Method of fabricating liquid crystal display device

A method of fabricating a liquid crystal display device includes: a first step of attaching a polarizing plate to an outer surface of a liquid crystal panel; a second step of attaching a tape carrier package (TCP) to the liquid crystal panel; a third step of coating a resin onto a rear surface of the TCP and a connection portion of the liquid crystal panel and the TCP; a fourth step of inspecting the TCP and the liquid crystal display panel; a fifth step of inserting the liquid crystal panel into a transferring means; a sixth step of transferring the transferring means; a seventh step of extracting the liquid crystal panel from the transferring means; a eighth step of attaching the TCP to a printed circuit board (PCB); a ninth step of inspecting the PCB, the TCP and the liquid crystal panel; and a tenth step of assembling the liquid crystal panel and a backlight unit with a plurality of frames.

This application claims the benefit of Korean Patent Application No. 10-2008-0132543, filed in Korea on Dec. 23, 2008, which is hereby incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present application relates to a method of fabricating a liquid crystal display device, and more particularly, to a method of fabricating a liquid crystal display device having a liquid crystal panel, a printed circuit board and a tap carrier package.

2. Discussion of the Related Art

As information age progresses, flat panel display (FPD) devices having light weight, thin profile, and low power consumption have been substituted for cathode ray tube (CRT) devices. Liquid crystal display (LCD) devices, plasma display panel (PDP) devices, field emission display (FED) devices, and electroluminescent display (ELD) devices are examples of the FPD devices. Since the LCD devices have excellent characteristics of high resolution, high contrast ratio and displaying moving images, the LCD devices have been widely used in a notebook computer, a monitor and a television.

In general, an LCD device includes a driving circuit unit that generates a gate signal, a data signal and a control signal using an image signal from an external system and supplies a power, a liquid crystal panel that displays images using the gate signal, the data signal and the control signal, and a backlight unit that supplies a light to the liquid crystal panel.

For example, the driving circuit unit includes a printed circuit board (PCB), where circuits generating RGB data and control signals using the image signal and a clock signal of the external system are formed, and a tape carrier package (TCP), where circuits generating the gate signal and the data signal using the RGB data and the control signals are formed. The PCB is connected to the liquid crystal panel through the TCP. The liquid crystal panel includes a first substrate having a pixel electrode, a second substrate having a common electrode and a liquid crystal layer. The first and second substrates face and are spaced apart from each other and the liquid crystal layer is interposed between the first and second substrates. The transmittance of the liquid crystal layer is changed according to the electric field generated between the pixel electrode and the common electrode to display the images. The backlight unit is disposed under the liquid crystal panel as a light source of the LCD device.

The LCD device is completed by modularizing the driving circuit unit, the liquid crystal panel and the backlight unit with a top frame, a main frame and a bottom frame. The steps of attaching the driving circuit unit such as the PCB and the TCP to the liquid crystal panel and wrapping the driving circuit unit, the liquid crystal panel and the backlight unit with the top, main and bottom frames may be referred to as a module process.

FIG. 1is a view showing a method of fabricating a liquid crystal display device according to the related art.

InFIG. 1, a liquid crystal panel is fabricated through a panel process line100. In a module process line200, a tape carrier package (TCP) and a printed circuit board (PCB) are attached to the liquid crystal panel, and the liquid crystal panel, the TCP, the PCB and a backlight unit are assembled using a top frame, a main frame and a bottom frame, thereby a liquid crystal display (LCD) device completed.

In a liquid crystal injection apparatus110, a liquid crystal layer is formed between a first substrate having a gate line, a data line, a thin film transistor (TFT) and a pixel electrode and a second substrate having a color filter layer, a black matrix and a common electrode, thereby the liquid crystal panel completed. The completed liquid crystal panel in the liquid crystal injection apparatus110is transferred to an auto probe apparatus120. Defects of the liquid crystal panel such as an electric shortage or an electric disconnection in the gate line and the data line are inspected in the auto probe apparatus120.

