Method of manufacturing liquid crystal display

In a method of manufacturing a liquid crystal display, first, a panel assembly structure including a first substrate, a second substrate and several sealants connecting inner surfaces of the first and second substrate is provided. The first substrate includes several third substrates. The second substrate includes several fourth substrates corresponding to the third substrates, respectively. Each third substrate, the corresponding fourth substrate and the corresponding sealant form a panel. First and second polarizers are adhered correspondingly to outer surfaces of the third and fourth substrates. The panels are separated after the adherence of the first and second polarizers.

This application claims the benefit of Taiwan application Serial No. 94118468, filed Jun. 3, 2005, the subject matter of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to a method of manufacturing liquid crystal displays.

2. Description of the Related Art

Refer toFIG. 1, a flow chart of a conventional method of manufacturing liquid crystal displays (LCDs) is illustrated. In step11, a panel assembly structure is provided. For example, in the One Drop Fill (ODF) process, the panel assembly structure includes an upper substrate, a lower substrate, several sealants and liquid crystals. The upper substrate and the lower substrate are disposed parallel to each other. The sealants connect the inner surfaces of the first substrate and the second substrate. Liquid crystals are filled between the upper substrate and the lower substrate, and surrounded by the corresponding sealant. The upper substrate includes several color filter (CF) substrates. The lower substrate includes several thin film transistor (TFT) substrates corresponding to the CF substrates, respectively. Each CF substrate, the corresponding TFT substrate, the corresponding sealant and the corresponding liquid crystals are combined to form a liquid crystal display (LCD) panel. In another conventional liquid crystal injection process, each CF substrate, the corresponding TFT substrate and the corresponding sealant are combined to form a panel to be filled with liquid crystals.

Next, in step12, the upper substrate and the lower substrate are cut by using a wheel cutter, for separating the LCD panels or the panels ready to be filled with liquid crystals. Meanwhile, in the liquid crystal injection process, liquid crystals are injected into each panel ready to be filled with liquid crystals through the liquid crystal injection opening of the corresponding sealant. After the liquid crystals have been injected, the liquid crystal injection openings are sealed and closed. The LCD panels manufactured by the liquid crystal injection process is formed completely in this step.

Then, in step13, the TFT substrate of each LCD panel is ground and beveled by using a grinding wheel. The grinding wheel mainly grinds two edges of both Gate-driver side and Data-driver side of each TFT substrate that outer leads extend to. The grinding wheel also bevels partially the corners of each TFT substrate. As a result, sharp glass edges are avoided, so that, for example, connecting between a chip in a chip on glass (COG) process and an outer circuit (e.g., a driving PCB) is no more affected by such sharp edges, particularly, in a step of electrically connecting a PCB to the TFT substrate via a flexible circuit board (FPC). Alternatively, a tape automatic bonding (TAB) process is no more affected by such sharp edges, particularly, in a step of electrically connecting a package with a IC chip (also known as a tape carrier package, TCP) to the outer leads through a tape automatic bonding (TAB) process. This grinding and/or beveling process is useful especially because when a flexible circuit board (FPC) or a TCP is electrically connected to the outer leads, the flexible circuit board or the tape is easily damaged by the sharp edges or sharp corners of the TFT substrate, resulting in a decrease in the yield rate of the LCD panels.

In step14, because many particles, powders or foreign matters are generated in step of grinding and beveling the TFT substrate by using a grinding wheel, each LCD panel is cleaned by water and then scraped to be dry. As a result, the LCD panels are kept clean for the next step. Afterward, in step15, an upper polarizer and a lower polarizer are adhered correspondingly on outer surfaces of the CF substrate and the TFT substrate in each LCD panel. For example, a light transmission axis of the upper polarizer is perpendicular to a light transmission axis of the lower polarizer. Subsequently, in step16, a test card is electrically connected to the outer leads of each LCD panel one by one, for inputting test signals. The image quality of each LCD panel is observed by an operator when the LCD panel is under light-emission. Usually each LCD panel is loaded/unloaded on a testing machine one by one by using a robot arm. Then, the test card is electrically connected to the outer leads of the LCD panel on the testing machine for inputting the test signals. The image quality of each LCD panel is preferably observed by the operator when the LCD panel is under light-emission, for singling out defect LCD panels to proceed a re-work process. The qualified LCD panels are continuously sent to the next process station for proceeding the next step, e.g., in step17, a COG process or a TAB process is proceeded on each LCD panel. For example, a chip is electrically connected to the outer leads through an anisotropic conductive film (ACF) in the COG step. Then, the outer leads are electrically connected to the outer circuit, a driving PCB, through the flexible circuit board (FPC). For another example, the TCP is electrically connected to the outer leads through the ACF in the TAB step, and the PCB is electrically connected to a package through the ACF. As a result, the PCB is electrically connected to the outer leads through the TCP package. Afterward, in step18, the LCD panel and a backlight module are assembled to form a completed LCD.

