Curved Display Lamination Using Electrostatic Support
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Solution Overview
Problem
Existing display device manufacturing methods lack reliability in laminating curved display panels and windows, leading to potential physical damage and inefficiencies in the lamination process.
Innovation Solution
A display device manufacturing apparatus and method utilizing a support portion with a core, conductive, and pad structure, along with a magnetic portion, to create an electrostatic attractive force for reliable lamination of curved display panels and windows, using a guide film and roller portions to prevent waviness and ensure proper alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional lamination methods are used for curved display panels, then the manufacturing process is simple, but the lamination reliability is poor and physical damage may occur
Solution Approach 1:
The support portion is divided into multiple segments including a core portion, conductive portion, and pad portion, each performing specific functions. The magnetic portion is also segmented into first and second magnetic portions that can be independently controlled. This segmentation allows the complex apparatus to be managed through modular components while achieving high lamination reliability for curved display panels.
Solution Approach 2:
The patent replaces conventional mechanical lamination methods with an electrostatic lamination system. The conductive portion and magnetic portion generate electrostatic attractive forces that hold the curved display panel and window in position without direct mechanical contact, eliminating the risk of physical damage while maintaining lamination reliability.
2Manufacturing precision
If conventional lamination methods are used, then the process is fast, but the alignment precision is poor and waviness occurs
Solution Approach 1:
The pad portion acts as an intermediary between the support structure and the curved display panel. It provides a cushioning layer that ensures uniform contact and prevents waviness while maintaining alignment precision. The guide film portion also serves as an intermediary that guides the panel into proper position during the lamination process.
Solution Approach 2:
The patent utilizes electrostatic parameters (electric field strength, charge distribution) to control the lamination process. By adjusting the electrostatic attractive force between the conductive and magnetic portions, the system achieves both high alignment precision and maintains efficient lamination speed without requiring slow mechanical adjustment.
3Reliability
If electrostatic attractive force is used for lamination, then lamination reliability improves, but energy consumption increases
Solution Approach 1:
The electrostatic attractive force is applied selectively only to the curved display panel and window portions that require precise positioning and lamination. The conductive and magnetic portions generate electrostatic fields only in the necessary regions, avoiding excessive energy consumption across the entire display assembly while maintaining high lamination reliability where needed.
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 solution enables reliable and efficient lamination of curved display panels and windows, preventing physical damage and ensuring accurate alignment, thereby improving the manufacturing process.
Implementation Method 1
A current may flow in the magnetic portion, and an electrostatic attractive force may be formed between the magnetic portion and the conductive portion.
Data Source
AI summary
A display device manufacturing apparatus includes a support portion including a core portion and a conductive portion disposed over the core portion. The core portion includes a first flat surface extending in a first direction; a second flat surface extending in the first direction and being opposite to the first flat surface; and a curved surface extending between the first flat surface and the second flat surface. The conductive portion includes a first flat conductive portion overlapping the first flat surface of the core portion in a second direction; a second flat conductive portion overlapping the second flat surface of the core portion in the second direction; and a curved conductive portion extending between the first flat conductive portion and the second flat conductive portion.