3D Display Panel Bonding With Guide Film and Vacuum Shaping
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Solution Overview
Problem
Existing manufacturing methods for flexible display panels, particularly those with three-dimensional designs, suffer from defects such as cracks, shrinkage, and bubbles in the edge area due to the complexity of machinery and processes involved.
Innovation Solution
A method involving the use of a guide film and OCA film attached to a display panel, followed by cutting and shaping processes using a shape stage and diaphragm pad, which includes bonding steps with controlled pressures to form a completely bonded three-dimensional display panel, eliminating the need for complex machinery like clamps and rollers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If complex machinery like clamps and rollers is used for shaping three-dimensional display panels, then the shaping capability is improved, but the risk of equipment malfunction increases and productivity decreases
Solution Approach 1:
The patent removes complex machinery such as clamps and rollers from the shaping process. Instead, it uses a simple shape stage with vacuum holes that directly form the three-dimensional shape through vacuum adsorption, eliminating the need for complicated mechanical components while maintaining effective shaping capability
Solution Approach 2:
The patent replaces the mechanical system of clamps and rollers with a vacuum-based system. The shape stage uses vacuum pressure through holes to adsorb and shape the display panel, substituting mechanical contact and force application with a field-based vacuum mechanism that is simpler and more reliable
2Shape
If complex machinery like clamps and rollers is used for shaping three-dimensional display panels, then the shaping capability is improved, but productivity decreases
Solution Approach 1:
By removing complex machinery from the process, the patent reduces setup time, maintenance requirements, and potential failure points. The simplified shape stage with vacuum holes enables faster operation and higher productivity while maintaining the ability to form three-dimensional shapes effectively
Solution Approach 2:
The vacuum-based shape stage system is simpler and more self-regulating than mechanical clamps and rollers. It automatically adsorbs and shapes the panel through vacuum pressure without requiring complex mechanical adjustments or interventions, thereby improving manufacturing efficiency and productivity
3Device complexity
If conventional bonding methods are used without guide film and OCA film, then the process is simpler, but defects like cracks, shrinkage, and bubbles occur in the edge area
Solution Approach 1:
The patent introduces a guide film and OCA film as intermediary layers between the display panel and the bonding process. These films act as mediators that control the bonding process, prevent direct contact issues, and eliminate defects such as cracks, shrinkage, and bubbles in the edge area while maintaining process effectiveness
Solution Approach 2:
The guide film and OCA film are attached to the display panel before the bonding process begins. This preliminary action prepares the panel for bonding by providing a controlled interface that prevents defects during the subsequent bonding and shaping operations, ensuring high reliability without excessive complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method prevents defects in the edge area and enhances manufacturing efficiency by reducing the risk of equipment malfunction and increasing productivity.
Implementation Method 1
a plurality of vacuum holes may be formed on an outer surface of the shape stage... the plurality of vacuum holes may be through holes that allow the central portion and the edge portion to be adsorbed onto the outer surface of the shape stage by negative pressure generated on an inner surface of the shape stage
Implementation Method 2
the OCA film may include a substrate and an OCA release liner attached to the substrate... peeling the OCA release liner from the substrate and bonding the cover glass onto the substrate
Data Source
AI summary
A method of manufacturing a display device including a three-dimensional display panel, includes attaching a guide film onto a back surface of the display panel, attaching an OCA film onto a front surface of the display panel, cutting the attached display panel, guide film, and OCA film, performing a pre-forming process by pressing the cut display panel, guide film, and OCA film onto a shape stage, performing a first bonding process by attaching and pressing a cover glass onto the OCA film, removing the shape stage from the guide film and introducing a diaphragm pad into a position where the shape stage was previously placed, performing a second bonding process by pressing the cover glass onto the diaphragm pad, and removing the diaphragm pad from the guide film and removing the guide film.