Our Process
As liquid crystal displays (LCDs) become larger, Corning continues to be a consistent leader in the growth and development of large-generation glass substrates. Corning’s proprietary fusion manufacturing process is at the core of our leadership in LCD glass technology. This extraordinarily precise, highly automated draw process produces glass substrates with exceptionally clean, smooth, flat surfaces, and inherent dimensional stability – qualities essential to the successful manufacture of LCD screens.
The process begins when raw materials are blended into a glass composition, which is melted and conditioned. The molten glass is fed into a trough called an “isopipe,” overfilling until the glass flows evenly over both sides. It then rejoins, or fuses, at the bottom, where it is drawn down to form a continuous sheet of flat glass.
Corning’s fusion manufacturing process offers critical advantages for the display industry, including:
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Producing glass that is flat with excellent thickness control. Substrate flatness is particularly critical in the production of panels for liquid crystal display (LCD) TVs. Any deviations from flatness can result in distortions. With Corning’s proprietary fusion process, the glass is formed in air and drawn down to form an incredibly flat piece of glass with very precise thickness controls.
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Pristine surface quality and scalability. Because glass formed using this method requires no subsequent surface grinding or polishing, fusion is an optimal technology for producing high-quality, large-generation LCD glass substrates. To maintain this quality from start to finish, Corning has entirely mechanized the substrate handling processes. The end result helps the industry supply more affordable, large-sized televisions for consumers. No matter how large next-generation substrates become, Corning will continue to focus on the technology behind the glass and provide what’s next in advanced display.
Corning’s innovations don’t end on the manufacturing floor. One of Corning's greatest strengths is our focus on developing the technology behind the glass. Our research has delivered such life-changing innovations as the glass envelope for Edison's light bulb, the glass envelope for cathode ray picture tubes (CRTs), and the first low-loss optical fiber capable of use in telecommunications. We continue to investigate new glass compositions and process innovations at our five major research facilities:
- Sullivan Park in Corning, New York
- Corning Technology Center in Shizuoka, Japan
- Corning European Technology Center in Avon, France
- Corning Research Center Taiwan in HsinChu, Taiwan
- Taichung Analytical Lab in Taichung, Taiwan
Scientists in these facilities work closely with Display Technologies’ commercial, engineering, and manufacturing staff to anticipate industry trends and deliver new or improved glass substrates that add value to customers’ products and processes. Through this ongoing process, Corning Display Technologies continues to lead through technology innovation in the fast-paced display industry.