Curved Display Panel Manufacturing via Substrate Paring and Fixing Layers
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Solution Overview
Problem
Conventional methods for manufacturing curved liquid crystal display panels face challenges such as substrate separation and cell gap collapse during the bending process, leading to irregular deformations and increased manufacturing costs.
Innovation Solution
The method involves forming fixing layers on the unbent edge areas of substrates after partial parring, along with attaching light-transparent reinforcing plates to maintain structural integrity and prevent cell gap collapse, allowing for the formation of a stable curved display panel shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If glass substrates are pared and bent to create a curved display panel, then the display panel can achieve a curved shape, but the two substrates may separate and the cell gap may collapse during the bending process
Solution Approach 1:
The patent applies preliminary action by forming fixing layers on the substrates before the bending process. These fixing layers are deposited in advance on specific regions of the substrates to prevent separation during subsequent bending, thereby addressing the reliability issue before the shape transformation occurs
Solution Approach 2:
The fixing layers act as intermediary elements between the two substrates. These layers are introduced to mediate the interaction between substrates during bending, preventing direct separation and maintaining cell gap integrity by providing an intermediate bonding interface
2Adaptability or versatility
If flexible substrates are used instead of glass substrates to enable bending, then the display panel can be bent by external force, but the manufacturing process becomes difficult and manufacturing cost increases
Solution Approach 1:
The patent applies local quality by making only specific regions of the glass substrates flexible through selective paring. Instead of making the entire substrate flexible (which would require complex manufacturing), only the bending region is thinned to enable curvature while maintaining ease of manufacturing for the majority of the substrate structure
Solution Approach 2:
The patent changes the physical parameter of substrate thickness locally through paring. By reducing the thickness of glass substrates in specific regions, the mechanical properties are altered to enable bending while maintaining the overall structural integrity and simplicity of manufacturing
3Shape
If the outer end portions of substrates are bent to form a curved surface, then the desired curved shape is achieved, but the substrates become farther from one another causing deformation and separation
Solution Approach 1:
The patent applies the counterweight principle by introducing fixing layers that provide counteracting bonding force to compensate for the separating force generated during bending. These fixing layers are strategically positioned to provide opposing force that prevents substrates from moving farther apart during the curvature formation process
Data Source
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Figure 3(a)~3(b)
AI summary
A curved display panel manufacturing method for manufacturing a curved display panel having a curved shape using a flat display panel having a first substrate and a second substrate facing one another includes: paring partially outer portions of the first substrate and the second substrate so as to reduce thicknesses thereof to predetermined thicknesses; and forming fixing layers at edge areas which are not bent in a state of being bent to the desired curved shape among the edge areas of the first substrate and the second substrate.