Curved Display Cover Bonding With Pre-Cured Adhesive Layer
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Solution Overview
Problem
Display devices face challenges in preventing adhesion defects of cover layers on curved surfaces and discoloration of light blocking layers due to curing processes, which affect their performance and reliability.
Innovation Solution
A method of manufacturing display devices involves forming an adhesive layer with specific properties, such as a modulus of 103 Pa to 106 Pa and a peel strength of 2,000 gf/in or greater, which is cured before bonding with the light blocking layer and cover layer, ensuring complete curing and adhesiveness, even on curved surfaces, and forming the light blocking layer after adhesive curing to prevent discoloration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the adhesive layer is cured before bonding with the cover layer on a curved surface, then complete curing and adhesiveness are achieved, but adhesion defects may occur due to the curved surface geometry
Solution Approach 1:
The patent modifies the physical and chemical parameters of the adhesive material, specifically setting the modulus in the range of 10³ Pa to 10⁶ Pa and viscosity of 1 cps to 30 cps at room temperature. These parameter changes enable the adhesive to achieve complete curing while maintaining adaptability to curved surfaces, preventing adhesion defects despite the geometric complexity.
Solution Approach 2:
The adhesive layer is cured in advance before the cover layer is bonded to it. This preliminary curing action ensures complete adhesiveness and prevents adhesion defects, as the adhesive achieves its full bonding capability before the cover layer is applied, eliminating potential issues related to curved surface bonding.
2Reliability
If ultraviolet light or heat is applied to cure the adhesive layer, then complete curing is achieved, but discoloration of the light blocking layer occurs
Solution Approach 1:
The adhesive layer is cured before the light blocking layer is formed or positioned. This preliminary curing action eliminates the need to apply ultraviolet light or heat after the light blocking layer is in place, thereby preventing discoloration while still achieving complete curing of the adhesive.
Solution Approach 2:
The curing process is extracted and performed separately from the light blocking layer formation process. By curing the adhesive in advance, the harmful effects of ultraviolet light and heat on the light blocking layer are eliminated, as these curing agents are not applied when the light blocking layer is present.
3Strength
If the adhesive layer has high peel strength to ensure adhesion, then bonding reliability improves, but the adhesive material properties become more difficult to control
Solution Approach 1:
The patent specifies precise parameter ranges for the adhesive material: modulus of 10³ Pa to 10⁶ Pa and viscosity of 1 cps to 30 cps at room temperature. These controlled parameter changes enable the adhesive to achieve high peel strength (about 2,000 gf/in or greater) while maintaining ease of manufacture through well-defined material specifications.
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 approach effectively prevents adhesion defects and discoloration, enhancing the reliability and performance of display devices by ensuring complete curing and adhesiveness of the adhesive layer and avoiding discoloration of the light blocking layer during the curing process.
Implementation Method 1
The curing of the adhesive material layer may include irradiating an ultraviolet light onto the adhesive material layer
Implementation Method 2
The curing of the adhesive material layer may include applying a heat to the adhesive material layer
Data Source
AI summary
A method of manufacturing a display device includes providing an adhesive material layer on a display panel, curing the adhesive material layer to form an adhesive layer, providing a cover layer on the adhesive layer, and adhering the cover layer to the adhesive layer, and a modulus of the adhesive layer at room temperature is in a range of about 103 Pa to about 106 Pa.