TFT LCD Manufacturing Process

In the intricate world of display technology, the manufacturing of Thin Film Transistor (TFT) Liquid Crystal Display (LCD) modules is a testament to modern engineering marvels. At LONGTECH, our expertise begins where the foundational Array and Cell processes end, focusing on the crucial final stages of module production. This blog aims to detail not only these initial stages but also how LONGTECH’s specialized processes contribute to creating superior TFT LCD modules.

The Array and Cell processes are the backbone of TFT LCD module manufacturing, involving complex steps like thin film application, photolithography, and liquid crystal dispensing. These stages lay the groundwork for the high-quality modules that LONGTECH is known for. Our contribution, starting post these stages, involves meticulous assembly, testing, and finishing, ensuring that each module meets our stringent standards of quality and functionality.

Let’s explore the complete journey of a TFT LCD module, from the initial Array and Cell processes to LONGTECH’s specialized finishing touches. This comprehensive overview will highlight our commitment to quality and the advanced technology that positions us as a leader in the TFT LCD market.

Array and Cell Processes: Laying the Groundwork

Array Process

1. Thin Film Application:
   • Layer Deposition: Applying layers like amorphous silicon onto the glass substrate.
   • Transistor Foundation: Establishing the base structure for transistors.
2. Photolithography:
   • Film Patterning: Utilizing light exposure to pattern the thin film.
   • Layout Definition: Essential for accurately defining pixel and transistor layouts.
3. Etching:
   • Material Removal: Eliminating excess material to sculpt transistors and circuits.
   • Circuit Precision: Ensuring the accuracy and precision of the circuitry.
4. Stripping:
   • Residue Removal: Clearing away any residual photoresist materials.
   • Process Preparation: Setting the stage for the upcoming cell process.

Cell Process

1. Polyimide Printing:
   • Layer Application: Applying polyimide layers for liquid crystal alignment.
   • Light Modulation: Crucial for controlled modulation of light through the display.
2. Rubbing:
   • Polyimide Alignment: Mechanical process for aligning the polyimide layer.
   • Liquid Crystal Orientation: Determines the orientation of liquid crystal molecules for display clarity.
3. Spacer Spread:
   • Spacer Distribution: Evenly distributing microscopic spacers to maintain cell gap.
   • Display Uniformity: Vital for maintaining consistent display thickness and quality.
4. Sealant Patterning:
   • Sealant Application: Applying sealants to define the liquid crystal area.
   • Leakage Prevention: Helps in preventing leakage and contamination.
5. Liquid Crystal Dispensing:
   • Material Addition: Precise injection of liquid crystal material into the module.
   • Display Functionality: Integral to the module’s core display characteristics.
6. Assemble & Seal:
   • Substrate Joining: Merging the front and back substrates of the module.
   • Secure Sealing: Ensures the liquid crystals are encased securely for optimal performance.
7. Polariser Lamination:
   • Filter Application: Affixing polarizing filters to the module.
   • Contrast Enhancement: Improves display contrast and visual clarity.

LONGTECH’s Specialized TFT LCD Module Process

Full-automatic production line

1. Wiping and Cleaning:
   • Preparation: Ensuring that pre-processed components are completely clean.
   • Quality Maintenance: Vital for preserving the integrity of components before assembly.
2. COG (Chip-On-Glass):
   • Integration: Attaching microchips onto the glass substrate.
   • Functionality Control: Crucial for managing the display’s performance and capabilities.
3. FOG (Film-On-Glass):
   • Conductive Film Application: Adding films for touch functionality.
   • Alignment and Bonding: Precision in this step ensures touch screen accuracy.
4. Electrical Testing:
   • Integrity Checks: Confirming the electrical functioning of the modules.
   • Quality Assurance: A key phase to ensure product reliability and performance.
5. Applying Protective Glue:
   • Structural Reinforcement: Enhancing the module’s durability.
   • Environmental Protection: Guarding against operational and environmental stressors.
6. Applying Protective Tape:
   • Final Preparation: A step for safe handling and transportation.
   • Integrity Maintenance: Keeping the module secure until its integration into devices.