However, conventionally, the TFT substrate is ground and beveled in step13by using a grinding wheel. As a result, many particles, powders or foreign matters are generated. Therefore, each LCD panel need to be cleaned by water and then is scraped dry in step14. The manufacturing steps are redundancy and complicated. The cost is raised for purchasing equipment, such as a grinding wheel machine, a cleaning machine and a scraping machine. When the particles, powders or foreign matters are still not cleaned, the LCD panels easily have defects due to the adhesion of such particles, powders or foreign matters.

Moreover, when the LCD panel is not scraped dry in step14, the polarizers cannot be adhered well in step15. Further, a Newton ring or a water mark occurs because the water remains on the outer surface of the LCD panel. As a result, the image quality of the LCD is affected.

Furthermore, when the panel assembly structure is cut, e.g., into 502 small-size (for example, 1.2 inch, that is, about 620 mm*750 mm) LCD panels, each LCD panel is attached with polarizers and is tested by the test card. In other words, 502 polarizers are adhered in step15, and the automatically loaded/unloaded process is proceeded 502 times in step16to test all the LCD panels. As a result, it is very time-consuming to adhere polarizers and to test all the LCD panels502times. The manufacturing process of the LCD is inefficient and uneconomic.

SUMMARY OF THE INVENTION

In an aspect, the invention to provides a method of manufacturing liquid crystal displays in which polarizers are adhered on the respective substrates before liquid crystal display panels are separated from each other. As a result, the time for adhering the polarizers of the liquid crystal display panels is reduced. In a further aspect, the liquid crystal display panels are tested under light-emission before the liquid crystal display panels are separated from each other. Therefore, the time for testing all the liquid crystal display panels is reduced as well. In another aspect, the substrates of the LCD panels are cut by using lasers, for avoiding particles, powders or foreign matters that would otherwise generated in a conventional step of cutting the substrates by using a wheel cutter. The liquid crystal display panels are prevented from having defects due to adhesion of such powders, particles or powders. In yet another aspect, the liquid crystal display panels are ground and beveled by using a laser. As a result, particles, powders or foreign matters that would otherwise generated in a conventional process of grinding and beveling the liquid crystal display panels by using a grinding wheel are avoided. Thus, the liquid crystal display panels are prevented from having defects due to the adhesion of such particles, powders or foreign matters. The process of manufacturing liquid crystal displays is therefore simplified, also because the conventional step of cleaning and scraping the liquid crystal display panels is skipped. Moreover, the cost is lowered because the expense for the equipment is greatly reduced.

In an aspect, a method of manufacturing liquid crystal displays comprises the steps of: providing a panel assembly structure comprising a first substrate, a second substrate and a plurality of sealants, the first substrate and the second substrate being disposed parallel to each other, the sealants connecting inner surfaces of the first substrate and the second substrate, the first substrate comprising a plurality of first regions defining third substrates, the second substrate comprising a plurality of second regions defining fourth substrates corresponding to the third substrates, respectively, each third substrate, the corresponding fourth substrate and the corresponding sealant together forming an LCD panel; cutting the first substrate for separating the first regions to obtain separated third substrates; adhering a plurality of first polarizers on outer surfaces of the third substrates, respectively; adhering a second polarizer on an outer surface of the second substrate, the second polarizer comprising a plurality of third regions defining third polarizers corresponding to the fourth substrates, respectively; cutting the second polarizer for separating the third regions to obtain separated third polarizers; and cutting the second substrate for separating the second regions to obtain separated fourth substrates, so that the LCD panels are separated from each other after said adhering steps.

In a further aspect, a method of manufacturing liquid crystal displays comprises the steps of: providing a panel assembly structure comprising a first substrate, a second substrate and a plurality of sealants, the first substrates and the second substrate being disposed parallel to each other, the sealants connecting inner surfaces of the first substrate and the second substrate, the first substrate comprising a plurality of first regions defining third substrates, the second substrate comprising a plurality of second regions defining fourth substrates corresponding to the third substrates, respectively, each third substrate, the corresponding fourth substrate and the corresponding sealant together forming an LCD panel; adhering a first polarizer on an outer surface of the first substrate, the first polarizer comprising a plurality of third regions defining second polarizers corresponding to the third substrates, respectively; cutting the first polarizer for separating the third regions to obtain separated second polarizers; cutting the first substrate for separating the first regions to obtain separated third substrates; adhering a third polarizer on an outer surface of the second substrate, the third polarizer comprising a plurality of fourth regions defining fourth polarizers corresponding to the fourth substrates, respectively; cutting the third polarizer for separating the fourth regions to obtain separated fourth polarizers; and cutting the second substrate for separating the second regions to obtain separated fourth substrates, so that the LCD panels are separated from each other after said adhering steps.