The liquid crystal panel passing the inspection of defects in the auto probe apparatus120is transferred to a polarizing plate attachment apparatus210in the module process line200. In the polarizing plate attachment apparatus210, a polarizing plate is attached to each of outer surfaces of the first and second substrates. Next, the liquid crystal panel having the polarizing plate is transferred to a tape automated bonding (TAB) apparatus220and the TCP is attached to each of adjacent side portions of the liquid crystal panel in the TAB apparatus220. Next, the liquid crystal panel having the TCP is transferred to a PCB bonding apparatus230and the TCP is bonded to the PCB in the PCB bonding apparatus230. Next, the liquid crystal panel having the TCP and the PCB is transferred to a resin coating apparatus240. In the resin coating apparatus240, a resin is coated onto connection portions of the liquid crystal panel and the TCP and of the TCP and the PCB and then the resin is cured.

Next, the liquid crystal panel is transferred to a driving circuit unit inspection apparatus250and defects in the TCP and the PCB are inspected in the driving circuit unit inspection apparatus250. Next, the liquid crystal panel passing the inspection of defects in the driving circuit unit inspection apparatus250is transferred to a frame assembling apparatus260. In the frame assembling apparatus260, the top, main and bottom frames wrap the liquid crystal panel, the TCP, the PCB and the backlight unit so that the LCD device can be completed.

The panel process line100where the liquid crystal panel is fabricated has a different degree of cleanliness from the module process line200where the TCP and the PCB are connected to the liquid crystal panel. Since particles definitely deteriorate fine patterns such as the gate line, the data line and the TFT, the panel process line100may have a relatively high degree of cleanliness. In addition, since the particles seldom deteriorate the electric connections between large-sized patterns such as pads of the liquid crystal panel, the TCP and the PCB, the module process line200may have a medium degree of cleanliness for reduction in maintenance cost. For example, the panel process line100may have a first degree of cleanliness of class 1000 and the module process line200may have a second degree of cleanliness within a range of class 1000 to class 10000. Here, the class (ea/feet3) may be defined by the number of particles having a diameter over 0.5 μm in one cubic feet. In addition, the first degree of cleanliness of class 1000 may be defined to be higher than the second degree of cleanliness within a range of class 1000 to class 10000.

All the steps performed in the module process line200do not require the second degree of cleanliness, and some steps may be performed without reduction in process yield even under a degree of cleanliness lower than the second degree of cleanliness. However, since the steps in the module process line200may hardly be divided, production cost and fabrication time increase due to excessive maintenance cost for some steps.

SUMMARY OF THE INVENTION

Accordingly, embodiments of the invention are directed to a method of fabricating a liquid crystal display device that substantially obviates one or more of problems due to limitations and disadvantages of the related art.

An advantage of the invention is to provide a method of fabricating a liquid crystal display device where production cost and fabrication time are reduced by performing steps for a module process under different degrees of cleanliness.

Another advantage of the invention is to provide a method of fabricating a liquid crystal display device where reduction in process yield is prevented by transferring a liquid crystal panel between steps for a module process without contamination.

Another advantage of the invention is to provide a method of fabricating a liquid crystal display device where fabrication efficiency is improved by connecting a plurality of apparatuses for a module process as in-line type.

To achieve these and other advantages and in accordance with the purpose of the invention, as embodied and broadly described, according to an aspect of the invention, a method of fabricating a liquid crystal display device includes: a first step of attaching a polarizing plate to an outer surface of a liquid crystal panel; a second step of attaching a tape carrier package (TCP) to the liquid crystal panel; a third step of coating a resin onto a rear surface of the TCP and a connection portion of the liquid crystal panel and the TCP; a fourth step of inspecting the TCP and the liquid crystal display panel; a fifth step of inserting the liquid crystal panel into a transferring means; a sixth step of transferring the transferring means; a seventh step of extracting the liquid crystal panel from the transferring means; a eighth step of attaching the TCP to a printed circuit board (PCB); a ninth step of inspecting the PCB, the TCP and the liquid crystal panel; and a tenth step of assembling the liquid crystal panel and a backlight unit with a plurality of frames.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Reference will now be made in detail to the illustrated embodiments of the present invention, which are illustrated in the accompanying drawings.

FIG. 2is a cross-sectional view showing a liquid crystal display device according to the present invention, andFIG. 3is an exploded perspective view showing a liquid crystal display device according to the present invention.

