Adhesion Spacer Design for Flexible Display Substrate Stability

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Solution Overview

Problem

In display devices, especially flexible-type displays, external forces cause displacement of substrates and optical films, leading to degradation in display quality due to unattached spacer ends, which can result in misalignment of elements and image distortion.

Innovation Solution

The implementation of adhesion spacers with a distal end portion opposing the substrate and an adhesive member to secure the spacer ends, maintaining a consistent cell gap and preventing substrate displacement, while using fillers in the adhesive to enhance adhesivity and maintain distance between the spacer ends and the substrate.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the distal end of the spacer is not attached to the other substrate, then the spacer structure is simple and easy to manufacture, but the substrate displacement occurs under external force leading to degradation in display quality

Engineering Contradiction:

Improvespacer structure simplicityVSAvoidsubstrate position stability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The spacer system is segmented into two functional types: maintenance spacers (with unattached distal ends) that keep the cell gap, and adhesion spacers (with attached distal ends) that prevent substrate displacement. This segmentation allows each type to perform its specific function optimally without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

An adhesive member is introduced as an intermediary substance to attach the distal end of the adhesion spacer to the first substrate. This adhesive mediator enables the spacer to fulfill the dual role of maintaining cell gap and preventing substrate displacement simultaneously.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the distal end of the spacer is attached to the substrate using adhesive, then the substrate displacement is prevented, but the manufacturing process becomes more complex

Engineering Contradiction:

Improvesubstrate position stabilityVSAvoidspacer structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The adhesive member is applied locally only at the distal end portion of specific spacers (adhesion spacers) rather than uniformly across all spacers or the entire substrate. This localized application reduces manufacturing complexity while achieving the desired substrate fixation effect where most needed.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Instead of attaching all spacers to the substrate, only a subset of spacers (adhesion spacers) have their distal ends attached, while others (maintenance spacers) remain unattached. This partial action approach provides sufficient substrate stabilization without the excessive complexity of universal attachment.

Inventive Principle:

Principle #16Partial or excessive action

3Strength

If adhesive member is used to attach spacer ends, then adhesivity is enhanced, but the risk of adhesive extrusion increases

Engineering Contradiction:

Improveadhesive bonding strengthVSAvoidadhesive extrusion

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The spacer cross-sectional shape is designed with asymmetry, featuring a wider width in the horizontal direction than in the vertical direction. This asymmetric geometry creates a geometric constraint that prevents adhesive extrusion in the horizontal direction while allowing sufficient adhesive bonding in the vertical attachment direction.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The spacer's asymmetric cross-sectional shape is designed in advance to inherently prevent adhesive extrusion before the adhesive is applied. This preliminary geometric design ensures that when adhesive is applied to attach the distal end, it cannot extrude horizontally due to the width constraint, while still providing strong vertical bonding.

Inventive Principle:

Principle #10Preliminary action

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 configuration improves display quality by preventing substrate displacement and maintaining alignment of elements, reducing image distortion and enhancing adhesivity through the use of fillers in the adhesive, ensuring stable performance under external forces.

Implementation Method 1

an adhesive member adhering the distal end portion and the first substrate together

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

using fillers in the adhesive to enhance adhesivity and maintain distance between the spacer ends and the substrate

Methodology Applied

Scientific EffectPhysical support through filler particles: Suspension

Data Source

PatentUS11402697B2Display device

Publication Date: 2022.08.02 MAGNOLIA WHITE CORP

AI summary

According to one embodiment, a display device includes a first substrate, a second substrate opposing the first substrate, a first spacer projecting from the second substrate towards the first substrate and including a distal end portion opposing the first substrate with a gap therebetween, a second spacer projecting from the second substrate towards the first substrate and in contact with the first substrate and an adhesive member adhering the distal end portion and the first substrate together. A total height of the first spacer and the adhesive member is the same as a height of the second spacer.