In a further aspect, a method of manufacturing liquid crystal displays comprises the steps of: providing a panel assembly structure comprising a first substrate, a second substrate and a plurality of sealants, the first substrate and the second substrate being disposed parallel to each other, the sealants connecting inner surfaces of the first substrate and the second substrate, the first substrate comprising a plurality of first regions defining third substrates, the second substrate comprising a plurality of second regions defining fourth substrates corresponding to the third substrates, respectively, each third substrate, the corresponding fourth substrate and the corresponding sealant together forming an LCD panel; adhering a first polarizer on an outer surface of the first substrate, the first polarizer comprising a plurality of third regions defining second polarizers corresponding to the third substrates, respectively; adhering a third polarizer on an outer surface of the second substrate, the third polarizer comprising a plurality of fourth regions defining fourth polarizers corresponding to the fourth substrates, respectively; cutting the first polarizer for separating the third regions to obtain separated second polarizers; cutting the first substrate for separating the first regions to obtain separated third substrates; cutting the third polarizer for separating fourth regions to obtain separated the fourth polarizers; and cutting the second substrate for separating the second regions to obtain separated fourth substrates, so that the LCD panels are separated from each other after said adhering steps.

In a further aspect, a method of manufacturing liquid crystal displays comprises the steps of: providing a panel assembly structure comprising a first substrate, a second substrate and a plurality of sealants, the first substrate and the second substrate being disposed parallel to each other, the sealants connecting the inner surfaces of the first substrate and the second substrate, the first substrate comprising a plurality of first regions defining third substrates, the second substrate comprising a plurality of second regions defining fourth substrates corresponding to the third substrates, respectively, each third substrate, the corresponding fourth substrate and the corresponding sealant together forming an LCD panel; cutting the first substrate for separating the first regions to obtain separated third substrates; adhering a plurality of first polarizers on outer surfaces of the third substrates, respectively; adhering a plurality of second polarizers corresponding to the fourth substrates, respectively, on an outer surface of the second substrate; and cutting the second substrate for separating the second regions to obtain separated fourth substrates, so that the LCD panels are separated from each other after said adhering steps.

In a further aspect, a method of manufacturing liquid crystal displays comprises the steps of: providing a panel assembly structure comprising a first substrate, a second substrate and a plurality of sealants, the first substrate and the second substrate being disposed parallel to each other, the sealants connecting the inner surfaces of the first substrate and the second substrate, the first substrate comprising a plurality of first regions defining third substrates, the second substrate comprising a plurality of second regions defining fourth substrates corresponding to the third substrates, respectively, each third substrate, the corresponding fourth substrate and the corresponding sealant together forming an LCD panel; adhering a plurality of first polarizers on outer surfaces of the third substrates, respectively; cutting the first substrate for separating the first regions to obtain separated third substrates; adhering a plurality of second polarizers corresponding to the fourth substrates, respectively, on an outer surface of the second substrate; and cutting the second substrate for separating the second regions to obtain separated fourth substrates, so that the LCD panels are separated from each other after said adhering steps.

In a further aspect, a method of manufacturing liquid crystal displays comprises the steps of: providing a panel assembly structure comprising a first substrate, a second substrate and a plurality of sealants, the first substrate and the second substrate being disposed parallel to each other, the sealants connecting the inner surfaces of the first substrate and the second substrate, the first substrate comprising a plurality of first regions defining third substrates, the second substrate comprising a plurality of second regions defining fourth substrates corresponding to third substrates, respectively, each third substrate, the corresponding fourth substrate and the corresponding sealant together forming an LCD panel; adhering a plurality of first polarizers on outer surfaces of the third substrates; adhering a plurality of second polarizers corresponding to the fourth substrates, respectively, on an outer surface of the second substrate; cutting the first substrate for separating the first regions to obtain separated third substrates; and cutting the second substrate for separating the second regions to obtain separated fourth substrates, so that the LCS panels are separated from each other after said adhering steps.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

Methods of manufacturing liquid crystal displays in accordance with the invention will be described herein below. In the disclosed methods, polarizers for each liquid crystal display panel are adhered before a panel assembly structure is separated into several liquid crystal display panels. The disclosed methods are advantageous over the conventional method in which the liquid crystal display panels are separated before the polarizers are adhered. As a result, the process of adhering polarizers is simplified and the time required for adhering the polarizers is reduced. Therefore, the yield rate of the manufactured liquid crystal displays is increased greatly.

First Embodiment

Refer toFIGS. 2˜3F,FIG. 2is a flow chart of the method of manufacturing a liquid crystal display according to the first embodiment of the invention, andFIGS. 3A˜3Fare cross-sectional views showing the manufacturing process of a liquid crystal display according to the first embodiment of the invention. First, in step21, a panel assembly structure30is provided as shown inFIG. 3A. InFIG. 3A, the panel assembly structure30includes a first substrate31, a second substrate32and several sealants33. The first substrate31and the second substrate32are disposed parallel to each other. The sealants33connect inner surfaces of the first substrate31and the second substrate32. The first substrate31includes several regions that will define third substrate31a. The second substrate32includes several regions that will define fourth substrates32aeach corresponding to one of the third substrates31a. Each third substrate31a, the corresponding fourth substrate32aand the corresponding sealant33are combined to form a panel. When the panel is filled with liquid crystals, the panel is a liquid crystal display panel. When the panel is not yet filled with any liquid crystal, the panel is an unfinished panel ready to be filled with liquid crystals in a following filling process. Besides, the third substrates31aare preferably color filter substrates, and the fourth substrates32aare preferably thin film transistor (TFT) substrates although other arrangements are not excluded. The fourth substrate (the thin film transistor substrate) is larger than the third substrate (the color filter substrate). An inner surface of each fourth substrate32aincludes several outer leads39located beyond a lateral surface of the corresponding third substrate31a. In the present embodiment of the invention, the panel assembly structure30further includes several liquid crystal cells34. For example, each liquid crystal cell34includes liquid crystals filled between one first substrate31and the corresponding second substrate32, and surrounded by the corresponding sealant33by the One Drop Fill (ODF) method. Also, each liquid crystal cell34is corresponding to one third substrate31aand the corresponding fourth substrate32a. Furthermore, each third substrate31a, the corresponding fourth substrate32a, the corresponding sealant33and the corresponding liquid crystal cell34are combined to form a liquid crystal panel35. Moreover, the first substrate31and the second substrate32are preferably glass substrates, insulation substrates or plastic substrates.