InFIGS. 2 and 3, a liquid crystal display device300includes a liquid crystal panel310, a driving circuit unit319, a backlight unit320, a main frame330, a top frame340and a bottom frame350. The liquid crystal panel310that displays images includes a first substrate312, a second substrate314facing and spaced apart from the first substrate312and a liquid crystal layer (not shown) between the first and second substrate312and314. The first and second substrates312and314may be referred to as an array substrate and a color filter substrate, respectively. Although not shown inFIGS. 2 and 3, a gate line, a data line, a thin film transistor (TFT) and a pixel electrode are formed on an inner surface of the first substrate312. The gate line and the data line cross each other to define a pixel region. The TFT is connected to the gate line and the data line, and the pixel electrode is connected to the TFT. In addition, a color filter layer, a black matrix and a common electrode are formed on an inner surface of the second substrate314. The color filter layer includes red, green and blue color filters each corresponding to the pixel region, and the black matrix corresponds to the gate line, the data line and the TFT. The common electrode covers the color filter layer and the black matrix.

The driving circuit unit319includes a tape carrier package (TCP)316, a driving integrated circuit (IC)317on the TCP316and a printed circuit board (PCB)318connected to the liquid crystal panel310through the TCP316. In another embodiment, the PCB may be connected to the liquid crystal panel through a flexible printed circuit (FPC). The TCP316includes a gate TCP316aand a data TCP316b, and the PCB includes a gate PCB318aand a data PCB318b. One end portion of the gate TCP316ais attached to a first edge portion of the liquid crystal panel310and the other end portion of the gate TCP316ais attached to the gate PCB318a. In addition, one end portion of the data TCP316bis attached to a second edge portion adjacent to the first side portion of the liquid crystal panel310and the other end portion of the data TCP316bis attached to the data PCB318b. After the TCP316and the PCB318are connected to the liquid crystal panel310, the TCP316is bent such that the PCB is disposed at a side surface of the main frame330or under a rear surface of the bottom frame350in a module process.

The PCB318generates RGB data and a plurality of control signals, which are supplied to the driving IC317of the TCP316, and the driving IC317generates a gate signal and a data signal, which is supplied to the gate line and the data line, respectively, of the liquid crystal panel310. In another embodiment, the LCD device may have a single PCB generating RGB data and a plurality of control signals, and the liquid crystal panel may have an additional line for transmitting the RGB data and the plurality of control signals. Although not shown inFIGS. 2 and 3, an alignment layer is formed on each of top surfaces of the first and second substrates312and314to contact the liquid crystal layer, and a seal pattern is formed at a boundary portion between the first and second substrates312and314. Further, a polarizing plate may be formed on each of outer surfaces of the first and second substrates312and314.

The back light unit320that supplies light to the liquid crystal panel310is disposed under the liquid crystal panel310. The back light unit320includes a lamp324, a reflecting plate322having a white color or a silver color, a light guide plate326and an optic sheet329. The lamp324is disposed at a side portion of the main frame330. The reflecting plate322, the light guide plate326and the optic sheet326are sequentially disposed over the bottom frame350. The backlight unit320may further include a lamp guide328surrounding the lamp324. The lamp guide328may include upper, side and lower surfaces and an opening facing the light guide plate326to protect the lamp328and improve light efficiency by reflecting light toward the light guide plate326. The lamp guide328may be integrated into the reflecting plate322in another embodiment.

The lamp324may include one of cold cathode fluorescent lamp (CCFL) and an external electrode fluorescent lamp (EEFL). The light from the lamp324passes through the light guide plate326to be uniformly diffused in the light guide plate326due to total reflection and is outputted from an upper surface of the light guide plate326to the liquid crystal panel310as a planar light. In addition, the light guide plate32may include specific patterns at an upper or a lower surface thereof to provide a uniform planar light. The light outputted from the lower surface of the light guide plate326is reflected by the reflecting plate322under the light guide plate326toward the liquid crystal panel310to improve light efficiency.

The optic sheet329may include a diffusing sheet329a, a prism sheet329band a protecting sheet329c. The diffusing sheet329adirectly over the light guide plate326disperses light from the light guide plate326and the prism sheet329bover the diffusing sheet329acollects the dispersed light. The protecting sheet329cprotects the prism sheet329b.Accordingly, the light passing through the optic sheet329normally enters the liquid crystal panel310with a uniform brightness distribution.

