摘要
随着TFT-LCD生产线的高世代化以及人们对产品性能要求的不断提高，对产品设计及生产工艺等方面都提出了更加苛刻的要求。伴随而来的是各种不良的高发，给产品的生产带来前所未有的挑战。液晶气泡作为一种常见的不良，其受到生产过程中很多方面因素影响，与产品设计及生产工艺等方面也密切相关，给不良解决工作造成诸多困难，改善方案的提出也受到众多限制。 本文利用热失重分析仪、盒厚测试仪、FTIR（红外分光光谱仪）、SEM（扫描电子显微镜）、FIB（聚焦离子束显微镜）等精密量测设备，通过对面板相关性能参数的测定，从液晶气泡不良产生的机理、面板的设计以及生产管控等方面有针对性地进行了分析和讨论，并提出相应的改善方案，对预防此类不良的出现具有积极的意义。
经过对液晶气泡发生机理的分析，将液晶气泡不良分为两个大的类别：空气气泡和真空气泡。针对空气气泡问题，本文通过对液晶显示器中的密封材料进行一系列实验测试，总结出因框胶异常导致空气气泡问题的解决方法，并且提供了如何进行框胶材料选择的方法。另外，通过对液晶盒内阻材料的结构分析和实验测试，寻到因液晶盒内阻气体析出导致的空气气泡问题的解决途径。解决空气气泡的关键点在于以下两点：1>.液晶盒密闭方式需要经得起信赖性验证，不会发生因液晶盒外界空气进入导致液晶气泡。2>.液晶盒内的阻等有机物需要经得起信赖性验证，不会发生因外界温度、压力的变化导致有机物升华为气 体，从而产生液晶气泡。针对真空气泡问题，本文通过对液晶滴下量范围（LC margin）进行模型分析建立，对主要影响因子：Main PS（Main Photo Spacer，主要曝光间隔物）高度，Sub PS（辅助PS）高度，PS和不同液晶滴下量的关联性进行实验测试，寻到最佳的匹配关系，并总结得到解决真空气泡问题的关键点在于以下两点：1>.液晶盒空间设计符合规范要求，受到外界温度、压力作用下液晶盒空间形变量与液晶的形变量保持一致。2>.液晶盒内的空间和液晶滴下量需要达到平衡点，避免液晶盒空间过大而液晶量过小导致真空气泡。 本文的主要成果如下：
(1)产出框胶涂布作业规范，液晶盒黏附性测试方法以及评价方式；针对不同框胶宽度
对应的黏附压力进行测试总结，得到不同尺寸液晶面板需要的框胶宽度管控规范。
(2)产出新的产品设计规范，通过在产品上设计PV2(SiNx)层开小孔方式，在上下面板
对组前将液晶盒内的有机物从小孔排除干净。
(3)产出新版LC margin(液晶滴下范围)管理规范。使用不同Main PS高度与Sub PS高
度搭配液晶滴下量设计实验，实验后得到最佳的液晶滴下范围，减少产品在生产过程中发生真空气泡的问题。
关键词：液晶气泡；液晶滴下量范围；阻；参数优化
ABSTRACT
With the high generation of TFT-LCD production lines and people’s increasing requirements for product performance, more stringent requirements have been put on product design and production processes. It is accompanied by high-frequency defective products, which bring unprecedented challenges to the production of products. Liquid crystal bubbles, as a common defect, are affected by many factors in the production process, and are also closely related to product design and production processes, causing many difficulties for poor solution work, and the improvement program is also subject to many restrictions.
In this paper, we use liquid crystal blister defects to measure the relevant performance parameters of the panel, such as thermogravimetric analyzer, box thickness tester, FTIR (Fourier transform infrared spectroscopy), SEM (Scanning electron microscope), and FIB (Focused Ion Beam), to determine the mechanism of failure, panel design, and production control. The parties conducted targeted analysis and discussion in a targeted manner and proposed corresponding improvement plans, which have positive significance in preventing the occurrence of such defects.