Next, in step22, the first substrate31inFIG. 3Ais cut by using a first cutting device38afor separating the third substrates31a, as shown inFIG. 3B. The outer leads39of each fourth substrate32aare exposed to the surrounding. The first cutting device38apreferably includes a carbon dioxide (CO2) laser or another kind of laser suitable for cutting a glass substrate, an insulation substrate or a plastic substrate. In the present embodiment, a laser is used for cutting the substrates. As a result, the problem that many particles, foreign matters or powders are generated in a conventional step of cutting the substrate by a machine is solved. Furthermore, burrs are not generated on edges of the cut substrates. Therefore, the separated liquid crystal panels are prevented from having defects due to adhering the particles, foreign matters or powders.

Then, in step23, polarizers36aare adhered on outer surfaces of the third substrates31a, respectively, as shown inFIG. 3C. Many processes can be used for adhering the polarizers. For example, several cracks corresponding to the outlines and positions of the third substrates31aare formed on a large-sheet polarizer, so that small-piece polarizers within the cracks can be separated from the large-sheet polarizer easily, thereby several polarizers36acan be formed after the following adhering step. Afterward, the larger polarizer is adhered on the first substrate31so that the polarizers36acorrespond to the third substrates31a, respectively. Then, the larger polarizer is removed except that the polarizers36aremain adhered on the third substrates31acorrespondingly. In another example, the panel assembly structure which is cut by the first cutting device is moved by an automatic moving platform, such as an x-y stage. Each polarizer36ais adhered on each third substrate31aone by one.

Afterward, in step24, a large-sheet polarizer37is adhered on an outer surface of the second substrate32. The polarizer37includes several regions that will define small-size polarizers37acorresponding to the fourth substrates32a, as shown inFIG. 3D.

In step25, the polarizer37inFIG. 3Dis cut by using a cutting device38bfor separating the polarizers37a. The unneeded part of the polarizer37is removed by tearing or another appropriate means, as shown inFIG. 3E. The above-described cutting device38bpreferably includes an excimer laser, a carbon dioxide (CO2) laser, or another laser suitable for cutting the polarizer. A light transmission axis of the polarizers36ais perpendicular to that of the polarizers37a. The polarizer is cut by a laser in the present embodiment, so that particles, foreign matters or powders are not generated. As a result, the cut liquid crystal display panels do not have defects due to the adherence of such particles, foreign matters or powders. Besides, the small-piece polarizers37acan be adhered correspondingly on the outer surface of the second substrate32by the same method described with respect to step23.

Then, in step26, the second substrate32inFIG. 3Eis cut by using a cutting device38cfor separating the fourth substrates32a. As a result, the liquid crystal display panels35are separated from each other, as shown inFIG. 3F. The cutting device38cpreferably includes a carbon dioxide (CO2) laser or another laser suitable for cutting a glass substrate, an insulation substrate, or a plastic substrate.

Although the ODF process is illustrated in the present embodiment, the liquid crystals34can also be filled between the other, described steps. In other words, the liquid crystals34can be filled between any two steps between the step of cutting the first substrate31and the step of cutting the second substrate32, for example, between the step22and the step23. Alternatively, the liquid crystals34can be filled before the step of cutting the first substrate31, for example, between the step21and step22. The liquid crystals34can be filled in the unfinished panels by a conventional vacuum injecting process.

In the present embodiment, the image quality of each liquid crystal display panel35can be tested between the step24and the step25. There are two kinds of testing processes illustrated as follows. Refer toFIGS. 4A˜4Bwhere the first testing process is illustrated.FIG. 4Ais a flow chart showing how the image quality of each liquid crystal display panel can be tested according to the embodiment of the invention.FIG. 4Bis a three dimensional view of several test cards before the test cards are electrically connected to the liquid crystal display panels obtained inFIG. 3D. In step41, testing signals are input to the liquid crystal display panels35correspondingly by several test cards42. Light is emitted by a light source53from an outer side of the third substrates31a, so that all the liquid crystal display panels35can be observed by an eye54of an operator from the outer side of the second substrate32at the same time. A contacting terminal of each test card42is electrically connected to the outer leads39of each liquid crystal display panel35correspondingly. As a result, the testing signals are input to each liquid crystal display panel35, so the image quality of all the liquid crystal display panels35under light-emission is tested. The defects of each panel can be observed in the above process of observing a large substrate with several panels. Furthermore, the differences of the image quality among the panels can also be observed.