As a result, the light emitted from the lamp324is concentrated by the lamp guide328and enters the light guide plate326. Next, the light is refracted toward the liquid crystal panel310in the light guide plate326and is processed through the optic sheet329to have a uniform brightness distribution. Finally, the liquid crystal panel310displays images using the light.

The liquid crystal panel310, the driving circuit unit319and the backlight unit329are assemble with the main, top and bottom frames330,340and350. The bottom frame350has a rectangular plate shape with edge portions thereof bent upwardly, and the liquid crystal panel310and the backlight unit329are sequentially disposed over the bottom frame350. The top frame340covers front edge surfaces of the liquid crystal panel310. The main frame330having a rectangular open ring shape surrounds side surfaces of the liquid crystal panel310and the backlight unit320. The main frame330is combined with the top and bottom frames340and350to wrap the liquid crystal panel310, the driving circuit unit319and the backlight unit329, thereby the LCD device300completed. The top frame340may be referred to as a top cover, a case top or a top case, the main frame330may be referred to as a support main, a guide panel, a main supporter or a mold frame, and the bottom frame350may be referred to as a cover bottom, a bottom cover or a lower cover. In another embodiment, the liquid crystal panel, the driving circuit unit and the backlight unit may be assembled with a plurality of frames, and the number of the plurality of frames may be varied.

FIG. 4is a view showing a method of fabricating a liquid crystal display device according to an embodiment of the present invention.

InFIG. 4, a liquid crystal panel310(ofFIG. 3) is fabricated through a panel process line400having a first degree of cleanliness, a tape carrier package (TCP)316(ofFIG. 3) is attached to the liquid crystal panel310through a first module process line500having a second degree of cleanliness. In addition, the TCP316is attached to a printed circuit board (PCB)318(ofFIG. 3) and the liquid crystal panel310having a driving circuit unit319(ofFIG. 3) such as the TCP316and the PCB318and a backlight unit320(ofFIG. 3) are assembled with main, top and bottom frames330,340,350(ofFIG. 3) through a second module process line600having a third degree of cleanliness, thereby a liquid crystal display (LCD) device300(ofFIG. 3) completed.

In the panel process line400, a first substrate312(ofFIG. 3) having a gate line, a data line, a thin film transistor (TFT) and a pixel electrode and a second substrate314(ofFIG. 3) having a black matrix, a color filter layer and a common electrode are attached to face and be spaced apart from each other. Further, in a liquid crystal injection apparatus410of the panel process line400, a liquid crystal material is injected to form a liquid crystal layer between the first and second substrates312and314, thereby the liquid crystal panel completed. The liquid crystal panel is transferred to an auto probe apparatus420and defects of the liquid crystal panel such as an electric shortage or an electric disconnection in the gate line and the data line are inspected in the auto probe apparatus420.

In another embodiment, the liquid crystal layer may be formed by a dispensing method, where the first and second substrates are attached after the liquid crystal layer is formed on one of the first and second substrates. The liquid crystal panel is completed by cutting the attached first and second substrates including the liquid crystal layer.

Since the gate line, the data line, the TFT, the pixel electrode, the black matrix, the color filter layer and the common electrode have relatively fine patterns that exemplary having a width smaller than about 100 m, the panel process line400where the liquid crystal injection apparatus410and the auto probe apparatus420are constituted has a relatively high degree of cleanliness as the first degree of cleanliness. For example, the first degree of cleanliness may be higher than a degree of cleanliness of class 1000. The class (ea/feet3) may be defined by the number of particles having a diameter over 0.5 m in one cubic feet. Further, as the degree of cleanliness becomes higher, the number of class is defined become smaller.

The liquid crystal panel310passing the inspection of defects in the auto probe apparatus420is transferred to a first polarizing plate attachment apparatus510in the first module process line500. In the polarizing plate attachment apparatus510, a polarizing plate is attached to each of outer surfaces of the first and second substrates312and314. Although not shown inFIG. 4, the liquid crystal panel310may be cleaned in a cleaning apparatus before the polarizing plate is attached.

