Patent ID: 8027015

Claim:
A method of manufacturing liquid crystal display (LCD) devices, comprising: providing a plurality of mother substrates having a major axis and a minor axis, wherein the length of the major axis of each mother substrate is the same and the length of the minor axis of each mother substrate is the same, and wherein the major axis and the minor axis of the plurality of mother substrates have lengths according to the following: selecting first characteristics of a first plurality of LCD panels and selecting second characteristics of a second plurality of LCD panels, said characteristics including: a diagonal length, an aspect ratio of a length of the LCD panel in a first direction to a length of the LCD panel in a second direction different from said first direction, and an operating mode; choosing a first number of the first plurality of LCD panels to provide on a first of the mother substrates and choosing a second number of the second plurality of LCD panels to provide on a second of the mother substrates; choosing an alignment of the major axis of the first LCD panels to be parallel to the major axis of the first mother substrate and choosing an alignment of the minor axis of the second LCD panels to be parallel to the major axis of the second mother substrate; choosing a size of a dummy region at an edge of the first mother substrate and choosing a size of a dummy region at an edge of the second mother substrate; choosing a first margin of the first mother substrate and a first margin of the second mother substrate, said first margins including: a distance between adjacent LCD panels on the mother substrate in the first direction, and a distance between the dummy region and the LCD panels in the first direction; and choosing a second margin of the first mother substrate and a second margin of the second mother substrate, said second margins including: a distance between adjacent LCD panels on the mother substrate in the second direction, and a distance between the dummy region and the LCD panels in the second direction, wherein the length of the major axis of the mother substrates and the length of the minor axis of the mother substrates are based on said first and second LCD panel characteristics, the first number and the second number of LCD panels, the alignment of the first and second LCD panels relative to the first and second mother substrates, the first and second margins, and said sizes of the dummy regions, such that a substrate efficiency of 90% or more is achieved in the major and minor axis directions for first mother substrate and a substrate efficiency of 90% or more is achieved in the major and minor axis directions for the second mother substrate, wherein a substrate efficiency calculation of 100% is based on assuming a total dummy region width of 30 mm or less and a margin of 0.3 to 4%; forming the first number of the first plurality of LCD panels on the first mother substrate; and forming the second number of the second plurality of LCD panels on the second mother substrate.