Alignment Key Structure for Display Panel Manufacturing
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Solution Overview
Problem
The reduction of bezel regions in display panels has made it necessary to minimize the number of alignment keys required for accurately aligning and attaching panels, as existing methods rely heavily on numerous alignment keys for precise alignment during the manufacturing process of two-sided or 3D displays.
Innovation Solution
The implementation of a display device and manufacturing method that includes specific alignment keys on substrates, where a first and second alignment key on one panel correspond to a third alignment key on another panel, allowing for reduced key usage while maintaining alignment accuracy through the formation and positioning of these keys.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If numerous alignment keys are used to ensure accurate alignment of panels, then alignment precision is improved, but device complexity and manufacturing time increase
Solution Approach 1:
The patent combines multiple alignment functions into a single alignment key structure. The alignment key includes a first alignment mark for aligning substrates within a panel and a second alignment mark for aligning multiple panels together, merging what would traditionally require separate alignment keys into one integrated component.
Solution Approach 2:
The alignment key is designed to serve multiple purposes: it aligns substrates during panel construction and simultaneously aligns multiple panels during assembly. This multi-functional design eliminates the need for separate alignment keys for different alignment stages, reducing overall complexity while maintaining precision.
2Manufacturing precision
If numerous alignment keys are used to ensure accurate alignment of panels, then alignment precision is improved, but manufacturing time increases
Solution Approach 1:
By combining multiple alignment functions into one alignment key, the patent reduces the number of alignment operations required during manufacturing. The single alignment key performs both substrate alignment and panel alignment functions simultaneously, streamlining the manufacturing process and reducing overall manufacturing time.
Solution Approach 2:
The alignment key is designed with pre-positioned alignment marks that guide the alignment process from the beginning. The first alignment mark establishes substrate alignment during panel construction, and the second alignment mark is pre-configured to enable subsequent panel alignment, eliminating the need for additional alignment steps.
3Area of stationary object
If bezel regions are reduced to improve display area, then display area increases, but the space available for alignment keys decreases
Solution Approach 1:
The patent merges the alignment key structure with the bezel region design, integrating alignment functionality directly into the bezel area. This integration allows the alignment key to occupy minimal space within the reduced bezel region while still providing accurate alignment capability.
Solution Approach 2:
The alignment key is segmented into distinct functional components (first alignment mark for substrate alignment, second alignment mark for panel alignment) that can be strategically positioned within the limited bezel space. This segmentation allows efficient use of the reduced bezel region while maintaining all necessary alignment functions.
Data Source
AI summary
Provided is a display panel comprising a first panel comprising a first lower substrate and a first upper substrate; a first alignment key formed in the first lower substrate; a second alignment key formed in the first upper substrate, the second alignment key is disposed in a position corresponding to the first alignment key; a second panel attached to the first panel; and a third alignment key formed in the second panel, the third alignment key is disposed in a position corresponding to the first and the second alignment keys and formed such that the first and the second alignment keys are identified.