Adhesive Resin Dispensing for Flat-Panel Protector Sheet Bonding
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Solution Overview
Problem
Existing methods for attaching a protector sheet to a display panel in flat-panel display devices often result in air bubble inclusion, increased production costs, and require significant installation space, particularly due to the need for vacuum chambers and complex press drive mechanisms.
Innovation Solution
A manufacturing method and apparatus that apply a bi-directionally Y-shaped branched line pattern of adhesive resin on the protector sheet or display panel, with circular or ellipsoidal dot patterns arranged symmetrically, to facilitate efficient bonding without air bubbles, reduce production costs, and minimize installation space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vacuum chambers and complex press drive mechanisms are used for attaching the protector sheet, then bonding reliability is improved, but device complexity and installation space increase
Solution Approach 1:
The patent extracts and eliminates the vacuum chamber from the bonding system by using a dispenser that applies adhesive resin in a controlled pattern directly at atmospheric pressure. The protector sheet is pressed onto the display panel using a simple pressing mechanism without requiring vacuum evacuation, thereby removing the complex vacuum system while maintaining bonding reliability through precise adhesive application.
Solution Approach 2:
The patent replaces the mechanical vacuum system with a controlled adhesive dispensing system. Instead of using vacuum pressure to bond the protector sheet, the invention uses precisely deposited adhesive resin patterns that bond effectively under atmospheric pressure with simple pressing, substituting a complex mechanical vacuum system with a simpler dispensing and pressing mechanism.
2Reliability
If vacuum chambers are used for attaching the protector sheet, then bonding reliability is improved, but installation space increases
Solution Approach 1:
The patent removes the vacuum chamber from the bonding process, replacing it with a compact adhesive dispensing system that operates at atmospheric pressure. This extraction of the vacuum chamber significantly reduces the installation space required while maintaining bonding reliability through controlled adhesive application patterns.
3Strength
If adhesive resin is applied uniformly across the entire bonding area, then bonding strength is improved, but air bubble inclusion increases
Solution Approach 1:
The patent segments the adhesive resin application into discrete patterns (dots, lines, or combinations) rather than uniform continuous coverage. The dispenser deposits adhesive at specific locations and intervals, creating a segmented pattern that allows air to escape through the gaps between adhesive segments, thereby reducing air bubble inclusion while maintaining adequate bonding strength through the distributed adhesive points.
Solution Approach 2:
The patent applies adhesive resin with varying local characteristics - different patterns (dots, lines, or combinations), different densities, and different distributions in different areas of the bonding surface. This local quality variation optimizes both bonding strength (where adhesive is concentrated) and air bubble prevention (where gaps are provided), allowing the adhesive pattern to be tailored to specific bonding requirements in different regions.
4Reliability
If complex press drive mechanisms are used, then bonding reliability is improved, but production cost increases
Solution Approach 1:
The patent replaces complex press drive mechanisms with a simpler system consisting of a dispenser for adhesive application and a basic pressing mechanism. The controlled adhesive patterns enable reliable bonding without requiring complex pressing systems, thereby reducing manufacturing costs while maintaining bonding reliability through the precision of the adhesive dispensing process.
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 effectively prevents air bubble inclusion, decreases production costs, and enhances production efficiency by allowing bonding under atmospheric pressure with simpler equipment setups.
Implementation Method 1
ultra-violet (UV) curing resin is applied on a predetermined area on the display panel or on the protector sheet... ultraviolet (UV) irradiation is made at a non-displaying periphery area on the display panel as to achieve a 'temporary bonding'
Data Source
AI summary
An embodiment of manufacturing method of a flat-panel display device having a display panel and a transparent protector sheet; comprises: setting a bi-directionally Y-shape branched line pattern within a rectangular to-be-bonded area, which is formed of two Y-shaped intersections of a center line and angle bisector lines of the corners, of the to-be-bonded area; and applying adhesive resin onto the protector sheet or onto the display panel by forming circular or ellipsoidal dot patterns of applied adhesive resin so that: the dot patterns are arranged on the center-line segment and on the branch lines or their vicinities; and the dot patterns are arranged in symmetry with respect to the center line and to its perpendicular bisector.