Refer toFIGS. 5A˜5Bwhere the second testing method is illustrated.FIG. 5Ais a flow chart showing an alternative method of testing the image quality of each liquid crystal display panel according to the embodiment of the invention.FIG. 5Billustrates a test card before the test card is electrically connected to each liquid crystal display panel inFIG. 3Done by one. A test card52and the liquid crystal display panels35are moved relatively in step51. For example, the test card52is fixed, and the liquid crystal display panels35are moved by a moving platform53, such as an x-y stage. Next, test signals are input to each liquid crystal display panel35by the test card52one by one. Then, light is emitted from a lateral side of the third substrates31a, so that the image quality of each liquid crystal display panel35can be observed by an eye of an operator. A contacting terminal of the test card52is electrically connected to the outer leads39of each liquid crystal display panel35one by one, so that testing signals are input to each liquid crystal display panel35. As a result, the image quality of each liquid crystal display panel under light-emission is tested.

After the liquid crystal display panels35are separated from each other, a chip and the liquid crystal display panel35are combined through a chip on glass (COG) process. Or, a package with a chip and the liquid crystal display panel35are combined through a tape automatic bonding (TAB) process. One liquid crystal display panel35is illustrated as follows.

Refer toFIGS. 6A˜6Dwhere the tape automatic bonding (TAB) process is illustrated.FIG. 6Ais a flow chart of combining the chip and the liquid crystal display panel through the TAB process according to the embodiment of the invention.FIG. 6Bis a cross-sectional view of the fourth substrate inFIG. 3Fafter the step of grinding the edges of the fourth substrate by a laser.FIG. 6Cis a three-dimensional view of the fourth substrate inFIG. 3Fafter the step of beveling the corners of the fourth substrate by a laser.FIG. 6Dis a three-dimensional view of the package combined with the liquid crystal display panel through the TAB process. First, in step61, the edges and corners of the fourth substrate32aare ground and beveled by a fourth laser. The edges of the fourth substrate32ainFIG. 3Fare sharp, and the corners of the fourth substrate32aare about right angles. Therefore, the edges and the corners of the fourth substrate32aare ground and beveled in step61for avoiding the package from being damaged by the sharp edges and corners of the fourth substrate32aafter the package has been combined with the liquid crystal display panel35. The edges and the corners of the fourth substrate32ain a thin film transistor substrate are ground and beveled by the fourth laser, as shown in a ground-edge area65in a dotted area inFIG. 6Band a beveling area66in a dotted area inFIG. 6C.

The edges and corners of the liquid crystal display panel are ground and beveled by a laser in the present embodiment. As a result, the foreign matters or particles generated in a conventional step of grinding and beveling the liquid crystal display panel by a grinding wheel are avoided. Besides, cleaning the foreign matters or the particles by water is not necessary. Defects of the liquid crystal display panel due to the adherence of such foreign matters or particles by is avoided. Afterward, in step62, a package63is disposed on the fourth substrate32a(the thin film transistor substrate) by a TAB process. The package63is electrically connected to the outer leads39of the liquid crystal display panel35as shown inFIG. 6D. InFIG. 6D, the package63is further electrically connected to a circuit board64. And the package63is a tape carrier package (TCP), or the package is completed by a chip on film (COF) process. Therefore, the liquid crystal display panel35, the polarizer36a, the polarizer37a, the package63, the circuit board64and a backlight module are combined to form a completed liquid crystal display.

Refer toFIGS. 7A˜7Bwhere the chip on glass process is illustratedFIG. 7Ais a flow chart showing how a chip and the liquid crystal display panel can be combined through the chip on glass process according to the embodiment of the invention.FIG. 7Bis a three-dimensional view of the chip after the chip has been combined with the liquid crystal display panel through the chip on glass process. In step71, the chip72is disposed on the fourth substrate32aof the thin film transistor substrate through the chip on glass process. The chip72is electrically connected to the outer leads39of the liquid crystal display panel35. The outer leads39are electrically connected to a print circuit board (PCB)74through the flexible circuit board73. Or, the step61of grinding and beveling the edges and corners of the fourth substrate32aof the thin film transistor substrate by the fourth laser can be proceeded before the chip72is combined with the liquid crystal display panel35. As a result, the liquid crystal display panel35, the polarizer36a, the polarizer37a, the chip72and the backlight module are combined to form a completed liquid crystal display.

However, an ordinarily skilled artisan in the field of the invention can understand that the invention is not limited to the above described processes. For example, several test cards42can test all the liquid crystal display panels35between the step22and the step23. In other words, the liquid crystal display panels can be tested by several test cards when the outer leads39are exposed. Or, one test card52is moved relatively to the liquid crystal display panels35for testing the liquid crystal display panels35one by one. What is worth mentioning is that before the operator observes the image quality of the liquid crystal display panels35under light-emission, two large-sheet polarizers are disposed correspondingly on the outer surfaces of the third substrates31aand the second substrate32. Furthermore, the sequence of the steps21˜25can be adjusted properly, and some of the steps21˜25can be proceeded at the same time. The polarizers of each liquid crystal display panel35can be adhered before the liquid crystal display panels35are separated in step26. Similarly, the step of testing the liquid crystal display panels35by several test cards or by one test card moved correspondingly to the liquid crystal display panels35, as shown inFIGS. 4A˜5B, can be inserted in the manufacturing process with the adjusted sequence of steps21˜25.

