Patent ID: 8199312

Claim:
A method of manufacturing an LCD device, comprising: providing a mother substrate having a major axis and a minor axis, wherein the major axis and the minor axis of the mother substrate have lengths according to the following: selecting characteristics of a plurality of LCD panels, said characteristics including: a diagonal length, an aspect ratio of a length of the panel in a first direction to a length of the panel in a second direction different from said first direction, and an operating mode; choosing a number of a plurality of LCD panels to provide on the mother substrate; choosing the alignment of the first direction of the LCD panels relative to the major axis of the mother substrate; choosing a size of a dummy region at an edge of the mother substrate; choosing a first margin of the mother substrate, said margin including: a distance between adjacent panels on the mother substrate in the first direction, and a distance between the dummy region and the LCD panel in the first direction; choosing a second margin of the mother substrate, said margin including: a distance between adjacent panels on the mother substrate in the second direction, and a distance between the dummy region and the LCD panel in the second direction; and wherein the length of the major axis of the mother substrate and the length of the minor axis of the mother substrate are based on said LCD panel characteristics, the number of LCD panels to provide on the substrate, the alignment of LCD panels relative to the mother substrate, the first and second margins, and said size of the dummy region, such that a substrate efficiency of 90% or more is achieved in the major and minor axis directions for the mother substrate, wherein a substrate efficiency of 100% is based on assuming a total dummy region width of 30 mm or less and a margin of 0.3 to 4%, and wherein the size of the mother substrate is determined to be 1100 mm by 1250 mm, forming the number of the plurality of LCD panels on the mother substrate.