Curved Display Lamination with Pre-aligned Jigs
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Solution Overview
Problem
Existing display device manufacturing processes face challenges in efficiently producing high-quality, curved display devices with accurate lamination of cover windows and display panels, often resulting in defects such as air bubbles due to the complexity of aligning and adhering curved surfaces.
Innovation Solution
A method and apparatus involving a partially curved cover window and display panel, with an adhesive layer, where the cover window is mounted on a first jig and the display panel on a second jig, allowing for precise lamination using actuators and fixing units to ensure clean adhesion without air bubbles, utilizing a clamping unit for alignment and adhesive application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a flexible manufacturing process is used to create curved display devices, then adaptability and shape diversity are improved, but manufacturing precision and lamination quality deteriorate due to alignment difficulties on curved surfaces
Solution Approach 1:
The patent applies preliminary action by pre-forming the curved shape of the cover window and display panel before the lamination process. The curved surfaces are prepared in advance with predetermined curvature radii, and alignment marks are pre-positioned on these curved surfaces. This allows the lamination process to proceed on pre-shaped components rather than attempting to form curves during assembly, thereby maintaining manufacturing precision while achieving shape diversity.
Solution Approach 2:
The patent introduces an intermediary alignment mechanism that includes alignment marks positioned on the curved surfaces and a lamination structure designed to accommodate these curved alignment features. This intermediary alignment system mediates between the curved geometry and the lamination process, enabling precise alignment on curved surfaces without requiring complex real-time adjustment mechanisms during assembly.
2Manufacturing precision
If complex alignment mechanisms are used to achieve precise lamination on curved surfaces, then manufacturing precision is improved, but device complexity and production time increase
Solution Approach 1:
The patent simplifies the alignment mechanism by pre-positioning alignment marks on the curved surfaces of the cover window and display panel before lamination. These alignment marks are incorporated into the component design itself rather than requiring complex external alignment devices. The lamination structure includes simple corresponding features that receive these pre-positioned marks, achieving high alignment accuracy through preliminary preparation rather than complex real-time mechanisms.
3Device complexity
If traditional lamination processes are used for curved surfaces, then process simplicity is maintained, but productivity and quality decrease due to air bubble defects and rework
Solution Approach 1:
The patent improves productivity by pre-forming the curved surfaces and pre-positioning alignment marks before lamination. This preliminary preparation eliminates the need for complex real-time alignment adjustments during the lamination process itself. The lamination structure is designed with features that naturally guide the alignment of curved components, enabling faster assembly without compromising quality. This approach maintains relative process simplicity while dramatically improving mass production efficiency by reducing air bubble defects and rework.
4Reliability
If curved display devices are manufactured with precise alignment, then product reliability is improved, but manufacturing time and cost increase
Solution Approach 1:
The patent reduces manufacturing time while maintaining high reliability by pre-forming the curved surfaces and pre-positioning alignment marks during component fabrication. This preliminary action ensures that when the lamination process occurs, the components are already prepared for precise alignment, eliminating time-consuming adjustment steps. The lamination structure includes features that facilitate quick and accurate assembly of the pre-prepared curved components, achieving both high product reliability and efficient manufacturing.
Data Source
AI summary
A display device, and a method and apparatus for manufacturing the display device, are provided. The display device includes a cover window including a curved portion, and a display panel smaller in at least one of length or width than the cover window and laminated on a flat portion of the cover window.