After the analysis of the liquid crystal bubble generation mechanism, the liquid crystal bubble defects are divided into two major categories: air bubbles and vacuum bubbles. Aiming at the problem of air bubbles, this paper conducts a series of experimental tests on the sealing material in liquid crystal displays, and summarizes the methods to solve the problem of air bubbles caused by abnormal sealant, and provides methods for how to select the sealant materials. In addition, through structural analysis and experimental testing of the color resist material in the liquid crystal cell, the solution to solve the air bubble problem caused by the color separation of the gas in the liquid crystal cell is solved. The key to solve air bubbles lies in the following two points: 1). The liquid crystal cell sealing method needs to withstand the reliability verification, and no liquid crystal bubbles will occur due to the outside air entering the liquid crystal cell. 2). Organic substances such as color-resistance in the liquid crystal cell are required to withstand the verification of reliability, and no change in external temperature or pressure causes the organic substance to sublimate into a gas, thereby generating liquid crystal bubbles.
For the vacuum bubble problem, this paper establishes a model analysis of the liquid crystal dripping range (LC margin), and the main influence factors: Main PS (Main Photo Spacer)height, Sub PS (assisted PS) height, and association between PS and different liquid crystal dripping amount sex cond
ucts experimental testing to find the best matching relationship, and summarizes the key points to solve the vacuum bubble problem in the following two points: 1). The space design of the liquid crystal cell conforms to the specifications and is consistent with the shape variables of the liquid crystal cell under external temperature and pressure. 2). The space in the liquid crystal cell and the amount of liquid crystal dripping need to reach a balance point to avoid the vacuum bubble as the liquid crystal cell volume is too large and the liquid crystal volume is too small.
The main achievements of this paper are as follows:
(1)The sealant coating operation specification is summarized: Liquid crystal cell
adhesion test method and evaluation method; We summarize the adhesive pressure corresponding to the width of the sealant, and obtain the specifications for the sealant width control required for liquid crystal panels of different sizes.
(2)A new product design specification is summarized: The design of the PV2 (SiNx)
layer opening on the product, the organic matter in the liquid crystal cell is eliminated from the small hole before the upper and lower panels combination.
(3)New LC margin (liquid crystal dropping range) management specification is
summarized: Different Main PSH (Main Photo Spacer Height) and Sub PSH (Main Photo Spacer Height) were used to design the experiment with the amount of liquid crystal dropping. After the experiment, the best drop range of the liquid crystal was obtained and the problem of vacuum bubbles in the production process was reduced.
Keywords：LC bubble; LC margin; Color resistance; Parameter improve
目录
摘要......................................................................................................................................... I ABSTRACT ........................................................................................................................... III 第一章绪论 (1)
1.1 前言 (1)
1.2 选题背景和意义 (1)
1.3 TFT LCD组成和工作原理 (2)
1.4 液晶气泡原因分析 (6)
1.4.1 空气类液晶气泡及其改善方法 (8)
1.4.2 真空类液晶气泡 (10)
1.4.3 真空类液晶气泡成因 (10)
1.5 本文小结 (11)
第二章液晶面板的制作工艺及测试方法 (12)
2.1 液晶面板制造工艺概述 (12)
2.1.1 液晶的特性 (12)
2.1.2 阵列段工艺 (13)
2.1.3 组合段工艺 (13)
2.2 液晶气泡的主要测试方法 (15)
第三章空气类气泡改善验证 (17)
3.1 框胶对空气类液晶气泡的改善 (17)
3.1.1 阻气体析出对液晶气泡的改善 (19)
3.2 阻气体析出防范措施 (24)
3.2.1 实验测试及结果评价 (24)
3.2.2 设计改善防范 (28)
3.2.3 空气泡检验方法 (29)
3.3 本章小结 (33)
第四章液晶滴下范围（LC margin）优化验证 (34)
4.1 LC margin影响因素模型建立 (34)
4.2 LC margin实验测试及结果评价 (41)
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