Liquid crystal display (LCD) televisions and plasma-based direct view televisions can amplify the slightest spec of dirt that finds its way into the micro-display assembly. At the Sony Technology Center-Pittsburgh in Mt. Pleasant, Pa., they control dirt with a flexible solution that combines roll-up doors and curtain walls in the production environment.

“Our ability to keep dirt out of the sets and off the optics is crucial,” says Scott Olsen, production support manager. “If quality control spots dirt on the set, it has to be completely disassembled. This is very time consuming.”

Sony installed curtain walls to match the conditions of a class 10,000 cleanroom. The reinforced curtain walls enclose a complex of rooms within the assembly area where 50 gowned employees work. In the plasma TV area, two 100-foot long walls in two locations create work zones. An 80 x 120 foot area encloses the LCD TV projection area, and has a changing area attached to it with a curtain wall passage.

Like the curtain walls, the roll-up door is constructed of heavy-duty vinyl and provides a tight seal around the perimeter. The top of the door is covered with a valance, the sides are surrounded by the guide rack, and the door panel has a bottom seal. A clear vinyl window lets light into the interlock area. The material is flame retardant, water repellent, mildew resistant and can withstand most chemicals.

Interlocking controls ensure that when one motorized roll-up door is open the other is closed. When the inner door opens, the fan system pushes dirt out of the room. Carts can't tear the door panels in cases of contact. Instead, the roll-up curtain pops out of its guides. The rollers are easily set back into position.

For Sony, which is always transforming its product line to meet market demands and advancing technology, the curtain wall enclosures give them the responsiveness they need to remain at the forefront. Olsen says, “If we change our manufacturing arrangement, we take down the curtains and use new space that matches our needs.”

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