Curved Display Panel Assembly via Segmented Unit Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Manufacturing curved or bent display and protective glass panels is technically challenging, resulting in low productivity and high costs due to increased waste and difficulty in managing flatness for large-sized panels.
Innovation Solution
A panel assembly comprising consecutively disposed first and second unit panels connected by a junction with a bonding frame and adhesive, allowing for efficient bonding and reduced bezel layer width near the edge, enabling easier formation of curved or bent shapes without light distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a single large-sized protective glass panel or display panel is manufactured, then the panel size increases to meet display requirements, but flatness management becomes difficult resulting in low productivity and high manufacturing costs
Solution Approach 1:
The panel is divided into multiple unit panels (first unit panel and second unit panel) that are consecutively disposed and bonded together through junctions. This segmentation allows each unit panel to be manufactured separately with easier flatness control, while the assembled structure achieves the required large size. The junctions with bonding frames connect the edge surfaces of adjacent unit panels, enabling modular manufacturing that improves productivity.
2Shape
If a curved or bent protective glass panel or display panel is manufactured, then the desired curved shape is achieved, but the yield of good products is low and manufacturing waste increases resulting in low productivity and high costs
Solution Approach 1:
The curved panel is constructed by assembling multiple unit panels through junctions with bonding frames, allowing the curved shape to be achieved through the arrangement of planar units rather than deforming a single large panel. This approach maintains high yield since each unit panel can be manufactured flat with standard processes, and the curvature is achieved post-manufacturing through assembly geometry.
Solution Approach 2:
The curvature is achieved by arranging unit panels in a three-dimensional configuration rather than deforming a two-dimensional panel. The junctions and bonding frames enable the transition from flat unit panels to a curved assembled structure, moving the shape formation to a different dimensional approach that avoids manufacturing defects.
3Shape
If the bezel layer width is reduced near the edge surface bonded to the junction, then the visible junction area is minimized improving aesthetics, but the bonding structure must be optimized to maintain structural integrity
Solution Approach 1:
The bezel layer width is varied locally: it is smaller in regions close to the bonded edge surfaces to minimize visible junctions and improve aesthetics, while maintaining adequate width in other regions to ensure structural integrity. The bonding frame structure is specifically designed at the edge surfaces to compensate for the reduced bezel width, ensuring proper bonding strength despite the aesthetic optimization.
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 enhances productivity and reduces manufacturing costs by improving yield and image quality in curved or bent display devices, allowing for various curvature implementations without being limited by single-panel deformation methods.
Implementation Method 1
an adhesive which fills the internal space of the bonding frame through the inlet and is applied to and cured on the edge surface of the first unit panel and the edge surface of the second unit panel through the outlets
Implementation Method 2
a bezel layer formed by printing and curing an opaque paint on an outer peripheral portion of the transparent glass panel
Data Source
AI summary
Provided is a panel for a display device, a method of manufacturing the same, and a panel assembly including the panel for a display device. The panel for a display device includes a first unit panel and a second unit panel that are consecutively disposed, and a junction configured to bond and connect an edge surface of the first unit panel to an edge surface of the second unit panel facing the edge surface of the first unit panel.