Next, the liquid crystal panel310having the polarizing plate is transferred to a tape automated bonding (TAB) apparatus520, and the TCP316is attached to each of adjacent side portions of the liquid crystal panel310in the TAB apparatus520. The TCP316including a driving integrated circuit (IC)317(ofFIG. 3) thereon is attached to a pad (not shown) in an portion of the first substrate312exposed by the second substrate314with an anisotropic conductive film (ACF) in a tape automated bonding (TAB) step. The ACF has a tape shape including a heat curable resin and conductive balls dispersed in the heat curable resin. When heat and force are applied to the ACF, the heat curable resin is hardened and the conductive balls are pressurized along one direction. As a result, two objects attached to the ACF are electrically connected to each other along the one direction. For example, after the ACF is disposed on the pad of the first substrate312and a first pad (not shown) of the TCP316is disposed on the ACF such that the first pad of the TCP316is aligned to the pad of the first substrate312, the TCP316, the ACF and the liquid crystal panel310are pre-attached with a lower pressure and a lower temperature. Then, the TCP316, the ACF and the liquid crystal panel310are attached to each other with a higher pressure and a higher temperature, thereby the step of attaching the TCP316to the liquid crystal panel310in the TAB apparatus520completed.

Next, the liquid crystal panel having the TCP316is transferred to a first resin coating apparatus530. In the first resin coating apparatus530, a first resin is coated onto a rear surface of the TCP and then cured. After the steps of the first module process line are finished, the liquid crystal panel310including the TCP316is sealed in a transferring means such as a clean box and the transferring means including the liquid crystal panel310is transferred to a second module process line600through atmospheric circumstances. The first resin is coated onto the rear surface of the TCP316to protect and prevent the TCP316from damage and contamination while the liquid crystal panel310including the TCP316is transferred through the atmospheric circumstances.

Next, the liquid crystal panel310having the TCP316is transferred to a second resin coating apparatus540. In the second resin coating apparatus540, a second resin is coated onto connection portions of the liquid crystal panel310and the TCP316and then cured to strengthen connection of the liquid crystal panel310and the TCP316. In addition, the second resin is used to protect and prevent a connection portion of the liquid crystal panel310and the TCP316from damage and contamination while liquid crystal panel310including the TCP316is transferred through the atmospheric circumstances.

Next, the liquid crystal panel310having the TCP316is transferred to a first driving circuit unit inspection apparatus550and defects of the TCP316such as abnormal attachment and abnormal operation are inspected in the first driving circuit unit inspection apparatus550. In addition, defects of the liquid crystal panel310such as such as an electric shortage or an electric disconnection in the gate line and the data line may also be inspected in the first driving circuit unit inspection apparatus550.

In a method of fabricating an LCD device300according to an embodiment of the present invention, since the TCP316is inspected by the first driving circuit unit inspection apparatus550of the first module process line500independently of the PCB318after the TCP316is attached in the first module process line500, the TCP316having defects may be replaced or may be repaired before the step of attaching the PCB318in the second module process line600. As a result, process yield for the LCD device300is improved and production cost and fabrication time are reduced.

The liquid crystal panel310passing the inspection of defects in the first driving circuit unit inspection apparatus550is transferred to and stocked in a first unloader560. The TAB apparatus520, the first resin coating apparatus530, the second resin coating apparatus540, the first driving circuit unit inspection apparatus550and the first unloader560may be connected to each other by an in-line type, where apparatuses are connected with a connecting means such as a conveyor or a robot arm so that the steps of apparatuses are automatically and sequentially performed without intervention of an operator.

Next, the liquid crystal panel310stocked in the first unloader560is transferred to an auto clave apparatus570and bubbles between the polarizing plate and each of the first and second substrates312and314are removed with heat and pressure in the auto clave apparatus570.

Next, the liquid crystal panel310is transferred to a horizontal stock apparatus580. In the horizontal stock apparatus580, the liquid crystal panel310is horizontally inserted into a transferring means (not shown) such as a clean box and the transferring means is hermitically sealed.

In another embodiment, the auto clave apparatus570may be omitted or may be constituted in the second module process line600, and the first unloader560and the horizontal stock apparatus580may be connected to each other by an in-line type using a connecting means such as a conveyor or a robot arm for automatic sequential performance of the corresponding steps.