The disclosed feature that the polarizers are adhered before the liquid crystal display panels are separated from each other shortens the adhering time of the polarizers of all the liquid crystal display panels. Furthermore, the disclosed feature that the liquid crystal display panels are tested under light-emission before the liquid crystal display panels are separated from each other shortens the testing time of all the liquid crystal display panels.

For example, when the panel assembly structure is separated into 502 liquid crystal display panels, all the 502 liquid crystal display panels are adhered and tested under light-emission by the test card before the 502 liquid crystal display panels are separated from each other in the present embodiment. In a conventional method, the polarizers are adhered on the 502 liquid crystal display panels one by one, and the 502 liquid crystal display panels are tested one by one as well. The adhering time of the polarizers of the liquid crystal display panels and the testing time of the liquid crystal display panels in the present embodiment are much less than those in the conventional method. As a result, the polarizers are adhered on several panels before the panels are separated from each other. Also, the panels are tested before the panels are separated from each other. Therefore, the manufacturing process of the liquid crystal display panel of the invention is more efficient and more economic than the conventional one.

Moreover, the manufacturing process of the liquid crystal display panel uses a laser to cut the substrate, so that the powders, particles or foreign matters generated in a convention step of cutting the substrate by a wheel cutter are avoided. Defects of the liquid crystal display panels due to the adherence of such powders, particles or foreign matters are avoided. Furthermore, the liquid crystal display panels are ground and beveled by a laser in the present embodiment, so that the powders, particles or foreign matter generated in a conventional step of grinding and beveling the liquid crystal display panels by a grinding wheel are avoided. As a result, defects of the liquid crystal display panels due to the adherence of such powders, particles or foreign matters are avoided. Therefore, the manufacturing process is simplified, and the step of water-cleaning and drying the liquid crystal display panels are skipped. The cost for purchasing the machines is reduced greatly.

Second Embodiment

Refer toFIGS. 8˜9G,FIG. 8is a flow chart of a method of manufacturing a liquid crystal display according to the second embodiment of the invention, andFIGS. 9A˜9Gare cross-sectional views showing the manufacturing process of the liquid crystal display according to the second embodiment of the invention. First, in step81, a panel assembly structure30is provided as shown inFIG. 9A. InFIG. 9A, the panel assembly structure30includes a first substrate31, a second substrate32and several sealants33. The first substrate31and the second substrate32are disposed parallel to each other. The sealants33connect inner surfaces of the first substrate31and the second substrate32. The first substrate31includes several regions that will define third substrates31a. The second substrate32includes several regions that will define fourth substrates32acorresponding to the third substrates31a. Each third substrate31a, the corresponding fourth substrate32aand the corresponding sealant33are combined to form a panel. When the panel is filled with liquid crystals, the panel is a liquid crystal display panel. When the panel does not include any liquid crystal, the panel is an unfinished panel ready to be filled with liquid crystals. Besides, the third substrates31aand the fourth substrates32aare color filter substrates and thin film transistor substrates respectively. The fourth substrate32a(the thin film transistor substrate) is larger than the third substrate31a(the color filter substrate). An inner surface of each fourth substrate32aincludes several outer leads39disposed adjacent to and beyond a lateral side of the corresponding third substrate31a. In the present embodiment of the invention, the panel assembly structure30further includes several liquid crystal cells34. Each liquid crystal cell34includes liquid crystals filled between the first substrate31and the corresponding second substrate32, and surrounded by the corresponding sealant33through a One Drop Fill (ODF) process. Also, each liquid crystal cell34is corresponding to one third substrate31aand the corresponding fourth substrate32a. Furthermore, each third substrate31a, the corresponding fourth substrate32a, the corresponding sealant33and the corresponding liquid crystal cell34are combined to form a liquid crystal display panel35. Moreover, the first substrate31and the second substrate32are preferably glass substrates, insulation substrates or plastic substrates.

Next, in step82, a large-sheet polarizer36is adhered on an outer surface of the first substrate31. The polarizer36includes several small-piece polarizers36acorresponding to the third substrates31a, respectively, as shown inFIG. 9B.

Then, in step83, the polarizer36inFIG. 9Bis cut by using a cutting device38dfor separating the polarizers36a, as shown inFIG. 9C. The cutting device38dpreferably includes an excimer laser, a carbon dioxide laser (CO2) or another laser suitable for cutting the polarizers. Besides, the step83of cutting the polarizer36by the cutting device38dcan be skipped when the small-piece polarizers36aare adhered correspondingly on the outer surface of the first substrate31by the same method described with respect to step23.

