, may be entirely washed in order to remove foreign
matter.
[0069] Of course, the pixel exposure portion 111 may be entirely
washed in order to form a reinforcement seal 180 in the next
process even in the case in which no preliminary inspection is
carried out.
[0070] Meanwhile, carbon dioxide (CO.sub.2) may be sprayed onto the
pixel exposure portion 111 in order to wash the pixel exposure
portion 111.
[0071] Here, carbon dioxide has low surface tension, whereby the
carbon dioxide may easily permeate into a microporous structure. In
addition, carbon dioxide has a higher diffusion coefficient than
liquid and has similar solubility to liquid, whereby the washing
effect of the carbon dioxide is high, and therefore it is possible
to easily remove micro-scale conductive material.
[0072] A spray nozzle 210, which is configured to spray carbon
dioxide, may be installed so as to be inclined at a predetermined
angle in order to spray the carbon dioxide toward the end of the
TFT substrate 110, which extends from the end of the color filter
substrate 150.
[0073] In the case in which carbon dioxide is sprayed through the
spray nozzle 210 in the state in which the spray nozzle is
installed so as to be inclined, as described above, the carbon
dioxide may be naturally discharged to the end of the TFT substrate
110 together with foreign matter without colliding with any
obstacle, whereby it is possible to completely remove the foreign
matter. In addition, it is possible to remove the conductors
remaining at the end of the TFT substrate 110 when the TFT
substrate 110 is cut together with the foreign matter by cutting
the conductors using the pressure of the carbon dioxide that is
sprayed (see FIG. 5).
[0074] As shown in FIG. 7, after the pixel exposure portion 111 is
washed, a reinforcement seal 180 may be installed at the pixel
exposure portion 111 in order to prevent foreign matter from
flowing into the pixel exposure portion 111 and at the same time to
increase the rigidity of the pixel exposure portion 111, the
thickness of which is relatively small.
[0075] The reinforcement seal 180 may be formed so as to entirely
cover the pixel exposure portion 111 from the end of the color
filter substrate 150 to the end of the TFT substrate 110 in order
to reinforce the pixel exposure portion 111.
[0076] A reinforcement material may be realized by the same
hardenable resin as the sealing material. The hardenable resin may
be applied to the portion at which the reinforcement seal 180 will
be formed, and hardening treatment may be performed on the
hardenable resin such that the hardenable resin is hardened in
order to form the reinforcement seal 180. The reinforcement seal
180 may be installed so as to also cover the hermetically sealing
seal 160.
[0077] Meanwhile, the hardenable resin, which is realized as the
reinforcement material, may be a naturally hardenable resin or a
thermosetting resin.
[0078] However, a UV-curable resin, which is hardened by
ultraviolet light, may be used as the hardenable resin in order to
minimize damage to the pixels due to heat. The reinforcement
material may be a material having higher hardness than the sealing
material after being hardened.
[0079] The reinforcement material may be applied through an
application nozzle 230 in order to form the reinforcement seal 180,
whereby the reinforcement seal is installed. The application nozzle
230 may be installed so as to be inclined at a predetermined angle
in order to spray the reinforcement material toward the end of the
TFT substrate 110, which extends from the end of the color filter
substrate 150.
[0080] In the case in which the reinforcement material is applied
through the application nozzle 230 in the state in which the spray
nozzle is installed so as to be inclined, as described above, the
reinforcement material may move from the end of the color filter
substrate 150 toward the end of the TFT substrate. At this time,
foreign matter remaining on the pixel exposure portion may be
discharged to the end of the TFT substrate, whereby the foreign
matter may be removed when the reinforcement seal is installed.
[0081] In addition, when the reinforcement material is discharged
from the TFT substrate 110, the reinforcement material may flow
downwards from the end of the TFT substrate 110, whereby the end of
the TFT substrate 110 may be covered by the reinforcement seal 180,
and therefore it is possible to prevent foreign matter from flowing
into a gap between the reinforcement seal 180 and the TFT substrate
110.
[0082] Meanwhile, after the reinforcement seal 180 is formed on the
pixel exposure portion 111, a final inspection is carried out.
[0083] The final inspection is carried out in the same manner as
the preliminary inspection. That is, the stretched display panel
100 is powered on in order to drive the stretched display panel
100, and then noise is detected in the stretched display panel
100.
[0084] Here, the final inspection may be accurately performed based
on an image of the display panel 100 captured using a camera, or
may be performed by the naked eye.
[0085] In the case in which noise is generated during the final
inspection, the hermetically sealing seal 160 and the reinforcement
seal 180 may be removed, and then foreign matter may be removed or
washed. Alternatively, the open-circuit line 170 may be formed
again, the hermetically sealing seal 160 and the reinforcement seal
180 may be formed again, and the inspection may be carried out
again.
[0086] After passing the final inspection, the manufacture of the
stretched display panel 100 according to the embodiment of the
present invention is completed. The manufactured stretched display
panel 100 may be delivered as is, or may be installed at a place at
which the stretched display panel 100 is to be installed in order
to use the stretched display panel 100.
[0087] In addition, the method of manufacturing the stretched
display panel 100 according to the embodiment of the present
invention may also be used in order to restore an existing
stretched display panel 100 that is classified as a defective panel
due to noise generated therein.
[0088] Meanwhile, as shown in FIG. 8, a stretched display panel
100, manufactured using the method of manufacturing the stretched
display panel 100 according to the embodiment of the present
invention, is configured to have a structure in which a TFT
substrate 110 protrudes further than a color filter substrate 150
such that horizontal pixel lines 113 are exposed and in which a
hermetically sealing seal 160 for preventing outflow of a polymer
liquid crystal layer is installed at the end of a color filter
substrate 150.
[0089] In addition, the stretched display panel is configured to
have a structure in which an open-circuit line 170 is formed
between a horizontal pixel line 113 that is located at the end of
the TFT substrate 110 and another horizontal pixel line 113
adjacent thereto in order to form an electrical open circuit
therebetween and in which a reinforcement seal 180 is finally
installed in order to entirely cover a pixel exposure portion
111.
[0090] In the stretched display panel 100, manufactured using the
method of manufacturing the stretched display panel 100 according
to the embodiment of the present invention, it is possible to
minimize the amount of noise that is generated in the stretched
display panel due to foreign matter, whereby it is possible to
considerably reduce the defect rate of the stretched display panel
100.
[0091] In addition, it is possible to restore an existing stretched
display panel 100 that is determined to be a defective panel due to
noise generated therein, whereby it is possible to minimize
financial loss due to discarding the same.
[0092] In addition, the reinforcement material is applied toward
the end of the TFT substrate 110 in order to form the reinforcement
seal 180, whereby it is possible to remove foreign matter using the
reinforcement material that is applied. At the same time, the
reinforcement seal 180 is formed so as to extend to the end of the
TFT substrate 110, whereby it is possible to prevent generation of
noise due to introduction of foreign matter into a gap between the
reinforcement seal 180 and the TFT substrate 110.
[0093] In addition, carbon dioxide is sprayed at the time of
washing the pixel exposure portion 111, whereby it is possible to
easily remove foreign matter using the carbon dioxide. The carbon
dioxide is sprayed toward the end of the TFT substrate 110 in order
to wash the TFT substrate 110, whereby it is possible to remove the
conductors remaining at the end of the TFT substrate 110 by cutting
the conductors using the carbon dioxide that is sprayed.
[0094] Although the preferred embodiments of the present invention
have been disclosed for illustrative purposes, those skilled in the
art will appreciate that various modifications, additions and
substitutions are possible, without departing from the scope and
spirit of the invention as disclosed in the accompanying
claims.
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