A width and a pitch of the pad of the liquid crystal panel310for the first pad of the TCP316are greater than a width of fine patterns formed through the panel process line400and are smaller than a width and a pitch of a pad of the PCB318for a second pad of the TCP316. Accordingly, the first module process line500where the TAB apparatus520is constituted has a medium degree of cleanliness lower than the first degree of cleanliness as the second degree of cleanliness. For example, the second degree of cleanliness may be a degree of cleanliness within a range of class 1000 to class 10000.

Next, the transferring means including the liquid crystal panel310is transferred to a loader610of the second module process line600through atmospheric circumstances and stocked in the loader610. In the loader610, the transferring means is unsealed and the liquid crystal panel310is extracted from the transferring means.

Next, the liquid crystal panel310is transferred to a PCB bonding apparatus620, and the TCP316attached to the liquid crystal panel310is attached to the PCB318in the PCB bonding apparatus620. For example, after the ACF is disposed on the pad of the PCB318and a second pad (not shown) of the TCP316is disposed on the ACF such that the second pad of the TCP316is aligned to the pad of the PCB318, the TCP316, the ACF and the PCB318are pre-attached with a lower pressure and a lower temperature. Then, the TCP316, the ACF and the PCB318are attached to each other with a higher pressure and a higher temperature, thereby the step of attaching the TCP316to the PCB318in the PCB bonding apparatus620completed. The first and second pads may be disposed at end portions of the TCP316, respectively.

Next, the liquid crystal panel310having the TCP316and the PCB318is transferred to a second driving circuit unit inspection apparatus630and defects of the PCB318such as abnormal attachment and abnormal operation are inspected in the second driving circuit unit inspection apparatus630. When defects of the PCB318are inspected, the PCB318having defects may be replaced or may be repaired before the liquid crystal panel310is transferred to a subsequent apparatus. In addition, defects of the TCP316may also be inspected in the second driving circuit unit inspection apparatus630. Further, since the PCB318includes circuits generating the RGB data and the plurality of control signals using an image signal from an external system, defects in image display such as a flicker as well as defects in operation of the PCB318and the TCP316may be inspected in the second driving circuit unit inspection apparatus630.

The liquid crystal panel310passing the inspection of defects in the second driving circuit unit inspection apparatus630is transferred to a second unloader640. The loader610, the PCB bonding apparatus620, the second driving circuit unit inspection apparatus630and the second unloader640may be connected to each other by an in-line type using a connecting means such as a conveyor or a robot arm for automatic sequential performance of the corresponding steps.

The liquid crystal panel310stocked in the second unloader640is transferred to a frame assembly apparatus650, and the liquid crystal panel310, the driving circuit unit319including the TCP316and the PCB318and the backlight unit320are wrapped with the main, top and bottom frames330,340and350in the frame assembly apparatus650, thereby the LCD device300completed.

The width and the pitch of the pad of the PCB318are greater than the width and the pitch of the pad of the liquid crystal panel310for the second pad of the TCP316. Accordingly, the second module process line600where the PCB bonding apparatus620is constituted has a lower degree of cleanliness lower than the second degree of cleanliness as the third degree of cleanliness. For example, the third degree of cleanliness may be lower than a degree of cleanliness of class 100000.

In a method of fabricating an LCD device300according to an embodiment of the present invention, the liquid crystal panel310is fabricated in the panel process line400having the first degree of cleanliness, and the polarizing plate and the TCP316are attached to the liquid crystal panel310in the first module process line500having the second degree of cleanliness lower than the first degree of cleanliness. In addition, the PCB318is attached to the TCP316combined with the liquid crystal panel310, and the liquid crystal310panel including the TCP316and the PCB318and the backlight unit320are assembled with the main, top and bottom frames330,340and350in the second module process line600having the third degree of cleanliness lower than the second degree of cleanliness. Since the steps for the module process are separately performed in the first and second module process lines500and600having different degrees of cleanliness from each other, production cost and fabrication time are reduced.

FIGS. 5A and 5Bare flow charts showing steps performed in first and second module process lines, respectively, according to an embodiment of the present invention.