Afterward, in step84, the first substrate31inFIG. 9Cis cut by using a cutting device38afor separating the third substrates31a, as shown inFIG. 9D. The outer leads39of each fourth substrate32aare exposed. The cutting device38apreferably includes a carbon dioxide (CO2) laser or another laser suitable for cutting a glass substrate, an insulation substrate or a plastic substrate.

Thereon, in step85, a large-sheet polarizer37is adhered on an outer surface of the second substrate32. The polarizer37includes several small-piece polarizers37acorresponding to the fourth substrates32a, respectively, as shown inFIG. 9E.

Subsequently, in step86, the polarizer37inFIG. 9Eis cut by using a cutting device38bfor separating the polarizers37a, as shown inFIG. 9F. The cutting device38bpreferably includes an excimer laser, a carbon dioxide (CO2) laser and another laser suitable for cutting the polarizers. A light transmission axis of the polarizers36ais perpendicular to a light transmission axis of the polarizers37a. Furthermore, the step85of cutting the polarizer37by the cutting device38bcan be skipped when the small-piece polarizers37aare adhered correspondingly on the outer surface of the second substrate32by the method described with respect to step23.

Then, in step87, the second substrate32inFIG. 9Fis cut by using a cutting device38cfor separating the fourth substrates32a, so that the liquid crystal display panels35are separated from each other, as shown inFIG. 9G. The cutting device38cpreferably includes a carbon dioxide (CO2) laser or another laser suitable for cutting the glass substrate, an insulation substrate or a plastic substrate by the same method described with respect to step23.

Although the ODF process is illustrated in the present embodiment, the liquid crystals34can be filled between the other, described steps. In other words, the liquid crystals34can be filled before the step of cutting the first substrate31, for example, between the step81and the step82. In the present embodiment of the invention, the liquid crystals34can be filled through a vacuum injection process.

The image quality of each liquid crystal display panel35can be tested as described above with respect to the first embodiment andFIGS. 4A-5B. However, an ordinarily skilled artisan the field of the invention can understand that the invention is not limited the above described processes. For example, the image quality of each liquid crystal display panel35can be tested between any of two steps between steps85˜87. After the liquid crystal display panels35are separated from each other, a chip and the liquid crystal display panel35are combined through a chip on glass process. Or, a package with a chip and the liquid crystal display panel35are combined through a TAB process. The TAB process has been described with respect toFIGS. 6A˜7B. Furthermore, the liquid crystal display panels35can be tested by several test cards42when the outer leads39of each liquid crystal display panel35are exposed between steps84˜85. Or, each liquid crystal display panel35can be tested by one test card52when the test card52is moved relatively to each liquid crystal display panel52. What is worth mentioning is that a large-sheet polarizer is disposed correspondingly on the outer surface of the second substrate32before the image quality of the liquid crystal display panels35under light-emission is observed by an operator. Furthermore, the sequence of the steps81˜86can be adjusted properly. Or, some of the steps81˜86can be proceeded at the same time. As a result, the polarizers of each liquid crystal display panel35can be still adhered before the step87of separating the liquid crystal display panels35. Similarly, the step of testing the liquid crystal display panels35by several test cards or one test card which is moved correspondingly to the liquid crystal display panels, as shown inFIGS. 4A˜5B, can be inserted in the manufacturing process with the adjusted sequence of steps81˜86.

Third Embodiment

Refer toFIGS. 10˜11H,FIG. 10is a flow chart of a method of manufacturing a liquid crystal display according the third embodiment of the invention, andFIGS. 11A˜11Gare cross-sectional views showing a manufacturing process of the liquid crystal display according to the third embodiment of the invention. First, in step81, a panel assembly structure30is provided, as shown inFIG. 11A. InFIG. 11A, the panel assembly structure30includes a first substrate31, a second substrate32and several sealants33. The first substrate31and the second substrate32are disposed parallel to each other. The sealants33connect inner surfaces of the first substrate31and the second substrate32. The first substrate31includes several regions that will define third substrates31a. The second substrate32includes several regions that will define fourth substrates32acorresponding to the third substrates31a. Each third substrate31a, the corresponding fourth substrate32aand the corresponding sealant33are combined to form a panel. When the panel is filled with liquid crystals, the panel is a liquid crystal display panel. When the panel does not include any liquid crystal, the panel is an unfinished panel ready to be filled with liquid crystals. Furthermore, the third substrates31aand the fourth substrates32aare preferably color filter substrates and thin film transistor substrates respectively. The fourth substrate32a(the thin film transistor substrate) is larger than the third substrate31a(the color filter substrate). An inner surface of each fourth substrate32aincludes several outer leads39disposed adjacent and beyond a lateral side of the corresponding third substrate31a. In the present embodiment, the panel assembly structure30further includes several liquid crystal cells34. Each liquid crystal cell includes liquid crystals34filled between each pair of first substrate31and second substrate32, and surrounded by the corresponding sealant33. Also, each liquid crystal cell34is corresponding to one third substrate31aand the corresponding fourth substrate32a. Moreover, each third substrate31a, the corresponding fourth substrate32a, the corresponding sealant33and the corresponding liquid crystal cell34are combined to form a liquid crystal display panel35. Furthermore, the first substrate31and the second substrate32are preferably glass substrates, insulation substrates or plastic substrates.

