Cuttable Display Panel Edge Sealing for Flexible Size Production
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing display technologies face limitations in manufacturing large-area and variously shaped display apparatuses, particularly in producing display panels of different sizes efficiently and cost-effectively.
Innovation Solution
A display panel design that includes a first and second substrate with subpixels, a dam at the non-display region, and a protective layer on the side surfaces, allowing for display panels of varying sizes to be manufactured through a simplified process by cutting and reusing defective regions, with moisture and oxygen penetration prevention through a dam and filler system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If display panels are manufactured in various sizes using traditional methods, then manufacturing flexibility is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The display panel manufacturing process is segmented into standardized modules that can be cut to various sizes after a single manufacturing run. The panel structure is divided into a display region and a non-display region, allowing flexible cutting positions while maintaining consistent manufacturing processes for all sizes.
Solution Approach 2:
A universal manufacturing process is established that produces all display panel sizes through a single production line. The standardized structure with display and non-display regions serves multiple functions: it maintains manufacturing consistency, allows flexible size variations, and enables defective region recycling across different panel sizes.
2Adaptability or versatility
If display panels are manufactured in various sizes using traditional methods, then product variety is improved, but manufacturing cost increases
Solution Approach 1:
The display panel is segmented into a display region and a non-display region, allowing the panel to be cut at various positions to create different sizes. This segmentation enables a single manufacturing process to produce multiple size variants, reducing the need for separate production lines for each size and thereby lowering manufacturing costs.
Solution Approach 2:
Defective regions in the non-display area are recovered and reused in subsequent manufacturing processes. Instead of discarding panels with defects in the non-display region, these regions are utilized for creating smaller panel sizes or for repairing defective areas, thereby reducing material waste and lowering overall manufacturing costs.
3Adaptability or versatility
If display panels are cut to various sizes, then manufacturing flexibility is improved, but moisture and oxygen penetration risk increases
Solution Approach 1:
The dam structure is formed in advance during the manufacturing process, before the panel is cut to its final size. This preliminary formation of the moisture and oxygen barrier ensures that the protective structure is already in place regardless of where the panel is cut, preventing harmful factor ingress at the cut edges.
Solution Approach 2:
A dam structure serves as an intermediary barrier between the display region and the external environment. This dam, formed by the inorganic layer extending beyond the display region, acts as a mediator that blocks moisture and oxygen from reaching the display elements, even when the panel is cut to various sizes.
4Loss of substance
If defective regions are recycled to reduce waste, then material utilization is improved, but manufacturing precision requirements increase
Solution Approach 1:
The display panel is segmented into a display region and a non-display region, with the understanding that the non-display region may contain defects. This segmentation allows defective areas to be isolated and reused for creating smaller panels or for repair purposes, reducing material waste while maintaining precision requirements for the functional display region.
Solution Approach 2:
Different quality standards are applied to different regions: the display region maintains high manufacturing precision requirements, while the non-display region accepts lower precision standards. This local quality approach allows defective non-display regions to be recycled without compromising the overall panel quality, thereby reducing material waste while managing precision requirements effectively.
Data Source
AI summary
A display panel can include a first substrate and a second substrate having a display region and a non-display region adjacent to the display region, a thin film transistor and a light emitting element arranged in each of a plurality of subpixels included in the display region, a dam arranged at the non-display region and an end of the display region between the first substrate and the second substrate, and a protective layer disposed on a side surface of the non-display region and a side surface of the end of the display region.