Air Gap Display Bonding with Dual Resin Spacers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing display apparatuses with air gap bonding structures face challenges in maintaining the distance between the display panel and the functional substrate, leading to display unevenness due to the use of double-sided tapes and adhesives, which are difficult to automate, have low adhesion strength, and result in productivity and manufacturing cost issues.
Innovation Solution
The use of a combination of first and second resins, where the first resin maintains the distance and the second resin adheres the functional substrate to the display panel, with the first resin being UV-curable and having a structural viscosity ratio of 4 to 8, and the second resin being moisture-curable with a viscosity of approximately 100 Pa·s, applied in a way that prevents wet-spreading and maintains an appropriate air gap.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If a thick double-sided tape is used to maintain the air gap between the display panel and functional substrate, then the distance between the display panel and functional substrate is maintained, but the adhesion strength per unit area is lowered due to bulk destruction of the foam material
Solution Approach 1:
The patent changes the material parameters by using a non-foam synthetic resin instead of foam material, and optimizes the thickness to 50-200 μm. This resolves the contradiction by providing sufficient adhesion strength while maintaining the required air gap distance through precise dimensional control of the non-foam material.
Solution Approach 2:
The patent creates a composite bonding structure by combining the non-foam synthetic resin spacer with UV-curable adhesive and moisture-curable adhesive. This composite approach maintains the air gap distance while ensuring strong adhesion through the combined functionality of the different materials.
2Reliability
If bonding is performed manually using double-sided tape, then the air gap structure is achieved, but productivity is reduced and manufacturing cost increases due to difficulty in automation and need for dedicated punching dies
Solution Approach 1:
The patent extracts the spacer function from the adhesive material itself by using a separate non-foam synthetic resin member with specific thickness (50-200 μm). This allows the bonding process to be automated using dispensing devices without requiring manual tape application or dedicated punching dies, significantly improving productivity while maintaining the air gap structure.
Solution Approach 2:
The patent replaces the mechanical manual bonding process with an automated dispensing system that applies UV-curable adhesive and moisture-curable adhesive. This substitution eliminates the need for manual tape application and dedicated punching dies, enhancing productivity and enabling automation while maintaining bonding reliability.
3Area of stationary object
If the size of the display apparatus is increased, then a wider double-sided tape is necessary, but it becomes difficult to attain a slim border display
Solution Approach 1:
The patent changes the material properties by using a non-foam synthetic resin with optimized thickness (50-200 μm) instead of thick foam tape. This allows the bonding structure to maintain the required air gap while having minimal width, enabling slim border displays even as the overall display apparatus size increases.
Solution Approach 2:
The patent applies the bonding materials selectively at the peripheral borders of the display panel and functional substrate. By concentrating the bonding function at the edges with minimal width, the patent enables large display areas with slim borders, as the bonding structure does not extend across the entire display area.
4Ease of manufacture
If adhesive made of resin is used instead of double-sided tape, then manufacturing cost is reduced and automated bonding is facilitated, but the distance between functional substrate and display panel cannot be maintained due to low resistance to weight
Solution Approach 1:
The patent segments the bonding system into three distinct functional components: (1) a non-foam synthetic resin spacer that maintains the air gap distance, (2) UV-curable adhesive for initial bonding, and (3) moisture-curable adhesive for permanent adhesion. This segmentation allows each component to perform its specific function effectively, maintaining the air gap while enabling automated manufacturing.
Solution Approach 2:
The patent introduces a non-foam synthetic resin spacer as an intermediary element between the display panel and functional substrate. This spacer acts as a mechanical stop that maintains the required air gap distance, while the UV-curable and moisture-curable adhesives provide the bonding function. This intermediary structure resolves the contradiction by separating the distance-maintaining function from the bonding function.
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 solution enhances productivity, reduces manufacturing costs, and ensures sufficient adhesion strength while preventing display unevenness by maintaining a consistent air gap and suppressing wet-spreading of the adhesive, allowing for a slim border design.
Implementation Method 1
having a structural viscosity ratio of 4 to 8
Implementation Method 2
the first resin being UV-curable
Implementation Method 3
the second resin being moisture-curable with a viscosity of approximately 100 Pa·s
Implementation Method 4
with a viscosity of approximately 100 Pa·s, applied in a way that prevents wet-spreading
Data Source
AI summary
A display apparatus comprises a display device, a functional substrate opposed to and bonded to the display device through an air space and, at peripheral borders on the opposite surfaces of the display device and the functional substrate, first resin maintaining the distance between the display device and the functional substrate and second resin adhering the display device and the functional substrate to each other.