Bonding 3D Cover to Flexible Display Panel
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Solution Overview
Problem
The existing methods for bonding a three-dimensional cover to flexible display panels are inefficient and prone to damaging the panels, as they involve directly pouring liquid adhesive, which results in low bonding efficiency and poor display performance.
Innovation Solution
A method using a conformable tool with fixtures and release films to shape and bond the flexible display panel with optical adhesive, reducing the risk of damage by minimizing the use of a roller and ensuring precise alignment with the three-dimensional cover.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If liquid adhesive is directly poured between the three-dimensional cover and the flexible display panel, then the bonding process is simple, but the bonding efficiency is low and the flexible display panel is easily damaged
Solution Approach 1:
The patent applies preliminary action by pre-coating the flexible display panel with optical adhesive and bonding it to a carrier film before the actual bonding process. This preparation ensures that the adhesive is already in optimal position and condition, eliminating the need for messy liquid adhesive pouring during production and significantly improving bonding efficiency while maintaining process simplicity
Solution Approach 2:
The patent introduces a carrier film as an intermediary between the flexible display panel and the three-dimensional cover. The carrier film provides a stable base for adhesive application and serves as a handling medium during the bonding process, preventing direct contact between liquid adhesive and the panel, thus improving efficiency while protecting the panel from damage
2Ease of manufacture
If liquid adhesive is directly poured between the three-dimensional cover and the flexible display panel, then the bonding process is simple, but the flexible display panel is easily damaged leading to poor display
Solution Approach 1:
The carrier film acts as a protective intermediary during the bonding process. It prevents liquid adhesive from directly contacting and potentially damaging the flexible display panel, while still allowing effective adhesive transfer to occur. This intermediary approach maintains both process simplicity and display quality reliability
Solution Approach 2:
The adhesive is pre-applied to the panel in a controlled manner before bonding, rather than being poured during the process. This preliminary action ensures proper adhesive distribution and prevents excess adhesive from damaging the panel, thereby maintaining display quality while keeping the overall process simple
3Manufacturing precision
If a conformable tool with fixtures is used to adjust the shape of the bonded body, then the shape matching precision is improved, but the device complexity increases
Solution Approach 1:
The patent employs a conformable tool with a flexible carrying surface that can be shaped to match the three-dimensional cover's contour. This flexible surface, combined with fixtures that apply localized force, enables precise shape adjustment without requiring a complex rigid tooling system. The flexibility of the carrying surface allows it to adapt to various shapes while maintaining manufacturing precision
Solution Approach 2:
The conformable tool incorporates fixtures that can dynamically adjust their position and applying force to different areas of the bonded body. This dynamic adjustment capability allows the tool to achieve precise shape matching for different three-dimensional cover geometries without requiring multiple specialized tools, thus improving precision while managing device 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 enhances bonding efficiency and reduces damage to the flexible display panel, ensuring a stable and effective attachment of the three-dimensional cover without compromising the panel's integrity.
Implementation Method 1
bonding a flexible display panel on a heavy release film by optical adhesive to obtain a bonded body
Implementation Method 2
controlling the fixtures of the conformable tool to adjust the shape of the bonded body so that the adjusted shape of the bonded body matches the shape of the three-dimensional cover
Implementation Method 3
bonding the three-dimensional cover to the flexible display panel through the optical adhesive
Data Source
AI summary
A method for bonding a three-dimensional cover, which includes the following steps: bonding a flexible display panel on a heavy release film through optical adhesive to obtain a bonded body; placing the bonded body on a carrying surface of a conformable tool, making the flexible display panel face the carrying surface of the conformable tool, and fixing two ends of the heavy release film in the bonded body to fixtures of the conformable tool; controlling the fixtures of the conformable tool to adjust the shape of the bonded body, so that the adjusted shape of the bonded body matches the three-dimensional cover; tearing off the heavy release film from the bonded body to obtain the flexible display panel with optical adhesive, and bonding the three-dimensional cover to the flexible display panel using the optical adhesive.