Curved Cover Panel Adhesive Structure to Prevent Release Film Lifting
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Solution Overview
Problem
During the manufacturing process of electronic devices, contamination and damage of cover panels occur due to lifting between the cover panel and release films, which can lead to foreign substances adhering to the adhesive layer and compromising the reliability of the device.
Innovation Solution
A cover panel design featuring a support with a curved upper surface and a protruding portion, along with a first adhesive layer that includes a main and protruding portion, is used to prevent lifting and reduce contamination or damage by ensuring proper adhesion and alignment with the release film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If release films are attached to the upper and lower surfaces of the cover panel to prevent contamination or damage, then the cover panel is protected during manufacturing, but lifting occurs between the cover panel and release film causing foreign substances to adhere to the adhesive layer
Solution Approach 1:
The adhesive layer is designed with a curved upper surface that has a convex shape in the third direction, matching the curved lower surface of the display panel. This curvature ensures uniform contact and adhesion between the adhesive layer and the display panel, preventing lifting that would otherwise occur with a flat adhesive layer, thereby preventing foreign substance adhesion while maintaining protection during manufacturing
Solution Approach 2:
The adhesive layer is designed with different local properties: the main portion has a flat lower surface for uniform attachment to the support, while the protruding portion extends beyond the support's outer side surface to provide additional adhesive coverage. This local differentiation ensures proper adhesion in different regions, preventing lifting and foreign substance contamination
2Ease of manufacture
If a flat adhesive layer is used on the support, then manufacturing is simple, but lifting occurs between the adhesive layer and release film causing contamination
Solution Approach 1:
The adhesive layer is formed with a curved upper surface that convexly protrudes in the third direction, matching the curved lower surface of the display panel. This curvature is achieved through controlled formation processes that create the desired shape while maintaining manufacturing feasibility, preventing lifting and contamination
Solution Approach 2:
The adhesive layer is divided into a main portion and a protruding portion. The main portion is attached to the support with its lower surface substantially parallel to the first and second directions, while the protruding portion extends beyond the support's outer side surface. This segmentation allows each portion to be optimized for its specific function while maintaining overall manufacturability
3Ease of manufacture
If the adhesive layer profile matches the support profile, then manufacturing alignment is easier, but the adhesive layer cannot extend beyond the support to prevent lifting at edges
Solution Approach 1:
The adhesive layer is segmented into a main portion and a protruding portion. The main portion aligns with the support for easy manufacturing, while the protruding portion extends beyond the support's outer side surface to provide additional coverage and prevent lifting at edges, thereby preventing foreign substance adhesion
Solution Approach 2:
The protruding portion of the adhesive layer extends in the radial direction beyond the support's outer side surface, utilizing the dimensional space available at the edges. This extension in another dimension allows the adhesive layer to prevent lifting and contamination at critical edge regions without complicating the manufacturing alignment process
Data Source
AI summary
A cover panel includes a support having an upper surface and a lower surface facing the upper surface and a first adhesive layer on the upper surface of the support. At least a portion of the lower surface of the support is a flat surface substantially parallel to a plane defined by a first direction and a second direction perpendicular to the first direction, and the upper surface of the support is a curved surface convex in a third direction perpendicular to the plane. The first adhesive layer has a main portion and a protruding portion, and the protruding portion protrudes from the main portion in a direction opposite to a direction toward a center of the main portion in a plan view.