Abstract:
An exemplary LCD panel ( 40 ) includes a first substrate ( 41 ) and a second substrate ( 42 ) opposite to each other, and a plurality of main sealants ( 43 ), a dummy sealant ( 44 ), and one or more dividing lines provided at one of the first and second substrates. The dummy sealant surrounds the main sealants. The dividing lines intersect the dummy sealant, the dummy sealant thereby define a plurality of overlap portions. And liquid crystal is disposed within each of the main sealants. A plurality of shielding portions ( 423 ) is provided at one of the first and second substrates, the shielding portions is positioned corresponding to the overlapped portions. With this configuration, it will be easier to cut the LCD panel into unit cells. Further, the LCD panel eliminates the need for mask, this decreases the costs thereof.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention relates to liquid crystal display (LCD) panels and their methods of manufacture, and especially to an LCD panel manufactured by a one-drop-fill (ODF) method.  
       BACKGROUND  
       [0002]     An LCD panel generally includes two glass substrates, a peripheral sealant, and a plurality of liquid crystal molecules disposed between the substrates. The sealant is printed on one of the glass substrates, and then adhered to the other glass substrate. The substrates and the sealant cooperatively form a space therebetween, with the liquid crystal molecules being filled in the space.  
         [0003]     There are generally two methods used for filling the liquid crystal molecules into the space. The first method is to fill the liquid crystal molecules through filling ports. This method includes the following steps: firstly, coating a sealant on a first glass substrate, the sealant being rectangular and having one or more gaps that function as filling ports; secondly, attaching a second glass substrate to the first glass substrate and curing the sealant, with a space being enclosed by the sealant and the two glass substrates; thirdly, immersing the filling ports in a liquid crystal in a vacuum chamber; and finally, introducing gas into the vacuum chamber to make the liquid crystal molecules fill up the space.  
         [0004]     The second method is the so-called one-drop-fill (ODF) method. This method comprises the following steps: firstly, printing a sealant on a first glass substrate, wherein the sealant is rectangular and continuous, and a space is enclosed by the sealant and the first glass substrate; secondly, putting liquid crystal molecules into the space drop by drop using a dispenser; and finally, combining a second glass substrate with the first glass substrate and curing the sealant.  
         [0005]     Referring to  FIG. 6 , a conventional LCD panel  10  includes a first substrate  11  and a second substrate  12  disposed opposite to each other and spaced apart a predetermined distance, a plurality of main sealants  13  and a dummy sealant  14  coated on an inner surface of the first substrate  11 , and a plurality of liquid crystal droplets  15  arranged on parts of the inner surface of the first substrate  11  surrounded by each of the main sealants  13 . The number of main sealants  13  corresponds to the number of LCD panel units that the LCD panel  10  can eventually yield. Each panel unit is used in the manufacture of a corresponding LCD device. The liquid crystal droplets  15  in each main sealant  13  eventually form a liquid crystal layer of a corresponding LCD panel unit.  
         [0006]     The main sealants  13  prevent the liquid crystal from leaking, and bond the first and second substrates  11 ,  12  together. The dummy sealant  14  is formed at a dummy region outside the main sealants  13 , and is for protecting the main sealants  13 .  
         [0007]     Also referring to  FIG. 7 , this is a plan view showing a plurality of scribing lines  16 , the main sealants  13 , and the dummy sealant  14  formed on the first substrate  11  of the LCD panel  10 . The scribing lines  16  are formed on the inner surface of the first substrate  11  using a scriber. The scribing lines  16  overlap portions of the dummy sealant  14 , thereby defining overlapping regions. Accordingly, the portions of the dummy sealant  14  located at the overlapping regions are referred as overlapped portions  161 .  
         [0008]     Also referring to  FIG. 8 , in assembly, the first substrate  11  and the second substrate  12  are attached together. An ultraviolet irradiating device  17  is provided above the second substrate  12  for curing the sealants  13 ,  14 , with a mask  18  being interposed between the ultraviolet irradiating device  17  and the second substrate  12 . The mask  18  defines a plurality of shielding areas  181  corresponding to the overlapped portions  161  of the dummy sealant  14 . The ultraviolet irradiating device  17  irradiates the second substrate  12  with ultraviolet (UV) rays and cures the sealants  13 ,  14 . The substrates  11 ,  12  are thereby bonded together, and the LCD panel  10  is thus assembled. Then the LCD panel  10  is sheared along the scribing lines  16 , thereby dividing the LCD panel  10  into a plurality of LCD panel units.  