Assembly & Inspection

1. Assembling LED Backlight:
   • Integration: Incorporating an LED backlight into the LCD module for uniform illumination.
   • Efficiency: Ensuring energy-efficient and accurate color reproduction.
2. Touch Panel Lamination (TP Lamination):
   • Alignment: Precisely aligning the touch panel with the LCD screen.
   • Responsiveness: Enhancing user interaction with a sensitive and accurate touch interface.
3. Metal Frame Assembly:
   • Stability: Mounting the LCD module in a metal frame for increased durability.
   • Design: Focusing on frame strength, weight, and compatibility for optimal performance.
4. Final Quality Inspection:
   • Testing: Conducting thorough tests for display quality, brightness, and touch functionality.
   • Standard Compliance: Ensuring each module meets LONGTECH’s high-quality standards.

Why Haven’t Ventured into TFT LCD Array and Cell Processes?

Collaboration with Industry Giants:

• We’ve established strong partnerships with leading manufacturers like BOE, Tianma, Auo, and others. This collaboration ensures we receive TFT LCD Panels that meet the highest quality standards. Our partners have already invested billions in the production line required for these processes, allowing us to leverage their expertise and advanced technology.

Guaranteed Quality:

• By sourcing panels from these industry leaders, we guarantee the absolute quality of our products. This approach allows us to focus on what we do best – assembling and customizing these high-quality panels to meet the specific needs of our clients. Our role becomes one of adding value through customization and technical support, rather than manufacturing the panels ourselves.

Cost Efficiency:

• Investing in the TFT LCD Array and Cell production line is a multi-billion dollar venture. For LONGTECH, directing such an immense amount of capital towards this stage of production would not align with our efficient cost management strategies. It’s a huge financial commitment that could potentially impact our ability to offer competitive prices to our clients.

Strategic Purchasing:

• By partnering with established manufacturers, we not only ensure quality but also maintain cost-effectiveness. These collaborations enable us to purchase TFT LCD Panels at competitive prices, passing on the cost benefits to our clients. This strategy aligns perfectly with our goal of providing high-quality products at reasonable prices, which is a key demand of our clientele.

Customization of TFT LCD Module

Custom TFT LCD module, a specialized form of liquid crystal display, is engineered to meet unique customer specifications. These modules are highly customizable, allowing adjustments in size, shape, color, resolution, and various other features to precisely fit the intended application. Such versatility makes them ideal for a diverse array of uses, from industrial equipment and medical devices to automotive displays and consumer electronics.

• TFT LCD panel
• FPC dimension
• Backlight
• Luminance
• Connection
• Interface

Custom TFT LCD Panels:

• When it comes to a fully customized TFT LCD panel solution, it’s important to understand the implications in terms of cost and quantity. For a complete customization, the tooling fee alone can soar up to $100,000. Additionally, the minimum order quantity (MOQ) for such tailored solutions often exceeds 10,000 pieces. Therefore, while total customization is feasible, it’s accompanied by significant financial and production commitments.

Opting for Standard Sizes with Custom Features:

• To balance customization with cost-effectiveness, we at LONGTECH recommend considering our range of existing TFT LCD panel sizes, like 2.4″, 3.5″, 4.3″, or 7″. These standard sizes offer the benefits of customization without the hefty tooling fees and high MOQs associated with totally custom panels.

Cost-Effective Customization Options:

• While the panel size remains standard, there’s still ample room for customization. We can tailor the TFT LCD interface, backlight, and T-CON (Timing Controller) board to meet specific requirements. This approach significantly reduces the tooling fee compared to a fully custom TFT LCD solution, making it a more accessible option for many clients.

Conclusion

At LONGTECH, our commitment to excellence in TFT LCD module manufacturing is unwavering. By understanding and mastering each step of this intricate process, we ensure the delivery of superior quality products, tailored to meet the unique demands of our clients.

LONGTECH’s TFT LCD modules are more than just displays; they are a key component in enhancing the functionality and user experience of a wide range of products. With our focus on customization, quality, and reliability, we provide solutions that precisely meet the needs of our diverse clientele.