1. TFT LCD panel large board cutting:
The TFT panel substrate that has been made, with cutting equipment for slitting small pieces, using automatic laser cutting machine into small pieces, testing, vacuum packaging.
2. Polarizer attachment:
In front of the TFT panel up and down respectively attached to the polarizer, to ensure that the polarizer angle light can be correctly modulated through the liquid crystal layer.
3. Driver IC Bonding:
Using fully automated equipment such as COG (Chip on Glass) or COF (Chip on Film), the driver IC is attached to the small sheet substrate of the TFT panel.
4. FPCA Bonding:
Connects the COG display panel to a printed circuit board (PCB) or flexible printed circuit (FPC) to provide power and signal input.
5. ACF Particle Inspection.
Examination of COG, FOG Bonding particles with differential dry microscope.
6. Electrical Performance Test:
Use test fixture to sort FOG semi-finished products, RGB, grayscale, white and black screen test.
7. Sealing:
Use full-automatic equipment to seal the COG IC on the tested FOG, and cure the UV adhesive behind between FPC and TFT panel.
8. Backlight assembly:
After sealing and curing the FOG, it is necessary to install the backlight unit (BL), including light guide plate, reflective sheet, diffusion sheet and LED light bar and other components, in order to ensure that the screen is uniformly illuminated.
9. Function test:
Conduct a comprehensive function test for each TFT LCD display screen to check for bad dots, uneven brightness and other problems.
10. Burn-in Test:
Allow the display to power on and work for 48 hours to simulate the conditions of long-term use, in order to detect potential reliability problems.
11. Appearance Inspection and Packaging:
Conduct a final cosmetic inspection to ensure that there is no physical damage or other surface defects.
Qualified products will be properly packaged, Quality Assurance (QA), implemented strict quality control measures to ensure that the product meets the expected quality standards, and finally warehoused for shipment.
In actual TFT display module production, the entire process not only follows the basic steps outlined above, but is also fully automated. Each step relies on precision equipment and technology to ensure a high degree of accuracy and consistency. Each step requires highly accurate operation and strict environmental control in order to ensure the quality and stability of the final product.
Hongcai follows strict production and quality procedures in the production of TFT LCD displays screen to ensure high and consistent product quality.
1. Fully automated production lines:
Hongcai has three fully automated COG bonding lines and a Class 10,000 clean room with a monthly production capacity of over 800 K. The highly automated equipment helps to minimize human error and improve production efficiency and product quality.
2. Quality Management System Certification:
The company has strictly passed international quality management system certifications such as ISO 9001:2015, demonstrating that it maintains the highest level of quality management and continuous improvement standards in all operations.
3. Process Control Program:
Hongcai implements a detailed production quality process control program, covering from incoming material inspection (IQC), in-process in-line quality control (IPQC), to finished product pre-shipment quality check (OQC). Each link has clear operation specifications, inspection items, instruments and equipment used, as well as an exception handling mechanism to ensure that each process is under strict control.
4. Precision testing equipment:
Hongcai is equipped with state-of-the-art testing equipment, such as RGB and brightness analyzers, cold and hot shock equipment, vibration equipment, FPC tensile testers, salt spray testers, etc., which are used to perform rigorous performance testing, including but not limited to temperature testing, COG/FOG testing, leveling testing and air pressure testing.
5. Regular Calibration and Maintenance:
The calibration accuracy of the bonding equipment is performed weekly to ensure that the equipment is always in optimal working condition.
6. Straight-through rate management:
The importance of a one-time pass rate of 99.5% or more reflects the company’s focus on first-time pass rates during the production process, which reduces the likelihood of rework and improves overall efficiency.
7. Aging test:
For TFT LCM finished products, aging tests for display failure are conducted to verify reliability and stability for long-term use.
8. Customer-oriented values:
Hongcai adheres to the quality policy of “Quality and Integrity” and puts customer satisfaction in the first place to provide high-quality products and services.
In summary, Hongcai not only adheres to, but also strictly enforces a complete set of production and quality procedures in the production of its TFT LCD displays to ensure that it delivers reliable and high-performance products to its customers.