         [0009]     Because the overlapped portions  161  of the dummy sealant  14  are masked during the UV irradiation process, the overlapped portions  161  are not hardened. This makes shearing of the LCD panel  10  along the scribing lines  16  easier.  
         [0010]     However, the need for the mask  18  increases the cost of the whole process. Further, the mask  18  must be accurately positioned between the ultraviolet irradiating device  17  and the second substrate  12 , so that the shielding areas  181  are precisely located above the overlapped portions  161  of the dummy sealant  14 . This can be time-consuming and troublesome. Further, if the mask  18  is not accurately positioned, the overlapped portions  161  may be cured or partly cured. When this happens, it is more difficult to shear the LCD panel  10  along the scribing lines  16 .  
         [0011]     Therefore, what is needed is an LCD panel which can overcome the above-described problems.  
       SUMMARY  
       [0012]     An LCD panel includes a first substrate and a second substrate opposite to each other, and a plurality of main sealants, a dummy sealant, and one or more dividing lines provided at one of the first and second substrates. The dummy sealant surrounds the main sealants. The dividing lines intersect the dummy sealant, the dummy sealant thereby define a plurality of overlap portions. And liquid crystal is disposed within each of the main sealants. A plurality of shielding portions is provided at one of the first and second substrates, the shielding portions is positioned corresponding to the overlapped portions.  
         [0013]     A method for manufacturing the LCD panel includes the steps of: providing a first substrate and a second substrate; forming a plurality of main sealants, a dummy sealant, and one or more dividing lines at one of the first and second substrates, the dummy sealant surrounding the main sealants, the dividing lines intersecting the dummy sealant, the dummy sealant thereby defining a plurality of overlap portions; forming a plurality of shielding portions at one of the first and second substrates, the shielding portions being positioned corresponding to the overlapped portions of the dummy sealant; dropping a plurality of liquid crystal droplets on regions of said one of the first and second substrates which are surrounded by the main sealant; attaching the first and second substrates together; irradiating the main and dummy sealant with UV rays, with the overlapped portions shielded by the shielding portions, thereby bonding the first and second substrates together; and dividing the bonded substrates into a plurality of LCD units.  
         [0014]     In summary, the shielding portions prevent UV rays from irradiating the overlapped portions of the dummy sealant. That is, the overlapped portions are not hardened so that it will be easier to cut the LCD panel into unit cells. Further, the LCD panel eliminates the need for mask, this decreases the costs thereof.  
         [0015]     Other novel features and advantages will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0016]      FIG. 1  is a schematic, exploded, isometric view of an LCD panel according to a first embodiment of the present invention, the LCD panel comprising two substrates.  
         [0017]      FIG. 2  is similar to  FIG. 1 , but showing the substrates attached together, and an ultraviolet irradiating device above the substrates irradiating a top one of the substrates with UV rays.  
         [0018]      FIG. 3  is a schematic, exploded, isometric view of a plurality of LCD panel units obtained after dividing the duly irradiated LCD panel shown in  FIG. 2 .  
         [0019]      FIG. 4  is a schematic, exploded, isometric view of an LCD panel according to a second embodiment of the present invention, the LCD panel comprising two substrates.  
         [0020]      FIG. 5  is similar to  FIG. 4 , but showing the substrates attached together, and an ultraviolet irradiating device below the substrates irradiating a bottom one of the substrates with UV rays.  
         [0021]      FIG. 6  is a schematic, exploded, isometric view of a conventional LCD panel, the LCD panel comprising two substrates.  
         [0022]      FIG. 7  is a top plan view of a bottom one of substrates of the LCD panel of  FIG. 6 , showing main sealants, a dummy sealant, and a plurality of scribing lines formed thereon.  
         [0023]      FIG. 8  is similar to  FIG. 6 , but showing the substrates attached together, and an ultraviolet irradiating device above the substrates irradiating a top one of the substrates with UV rays through a mask disposed therebetween. 
