Concave-Convex Protection Layer for Display Substrates
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Solution Overview
Problem
The challenge in display device manufacturing is the occurrence of air inclusion and quality defects due to substrate rigidity deterioration and air trapping during the attachment of protection films, which affects visibility and display quality, especially in ultra-thin panels.
Innovation Solution
A display device with a protection layer featuring a concave-convex pattern is introduced, utilizing polymer resins like acrylic, urethane, silicone, or epoxy, which minimizes air inclusion by providing a release path for trapped air and enhances adhesion stability, thereby reducing defects and improving visibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protection layer is attached to the substrate, then substrate protection is improved, but air inclusion and quality defects occur due to air trapping
Solution Approach 1:
The protection layer is designed with a microporous structure containing numerous small holes distributed throughout its thickness. These pores allow trapped air to escape during the attachment process, preventing air inclusion defects while maintaining the protection layer's protective function. The porous structure resolves the contradiction by providing both protection and air release pathways.
Solution Approach 2:
The invention converts the harmful effect of trapped air into a beneficial outcome by designing the protection layer with intentional pores that guide air escape. The air that would normally cause defects is now channeled through controlled pathways, transforming the harmful trapping effect into a controlled release mechanism that improves overall attachment quality.
2Length of moving object
If the substrate is made thinner to achieve ultra-thin panels, then slimness is improved, but substrate rigidity deteriorates leading to quality defects
Solution Approach 1:
The protection layer is constructed as a composite structure combining a base material with an integrated microporous network. This composite design provides enhanced mechanical support to the thin substrate while maintaining the overall slim profile. The porous composite structure delivers both the required rigidity for ultra-thin panels and the air release functionality.
Solution Approach 2:
The protection layer incorporates a curved or arched microporous structure rather than flat holes. This curved geometry provides structural reinforcement similar to arches in architecture, enhancing the rigidity of the thin substrate while the interconnected pores maintain air release capability throughout the layer.
3Reliability
If a protection layer is attached to the substrate, then substrate protection is improved, but visibility and display quality are reduced due to air inclusion
Solution Approach 1:
The microporous structure allows complete air evacuation during attachment, preventing air inclusion that would scatter light and reduce visibility. The pores ensure no air pockets remain between the protection layer and substrate, maintaining optical clarity and display quality while preserving protective functionality.
Data Source
AI summary
A display device comprises a substrate comprising a first surface and a second surface facing away from the first surface; a protection layer disposed over and bonded to the first surface of the substrate; and a plurality of pixels formed over the second surface of the substrate. The protection layer comprises a concave-convex pattern.