Absorption Layer for Laser Sealing Display Panels
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Solution Overview
Problem
The conventional laser sealing method for display panels results in unevenly heated frit due to laser beam reflection from metal lead lines, leading to unfavorable sealing effects, broken metal lead lines, and increased manufacturing complexity.
Innovation Solution
A sealing method is introduced where an absorption material layer is formed in the non-display area of the pixel array substrate to absorb a portion of the laser beam, preventing reflection and ensuring even heating of the frit by overlapping with the sealing material layer, thereby adhering the substrates effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional laser sealing method is used on metal lead line regions, then sealing process can be performed, but the frit is heated unevenly due to laser beam reflection from metal lead lines
Solution Approach 1:
An absorption material layer is introduced as an intermediary between the laser beam and the metal lead lines. This layer absorbs the laser beam energy before it reaches the metal lead lines, preventing reflection and ensuring uniform heating of the frit during the sealing process.
Solution Approach 2:
The harmful reflection of laser beams from metal lead lines is converted into a beneficial effect by using the absorption material layer to deliberately absorb the laser energy. This converts the problematic reflection into controlled absorption, achieving uniform heating and improved sealing quality.
2Reliability
If laser beam is used for sealing, then sealing can be achieved, but metal lead lines may be broken due to reflected laser beam
Solution Approach 1:
The absorption material layer is formed in advance in the metal lead line regions before the laser sealing process. This preliminary action ensures that when the laser beam is applied, the absorption material is already in position to protect the metal lead lines from reflected laser energy.
Solution Approach 2:
The absorption material layer serves as a protective intermediary that absorbs the laser beam energy before it can reflect off the metal lead lines and cause damage. This intermediary layer effectively shields the metal lead lines from harmful laser reflection.
3Manufacturing precision
If absorption material layer is added to prevent reflection, then sealing quality improves, but manufacturing process complexity increases
Solution Approach 1:
The absorption material layer formation process is merged with the existing sputtering process used for forming the pixel electrode. By combining these two processes into one sputtering step, the manufacturing process complexity is minimized while still achieving the desired absorption material layer formation in the metal lead line regions.
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 damages to the sealing material and enhances sealing strength, simplifies the manufacturing process, and improves yield without altering existing manufacturing conditions.
Implementation Method 1
the absorption material layer absorbs a portion of a laser beam passing through the sealing material layer in the laser processing process
Implementation Method 2
a laser processing process is performed on the sealing material layer of the second substrate, such that the first substrate is adhered to the second substrate by the sealing material layer
Data Source
AI summary
A display panel and a sealing process are provided. The display panel has a display area and a non-display area; the sealing process includes following steps. A first substrate having a pixel array in the display area is provided. An absorption material layer is formed in the non-display area of the first substrate. A second substrate having a sealing material layer in the non-display area is provided. The second substrate and the first substrate are assembled, and a display medium is formed therebetween. The absorption material layer and the sealing material layer at least partially overlap. A laser processing process is performed on the sealing material layer, so that the first substrate is adhered to the second substrate by the sealing material layer. The absorption material layer is adopted for absorbing a portion of a laser beam passing through the sealing material layer in the laser processing process.