     
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS  
       [0024]     Referring to  FIG. 1 , an LCD panel  40  according to a first embodiment of the present invention includes a first substrate  41  and a second substrate  42  disposed opposite to each other and spaced apart a predetermined distance, a plurality of main sealants  43  and a dummy sealant  44  coated on an inner surface of the first substrate  41 , and a plurality of liquid crystal droplets  45  on the inner surface of the first substrate  41  surrounded by each of the main sealants  43 . The number of main sealants  43  corresponds to the number of LCD panel units (see  FIG. 3 ) that the LCD panel  40  can eventually yield. Each panel unit is used in the manufacture of a corresponding LCD device. The liquid crystal droplets  45  in each main sealant  43  eventually form a liquid crystal layer of a corresponding LCD panel unit.  
         [0025]     The main sealants  43  prevent the liquid crystal from leaking, and bond the first and second substrates  41 ,  42  together. The dummy sealant  44  is formed at a dummy region outside the main sealants  43 , and is for protecting the main sealants  43 .  
         [0026]     A plurality of scribing lines (not shown) are formed on the inner surface of the first substrate  41  using a scriber. The scribing lines overlap portions of the dummy sealant  44 , thereby defining overlapping regions. Accordingly, the portions of the dummy sealant  44  located at the overlapping regions are referred to as overlapped portions. A plurality of shielding portions  423  are formed at an inner surface  421  of the second substrate  42 , and are positioned corresponding to the overlapped portions. The shielding portions  423  are portions of black matrix, which can prevent light beams from passing therethrough. The black matrix is a portion of color filter (not shown) formed at an inner surface  421  of the second substrate  42 .  
         [0027]     Also referring to  FIG. 2 , in assembly, the first substrate  41  and the second substrate  42  are attached together. An ultraviolet irradiating device  47  is provided above the second substrate  42 . The ultraviolet irradiating device  47  irradiates the second substrate  42  with UV rays and cures the sealants  43 ,  44 . The substrates  41 ,  42  are thereby bonded together, and the LCD panel  40  is thus assembled.  
         [0028]     Also referring to  FIG. 3 , the LCD panel  40  is then sheared along the scribing lines, thereby dividing the LCD panel  40  into a plurality of LCD panel units  51 ,  52 ,  53 ,  54 . Because the overlapped portions of the dummy sealant  44  are shielded by the shielding portions  423  during the UV irradiation process, the overlapped portions are not hardened. This makes shearing of the LCD panel  40  along the scribing lines easier.  
         [0029]     In summary, the shielding portions  423  prevent UV rays from irradiating the overlapped portions of the dummy sealant  44 . Thus the overlapped portions are not hardened, and it is easier to shear the LCD panel  40  into the individual LCD panel units  51 ,  52 ,  53 ,  54 . Further, the LCD panel  40  eliminates the need for a mask in the assembly process, thereby reducing costs.  
         [0030]     A method for manufacturing and dividing the LCD panel  40  includes the steps of: providing the first substrate  41  and the second substrate  42 ; forming the main sealants  43  and the dummy sealant  44  on the first substrate  41 , the dummy sealant  44  surrounding the main sealants  43 ; forming the scribing lines on the first substrate  41 , wherein portions of the dummy sealant  44  overlapped by the scribing lines are defined as the overlapped portions; forming the shielding portions  423  at the second substrate  42  at positions corresponding to the overlapped portions of the dummy sealant  44 ; dropping a plurality of liquid crystal droplets  45  on regions of the first substrate  41  surrounded by the main sealants  43 ; attaching the first and second substrates  41 ,  42  together; irradiating the sealants  43 ,  44  with UV rays, with the overlapped portions being shielded by the shielding portions  423 , thereby bonding the substrates  41 ,  42  together and forming the LCD panel  40 ; and dividing the LCD panel  40  into the plurality of LCD panel units  51 ,  52 ,  53 ,  54 .  
         [0031]     In an alternative embodiment of the LCD panel  40 , the shielding portions  423  can instead be formed at an outer surface of the second substrate  42 . The shielding portions  423  are positioned corresponding to the overlapped portions of the dummy sealant  44 . The shielding portions  423  maybe formed at the outer surface of the second substrate  42  by adhering.  
