Multi-Layer Cover Panel for Display Device Alignment and Protection
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Solution Overview
Problem
Existing display devices face challenges in achieving a thin thickness while maintaining improved light blocking and impact resistance properties, as well as ensuring proper alignment and preventing cracks in the display panel when a driving chip is pressed onto it.
Innovation Solution
The display device incorporates a display panel with defined pressed, non-pressed, and alignment mark areas, along with a cover panel comprising multiple functional layers. The first functional layer provides light blocking and impact resistance, the second functional layer offers heat dissipation with a step structure, and the third functional layer, made of transparent epoxy resin, enhances structural integrity and allows for alignment mark visibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a single-layer cover panel is used, then the device structure is simple, but light blocking and impact resistance properties are insufficient
Solution Approach 1:
The cover panel is divided into multiple functional layers: a first functional layer for light blocking, a second functional layer for impact resistance, and a third functional layer for additional protection. Each layer performs a specific function, allowing the device to achieve superior light blocking and impact resistance properties while maintaining a manageable structural complexity through functional segmentation.
Solution Approach 2:
The cover panel employs composite material construction with different layers made from materials optimized for specific functions. The first functional layer uses light-blocking materials, the second functional layer uses impact-resistant materials, and the third functional layer uses protective materials, creating a composite structure that delivers superior overall performance compared to single-layer alternatives.
2Length of moving object
If the cover panel is made thinner, then the device thickness is reduced, but impact resistance and structural integrity deteriorate
Solution Approach 1:
Instead of using a single thin layer, the protective function is segmented across multiple layers of varying thicknesses. The first functional layer is optimized for light blocking with appropriate thickness, the second functional layer provides impact resistance, and the third functional layer adds structural integrity. This segmentation allows each layer to be optimized for its specific function while collectively achieving both thin overall profile and high strength.
Solution Approach 2:
The multi-layer composite structure enables different thickness optimizations for different functions. By combining materials with different properties in a layered composite, the device achieves reduced overall thickness while maintaining superior impact resistance and structural integrity through the synergistic combination of layers.
3Ease of operation
If alignment marks are placed on the pressed area, then alignment is facilitated, but cracks may occur in the display panel during chip pressing
Solution Approach 1:
The cover panel is segmented into different functional layers with the third functional layer specifically positioned to overlap the alignment mark area. This segmentation allows alignment marks to be visible through the transparent third functional layer for easy alignment, while the first and second functional layers provide structural support and crack prevention during the pressing process.
Solution Approach 2:
The third functional layer acts as an intermediary element that is transparent to light, allowing alignment marks to be visible for easy alignment while still providing structural support. This intermediary layer mediates between the need for visible alignment marks and the need to prevent cracks during pressing by distributing stresses evenly across the pressed area.
4Object-affected harmful factors
If multiple functional layers are added to the cover panel, then light blocking and impact resistance are improved, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process is segmented into distinct steps for forming each functional layer: first forming the first functional layer for light blocking, then forming the second functional layer for impact resistance, and finally forming the third functional layer for protection and alignment mark visibility. This segmentation of the manufacturing process makes the complex multi-layer construction more manageable and controllable.
Solution Approach 2:
The first functional layer is formed in advance on the cover panel before the second and third functional layers are added. This preliminary action allows each layer to be optimized and prepared separately, simplifying the overall manufacturing process by breaking down the complex multi-layer formation into sequential, manageable steps rather than attempting to create all layers simultaneously.
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 configuration enables a display device with enhanced light blocking, impact resistance, and thin thickness, while allowing for easy alignment of the display panel and driving chip, and preventing cracks in the display panel during chip attachment.
Implementation Method 1
The first functional layer may include an acrylic resin, a photoinitiator, and a light blocking material. An optical density value of the first functional layer may be about 3.0 or more.
Implementation Method 2
The forming of the first functional layer may include coating a first ink composition on the rear surface of the display panel overlapping the non-pressed area; and curing a coated first ink composition with ultraviolet rays.
Implementation Method 3
The second functional layer may have a step overlapping the pressed area. A thickness of the second functional layer may be about 25 μm or more.
Data Source
AI summary
A display device includes a display panel including a pressed area, a non-pressed area, and an alignment mark area defined on a rear surface overlapping the pressed area, a driving chip disposed on a front surface of the display panel overlapping the pressed area, and a cover panel disposed on the rear surface of the display panel. The cover panel includes a first functional layer disposed on the rear surface of the display panel overlapping the non-pressed area, a second functional layer disposed on the first functional layer, extending along the first functional layer, and disposed on the rear surface of the display panel overlapping the pressed area, and a third functional layer disposed on the second functional layer overlapping the pressed area.