Next, in step102, a large-sheet polarizer36is adhered on an outer surface of the first substrate31. The polarizer36includes several small-piece polarizers36acorresponding to the third substrates31a, respectively, as shown inFIG. 11B.

Then, in step103, a large-sheet polarizer37is adhered on an outer surface of the second substrate32. The polarizer37includes several small-piece polarizers37acorresponding to the fourth substrates32a, respectively, as shown inFIG. 11C.

Afterward, in step104, the polarizer36inFIG. 11Cis cut by using a cutting device38dfor separating the polarizers36a, as shown inFIG. 11D. The cutting device38dpreferably includes an excimer laser, a carbon dioxide (CO2) laser, or another laser suitable for cutting the polarizer. Furthermore, the step104of cutting the polarizer36by the cutting device38dcan be skipped when the small-piece polarizers36aare adhered correspondingly on the outer surface of the first substrate31by the same method described with respect to step23.

In step105, the first substrate31is cut by using a cutting device38afor separating the third substrates31a, as shown inFIG. 11E. The outer leads39of each fourth substrate32aare exposed. The cutting device38apreferably includes carbon dioxide (CO2) laser or another laser suitable for cutting a glass substrate, an insulation substrate or a plastic substrate.

Subsequently, in step106, the polarizer37is cut by using a cutting device38bfor separating the polarizers37a, as shown inFIG. 11F. The cutting device38bpreferably includes an excimer laser, a carbon dioxide (CO2) laser or another laser suitable for cutting a polarizer. A light transmission axis of the polarizers36ais substantially perpendicular to a light transmission axis of the polarizers37a. Furthermore, the step106of cutting the polarizer37by the cutting device38bcan be skipped when the small-piece polarizers37aare adhered on the outer surface of the second substrate32by the same method described with respect to step23.

Later, in step107, the second substrate32inFIG. 11Fis cut by using a cutting device38cfor separating the fourth substrates32a. As a result, the liquid crystal display panels35are separated form each other, as shown inFIG. 11G. The cutting device38cpreferably includes a carbon dioxide (CO2) laser or another laser suitable for cutting a glass substrate, an insulation substrate or a plastic substrate.

Although the One Drop Fill (ODF) process is illustrated in the present embodiment, the liquid crystals34can be filled between the other described steps. In other words, the liquid crystals34can be filled before adhering the polarizer on the outer side of the first substrate31. For example, the liquid crystals34can be filled between the step101and the step102. Each liquid crystal34can be filled through a vacuum injection process.

The image quality of each liquid crystal display panel35can be tested as described above with respect to the first embodiment andFIGS. 4A-5B. However, an ordinarily skilled artisan the field of the present invention can understand that the invention is not limited the above described processes. For example, the image quality of each liquid crystal display panel35can be tested between any of two steps between steps105˜107. After the liquid crystal display panels35are separated from each other, a chip and the liquid crystal panel35are preferably combined through a chip on glass process. Or, a package with a chip and the liquid crystal display panel35are combined through a TAB process, as shown inFIGS. 6A˜7B. Furthermore, the sequence of the steps101˜106can be adjusted properly. Or, some of the steps101˜106can be proceeded at the same time. The polarizers of each liquid crystal display panel35can be still adhered before the liquid crystal display panels are separated from each other in step107. Similarly, step35of testing the liquid crystal display panels35by several test cards or one test card which is moved relatively to the liquid crystal display panels35, as shown inFIGS. 4A˜5B, can be inserted in the manufacturing process with the adjusted sequence of steps101˜106.

In the method of manufacturing a liquid crystal display according to the embodiments of the invention, the polarizers are adhered before the liquid crystal display panels are separated from each other. Therefore, the time for adhering the polarizers of all the liquid crystal display panels is shortened. Furthermore, the image quality of all the liquid crystal display panels under light-emission is tested before the liquid crystal display panels are separated from each other. As a result, the time for testing all the liquid crystal display panels by one or more test card is shortened. Moreover, the substrate is cut by a laser in the embodiments of the invention. As a result, powders, particles or foreign matters generated in a conventional step of cutting the substrate by a wheel cutter are avoided. Defects of liquid crystal display panels due to the adherence of such powders, particles or foreign matters can be avoided. Besides, the liquid crystal display panels are ground and beveled by a laser in the disclosed embodiments of the invention. Thus, powders, particles or foreign matters generated in a conventional step of grinding and beveling the liquid crystal display panels by a grinding wheel are avoided. As a result, defects of liquid crystal display panels due to the adherence of such powders, particles or foreign matters are avoided. Therefore, the manufacturing process is simplified. Also, the step of cleaning and drying the liquid crystal display panels is skipped. The cost of purchasing the machines is reduced greatly.

While the invention has been described by way of example and in terms of one or more preferred embodiment, it is to be understood that the invention is not limited thereto. On the contrary, it is intended that the invention covers various modifications and similar arrangements and procedures, and the scope of the appended claims therefore should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements and procedures.