         [0032]     Referring to  FIG. 4 , an LCD panel  60  according to a second embodiment of the present invention includes a first substrate  61  and a second substrate  62  disposed opposite to each other and spaced apart a predetermined distance, a plurality of main sealants  63  and a dummy sealant  64  coated on an inner surface  611  of the first substrate  61 , and a plurality of liquid crystal droplets  65  on the inner surface of the first substrate  61  surrounded by each of the main sealants  63 . The number of main sealants  63  corresponds to the number of LCD panel units that the LCD panel  60  can eventually yield. Each panel unit is used in the manufacture of a corresponding LCD device. The liquid crystal droplets  65  in each main sealant  63  eventually form a liquid crystal layer of a corresponding LCD panel unit.  
         [0033]     The main sealants  63  prevent the liquid crystal from leaking, and bonds the first and second substrates  61 ,  62  together. The dummy sealant  64  is formed at a dummy region outside the main sealants  63 , and is for protecting the main sealants  63 .  
         [0034]     A plurality of scribing lines (not shown) are formed on the inner surface of the first substrate  61  using a scriber. The scribing lines overlap portions of the dummy sealant  64 , thereby defining overlapping regions. Accordingly, the portions of the dummy sealant  64  located at the overlapping regions are referred to as overlapped portions. A plurality of shielding portions  613  are formed at the inner surface  611  of the first substrate  61 , and are positioned corresponding to the overlapped portions. The shielding portions  613  are made of opaque metal, which can prevent light beams from passing therethrough. The shielding portions  613  maybe formed at the inner surface  611  of the first substrate  61  at the same time with gate and/or source electrode.  
         [0035]     Also referring to  FIG. 5 , in assembly, the first substrate  61  and the second substrate  62  are attached together. An ultraviolet irradiating device  67  is provided below the first substrate  61 . The ultraviolet irradiating device  67  irradiates the first substrate  61  with UV rays and cures the sealants  63 ,  64 . The substrates  61 ,  62  are thereby bonded together, and the LCD panel  60  is thus assembled.  
         [0036]     The LCD panel  60  is then sheared along the scribing lines, thereby dividing the LCD panel  60  into a plurality of LCD panel units. Because the overlapped portions of the dummy sealant  64  are shielded by the shielding portions  613  during the UV irradiation process, the overlapped portions are not hardened. This makes shearing of the LCD panel  60  along the scribing lines easier.  
         [0037]     In summary, the shielding portions  613  prevent UV rays from irradiating the overlapped portions of the dummy sealant  64 . Thus, the overlapped portions are not hardened, and it is easier to shear the LCD panel  60  into the individual LCD panel units. Further, the LCD panel  60  eliminates the need for a mask in the assembly process, thereby reducing costs.  
         [0038]     A method for manufacturing and dividing the LCD panel  60  includes the steps of: providing the first substrate  61  and the second substrate  62 ; forming the main sealants  63  and the dummy sealant  64  on the first substrate  61 , the dummy sealant  64  surrounding the main sealants  63 ; forming the scribing lines on the first substrate  61 , wherein portions of the dummy sealant  64  overlapped by the scribing lines are defined as the overlapped portions; forming the shielding portions  613  at the first substrate  61  at positions corresponding to the overlapped portions of the dummy sealant  64 ; dropping a plurality of liquid crystal droplets  65  on regions of the inner surface  611  of the first substrate  61  surrounded by the main sealants  63 ; attaching the first and second substrates  61 ,  62  together; irradiating the sealants  63 ,  64  with UV rays, with the overlapped portions being shielded by the shielding portions  613 , thereby bonding the substrates  61 ,  62  together and forming the LCD panel  40 ; and dividing the LCD panel  60  into a plurality of LCD panel units.  
         [0039]     In an alternative embodiment of the LCD panel  60 , the shielding portions  613  can instead be formed at an outer surface of the first substrate  61 . The shielding portions  613  are positioned corresponding to the overlapped portions of the dummy sealant  64 . The shielding portions  613  maybe formed at the outer surface of the first substrate  61  by adhering.  
         [0040]     Also in an alternative embodiment of the LCD panels, the dummy sealant can instead overlap the scribing lines.  
         [0041]     It is to be understood, however, that even though numerous characteristics and advantages of various embodiments have been set forth in the foregoing description, together with details of the structures and functions of the embodiments, the disclosure is illustrative only, and changes may be made in detail to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.