Color Separation Substrate Bonding to Prevent Display Misalignment
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Solution Overview
Problem
The use of double-sided tape for bonding the color separation element substrate and TFT substrate in display devices leads to misalignment during reliability tests under high-temperature conditions due to warping of the TFT substrate caused by polarizer shrinkage, hindering reliability and frame narrowing in display devices.
Innovation Solution
A sealant layer is used to bond the color separation element substrate and liquid crystal panel, with color separation grooves on the substrate to enhance adhesive strength and prevent misalignment, utilizing thermal or UV curing to maintain alignment even under high temperature conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If double-sided tape is used to bond the color separation element substrate and TFT substrate, then bonding is achieved, but misalignment occurs during reliability tests under high-temperature conditions due to warping
Solution Approach 1:
The patent changes the bonding method from mechanical adhesion (double-sided tape) to chemical bonding (sealant layer) to eliminate temperature-dependent deformation. The sealant layer is applied in a peripheral bonding area and cured to form a rigid bond that maintains alignment stability under high-temperature reliability tests, preventing the warping-induced misalignment that occurs with tape bonding.
2Reliability
If a gap (Air-GAP) is provided between the color separation element substrate and TFT substrate, then light separation is achieved, but bonding complexity increases
Solution Approach 1:
The patent merges the gap formation function and bonding function into a single sealant layer structure. The sealant layer simultaneously creates the necessary air gap for light separation and provides the bonding connection between substrates, eliminating the need for separate gap-maintaining structures and simplifying the overall bonding architecture.
Solution Approach 2:
The sealant layer acts as an intermediary element that fulfills dual functions: it maintains the air gap necessary for optical performance while providing mechanical bonding. This intermediary structure resolves the contradiction by integrating both gap maintenance and bonding capabilities in one component.
3Adaptability or versatility
If the polarizer is attached to the TFT substrate, then display function is achieved, but warping occurs during high-temperature tests causing position shift
Solution Approach 1:
The patent applies preliminary anti-action by using the sealant layer bonding to counteract the warping force generated by polarizer shrinkage during high-temperature tests. The rigid sealant bond prevents the TFT substrate from deforming, thereby maintaining the positional accuracy of the polarizer and other bonded components despite the thermal stress.
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
The sealant layer with color separation grooves effectively maintains alignment and adhesion, preventing misalignment and enhancing light utilization efficiency by reducing light absorption, thus improving display device reliability and frame integrity.
Implementation Method 1
utilizing thermal or UV curing to maintain alignment even under high temperature conditions
Implementation Method 2
utilizing thermal or UV curing to maintain alignment even under high temperature conditions
Implementation Method 3
a color separation element with color separation grooves formed by a predetermined pattern of irregularities on the surface of a glass substrate, which diffract and separate the incoming white backlight in a specific direction for each respective RGB wavelength component
Implementation Method 4
a liquid crystal panel (a panel in which a CF substrate is stacked on a thin-film-transistor (TFT) substrate) in which CFs of RGB are formed in pixel units. In such devices, white backlight from a light source is made incident on the filters of the respective RGB pixels in accordance with the image to be displayed, thereby allowing light of wavelengths of the CF colors to pass through and absorbing light of wavelengths other than the CFs
Implementation Method 5
the polarizer attached to the TFT substrate shrinks during the test, and thus the TFT substrate is bent
Data Source
AI summary
According to one embodiment, a display device includes a liquid crystal panel and a color separation element substrate. The substrate includes a bonding area in a peripheral portion of a surface opposing the panel, and a color separation groove that serves as a color separation element is formed in an effective display area inside the bonding area. The panel includes a bonding area in a peripheral portion of the substrate on an incident surface side of the backlight, and a polarizer is disposed on an inner side the bonding area. The bonding area of the substrate and the bonding area of the panel are bonded to each other via a sealant layer formed from a sealant applied thereon and cured.