Adhesive Layer Hydrophobicity Gradient for Functional Layer Positioning
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Solution Overview
Problem
The manufacturing process of electronic devices is inefficient due to the complexity of integrating display panels and electronic modules, particularly in creating regions with varying light transmittance and the need for precise adhesive and functional layer placement.
Innovation Solution
The electronic device design includes a display panel with distinct regions, a lower member featuring an adhesive layer with different hydrophobicity and surface roughness for each region, and a functional layer positioned only under the first adhesive portion, allowing for simplified manufacturing by eliminating the need for separate processes to define the functional layer's overlap with the electronic module region.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a uniform adhesive layer is used across the entire display panel, then the manufacturing process is simple, but the functional layer cannot be precisely positioned relative to electronic modules
Solution Approach 1:
The adhesive layer is designed with spatially varying hydrophobicity: the first adhesive portion (corresponding to the display region) has lower hydrophobicity to bond with the functional layer, while the second adhesive portion (corresponding to the electronic module region) has higher hydrophobicity to prevent functional layer adhesion. This local differentiation enables precise functional layer positioning without complex manufacturing steps.
Solution Approach 2:
The hydrophobicity parameter of the adhesive layer is changed across different regions. By controlling the hydrophobicity values (lower in the first adhesive portion, higher in the second adhesive portion), the patent achieves selective bonding behavior that guides functional layer placement while maintaining a uniform adhesive layer structure, thus resolving the contradiction between precision and complexity.
2Ease of manufacture
If the functional layer is disposed below the entire adhesive layer, then the manufacturing process is simplified, but the electronic module region cannot be properly exposed for light transmission
Solution Approach 1:
The adhesive layer exhibits different hydrophobic properties in different regions: the second adhesive portion has higher hydrophobicity which prevents the functional layer from adhering in the electronic module region. This allows the functional layer to be simply placed across the entire adhesive layer while still achieving proper exposure of the electronic module region for light transmission, as the functional layer naturally avoids the hydrophobic second adhesive portion.
Solution Approach 2:
The hydrophobic second adhesive portion acts as a self-directed barrier that automatically prevents functional layer adhesion in the electronic module region. This self-service mechanism eliminates the need for complex masking or positioning steps, allowing the functional layer to self-position correctly while maintaining manufacturing simplicity.
3Productivity
If separate processes are used to define functional layer overlap with electronic module region, then positioning precision is improved, but manufacturing efficiency decreases
Solution Approach 1:
By changing the hydrophobicity parameter across the adhesive layer, the patent achieves precise functional layer positioning in a single coating process. The functional layer automatically positions itself over the hydrophilic first adhesive portion and avoids the hydrophobic second adhesive portion, eliminating the need for separate positioning processes and thereby maintaining high manufacturing efficiency while achieving precise positioning.
Solution Approach 2:
The adhesive layer's hydrophobicity gradient serves as a self-positioning guide for the functional layer. This self-service mechanism allows the functional layer to automatically achieve correct positioning relative to the electronic module region without requiring additional manufacturing steps, thus simultaneously improving productivity and positioning precision.
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 approach enhances manufacturing efficiency by reducing the complexity of adhesive and functional layer placement, allowing for easier integration of electronic modules and potentially reducing the overall thickness and cost of the device.
Implementation Method 1
a hydrophobicity of a first lower surface of the first adhesive portion is lower than a hydrophobicity of a second lower surface of the second adhesive portion
Implementation Method 2
a surface roughness of the first lower surface of the first adhesive portion is lower than a surface roughness of the second lower surface of the second adhesive portion
Data Source
AI summary
An electronic device includes an electronic module, a display panel including a second region corresponding to the electronic module and adjacent to a first region, and a lower member overlapping the first region. The lower member includes a functional layer corresponding to the first region, and an adhesive layer corresponding to the first and second regions. The adhesive layer includes a first adhesive portion defining a first lower surface of the adhesive layer which overlaps the first region of the display panel, a second adhesive portion which defines a second lower surface of the adhesive layer which overlaps the second region of the display panel, each of the first and second lower surfaces having hydrophobicity, and the hydrophobicity of the first lower surface of the first adhesive portion being lower than the hydrophobicity of the second lower surface of the second adhesive portion.