Daily production capacity: 1800 pair of glass plates, about 20 sec. for each glass plate throughput.
Glass substrate sources mainly from Japan. These are then ITO coated in China.
Mother glass standard size is 14" x 16". Glass thickness 1.1, 0.7, 0.55 and 0.4 mm.
TN, HTN, BTN (VA) and STN types can all be done on the same line. We just need to change the materials input and the process parameters.
General cleanroom condition: 10K class. Exposure areas: 1K class.
Minimum dot gap (or track gap) : 15um
Certified subcontractors are used for chrome mask fabrication. Film masks used for samples except COG types.
We use polyimide as PI (orientation layer) material. After controlled surface rubbing it is able to align the liquid crystal molecules in the preferred orientation to achieve the desired viewing direction as required by customer, or application.
Spacers are sprayed onto the inner glass surface prior to coupling, to help achieve cell gap uniformity throughout. Spacer sizes commonly in use are 3,4,5, 5.8, 6.8 um etc.to fit the overall optical performance need.
Pamping (final batch coupling) process requires 200 deg C and 1.5 hours curing time. It also needs another 3 hours to cool down before going to the next process.
Liquid crystal filling is done by vacuum suction and each cycle takes about 20 minutes.
Liquid crystals mainly sourced from Japan and Germany. Local China sources are also used for normal operating temperature and low duty types.
We carry out 100% visual and functional inspection as normal practice. Open circuit can be detected by naked (also adied when needed) eyes, while short circuit can be detected automatically by the tester with appropriate signal inputs.
Our scribers are equipped with hard carbide wheels which, by traversing (X and Y directions) along the batch outer surface, creates all relevant scribe lines, first on one glass and then the other.
The majority of our polarisers come from local and Taiwan sources.
In general polariser sheets need to be cut in oblique angles to fit the rubbing directions for best optical performance.
We practise AQL levels of: Major = 0.4; Minor = 1.0. However we can always adapt to fit customer needs. In some cases we can even take the 'C = 0 ' sampling plan.
We are running 2 shifts of 8 hours each with 2 to 3 hours overtime per shift as general practice,on a 6-day week production schedule. Sundays are usually reserved for general cleaning and plant/machine maintenance works.
Current overall capacity utilisation is > 95%. Low periods (Novemebr to March each year) utilisation is still > 85 % in general.
COG capacity: 2 semi-automatic COG bonding lines installed, each able to commit 50 kpcs/day, totalling 500 kpcs each month.
Current COG capacity utilisation: 300kpcs output per month, around 60% utilisation.
COG future plan: Add 2 more lines within one year.
COG anti-corrosion enhancement: A '141B' cleaning line is installed in addition to the normal cleaning process. This can produce a low temperature stream jet to remove whatever organic residue that might still be trapped within the external cell gap area. An operation manual normalising this corrosion prevention mechanism is in place with also the operation procedure included.
We carry out periodic and random sample reliability test (60℃×90%RH*12hrs) to assess and keep track of the aging characteristics of our COG finished products.
Our '3-in-1'product structure: Glass + Glass (cover plate + functional module), this is better in interference resistance compared with the Glass + Film combo.
The factory employs around 500 persons, about 350 to 400 are directly involved in the manufacturing chain.
The site started mass production from March 2008, obtained its ISO9000 certification in October of the same year, also in pursuit of TS16949 and ISO14000 official approvals.