At step ST11ofFIG. 5A, a liquid crystal panel310(ofFIG. 3) is cleaned and a polarizing plate is attached to an outer surfaces of the liquid crystal panel130in a first module process line500(ofFIG. 4) having a second degree of cleanliness.

At step ST12ofFIG. 5A, first pads of gate and data tape carrier packages (TCPs)316aand316b(ofFIG. 3) are attached to pads of the liquid crystal panel310using an anisotropic conductive film (ACF) interposed between the first pads of the gate and data TCPs316aand316band the pads of the liquid crystal panel310.

A first resin is coated onto rear surfaces of the gate and data TCPs316aand316bat step of ST13ofFIG. 5A, and a second resin is coated onto connection portions of the liquid crystal panel310and each of the gate and data TCPs316aand316bat step of ST14ofFIG. 5A. The first and second resins may be cured in a subsequent step.

At step ST15ofFIG. 5A, defects of the gate and data TCPs316aand316band the liquid crystal panel310are inspected by applying signals to the gate and data TCPs316aand316bconnected to the liquid crystal panel310.

The steps of ST12to ST16may be performed in a plurality of apparatuses connected in an in-line type. For example, the steps of ST12to ST16may be performed automatically and sequentially without intervention of an operator, thereby process efficiency improved.

Bubbles existing between the polarizing plate and the liquid crystal panel310are removed at step ST16ofFIG. 5A, and the liquid crystal panel310is horizontally inserted into a transferring means such as a clean box and the transferring means is hermitically sealed at step ST17ofFIG. 5A.

In addition, at step ST21ofFIG. 5B, the liquid crystal panel310is extracted from the transferring means in a second module process line600(ofFIG. 4) having a third degree of cleanliness lower than the second degree of cleanliness.

At step ST22ofFIG. 5B, second pads of the gate and pad TCPs316aand316bare attached to pads of gate and data printed circuit boards (PCBs)318aand318b, respectively, using an ACF interposed between the second pads of the gate and pad TCPs316aand316band the pads of the gate and data PCBs318aand318b.

At step ST23ofFIG. 5B, defects of the gate and data PCBs318aand318b, the gate and data TCPs316aand316band the liquid crystal panel310are inspected by applying signals to the gate and data PCBs318aand318bconnected to the liquid crystal panel310through the gate and data TCPs316aand316b.

The steps of ST21to ST23may be performed in a plurality of apparatuses connected in an in-line type. For example, the steps of ST21to ST23may be performed automatically and sequentially without intervention of an operator, thereby process efficiency improved.

At step ST24ofFIG. 5B, the liquid crystal panel310, the driving circuit unit319including the gate and data TCPs316aand316band the gate and data PCBs318aand318band a backlight unit320(ofFIG. 3) are wrapped and assembled with main, top and bottom frames330,340and350(ofFIG. 3), thereby the LCD device300(ofFIG. 3) completed.

Consequently, in a method of fabricating a liquid crystal display device according to an embodiment of the present invention, the polarizing plate and the TCP316are attached to the liquid crystal panel310in the first module line500having the second degree of cleanliness, and the TCP316connected to the liquid crystal panel310is attached to the PCB318in the second module process line600having the third degree of cleanliness lower than the second degree of cleanliness. In addition, the liquid crystal panel310, the driving circuit unit319including the TCP316and the PCB318and the backlight unit320are combined by the main, top and bottom frames330,340and350in the second module process line. Since the steps for the module process are separately performed in the first and second module process lines500and600, respectively, on the basis of optimum degrees of cleanliness, production cost and fabrication time are reduced.

Further, since the steps of attaching TCP316, coating first and second resins and inspecting the TCP316in the first module process line500and the steps of attaching the PCB318and inspecting the PCB318in the second module process line600are performed in a plurality of apparatuses connected in an in-line type, fabrication time is reduced and process efficiency is improved.

Moreover, since the liquid crystal panel310is transferred from the first module process line550to the second module process line600using a transferring means, contamination of the liquid crystal panel310is prevented and process yield is improved.

It will be apparent to those skilled in the art that various modifications and variations can be made in a method of fabricating a liquid crystal display device of embodiments of the invention without departing from the spirit or scope of the invention. Thus, it is intended that embodiments of the invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.