Adsorption Spacer for Ultra-Narrow Frame Display Panel Assembly
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Solution Overview
Problem
Existing TFT-LCD manufacturing processes face challenges in producing ultra-narrow frame display panels due to wide sealants, sealant fractures, bubbles, and uneven gaps, leading to defects like whitish displays and light leakage, caused by the need for UV curing and robotic misalignment during sealant application.
Innovation Solution
A display panel manufacturing method using an adsorption spacer with a groove-shaped adsorption portion made of highly-elastic resin, which facilitates vacuum adsorption for bonding substrates without the need for sealants, reducing the height and improving bonding strength, and eliminating the need for UV curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If sealant is used for adhesion and cell gap support, then bonding strength is improved, but frame width increases due to UV curing space requirements
Solution Approach 1:
The patent extracts the adhesion function from the sealant and transfers it to the adsorption spacer. The sealant is removed entirely from the peripheral region, eliminating the need for UV curing space. The adsorption spacer provides both mechanical support for cell gap and vacuum adhesion through its groove structure, resolving the contradiction between bonding strength and frame width.
Solution Approach 2:
The patent replaces the chemical bonding mechanism (UV-cured sealant) with a mechanical adhesion mechanism (vacuum adsorption through groove structure). This substitution eliminates the need for UV curing space while maintaining strong bonding, directly addressing the frame width issue.
2Strength
If sealant is coated at periphery, then adhesion is achieved, but defects occur due to sealant fracture and aggregation
Solution Approach 1:
The patent extracts the adhesion function from the sealant and assigns it to the adsorption spacer. By removing the sealant from the peripheral region, the source of defects (fracture, aggregation, bubbles) is eliminated. The adsorption spacer provides reliable adhesion through vacuum suction without the coating process issues.
Solution Approach 2:
The adsorption spacer is designed as a disposable component that performs adhesion during assembly and then maintains cell gap support. It replaces the reusable sealant that requires precise coating, simplifying the process and eliminating coating-related defects.
3Strength
If sealant is used for bonding, then substrates are adhered, but misalignment occurs during robotic assembly
Solution Approach 1:
The adsorption spacers are pre-formed with groove structures on the substrates before assembly. These grooves are precisely positioned in advance, providing predetermined adhesion points that guide the robotic assembly process and ensure accurate alignment between substrates.
Solution Approach 2:
The patent replaces the sealant coating process with a mechanical vacuum adsorption system. The groove structures provide fixed adhesion points that enable precise robotic manipulation and alignment, eliminating the variability associated with sealant coating and curing.
4Strength
If sealant coating process is used, then adhesion is achieved, but production efficiency decreases due to multiple process steps
Solution Approach 1:
The patent merges the adhesion function and cell gap support function into a single adsorption spacer component. This eliminates the need for separate sealant coating and curing processes, reducing the number of manufacturing steps and improving production efficiency while maintaining strong bonding.
Solution Approach 2:
The patent extracts the adhesion function from the sealant process entirely and transfers it to the adsorption spacer. This removal of the sealant coating and UV curing steps from the manufacturing process directly improves production efficiency by reducing process time and 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 allows for the production of display panels with ultra-narrow frames, reduces production costs and defects, enhances bonding strength, and improves product quality by eliminating sealant-related issues and misalignment during assembly.
Implementation Method 1
the first substrate and the second substrate are cell-assembled together through a vacuum adsorption effect of the adsorption spacer
Data Source
AI summary
A display panel comprises: a first substrate (1); a second substrate (3), provided opposite to the first substrate (1); and an adsorption spacer (2), provided between the first substrate (1) and the second substrate (3), wherein, the adsorption spacer (2) is provided with an adsorption portion, the first substrate (1) and the second substrate (3) are cell-assembled together through a vacuum adsorption effect of the adsorption spacer (2).