Delamination Reduction Layer for Display Device Adhesion
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Solution Overview
Problem
The removal of a PET layer from decoration films in display devices leads to delamination failures during manufacturing, increasing defect rates and requiring additional adhesive layers to enhance bonding between the decoration film and release paper.
Innovation Solution
A display device with a delamination reduction layer having higher surface energy than the print layer, which is formed in the same process as the print layer, minimizes delamination by increasing adhesive power and preventing bubble formation between the decoration film and cover window.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the PET layer is removed from the decoration film to reduce thickness, then the display device becomes thinner and more flexible, but the adhesive power between the decoration film and release paper decreases, causing delamination failures
Solution Approach 1:
The patent changes the chemical composition parameters of the adhesive layer by formulating it with specific ratios of acrylic resin, rubber resin, and initiators. This chemical parameter adjustment increases the adhesive power between the decoration film and release paper, resolving the delamination issue that occurs when the PET layer is removed for thinning the decoration film.
Solution Approach 2:
The patent uses a composite adhesive layer combining acrylic resin and rubber resin with specific physical properties (viscosity of 50-200 cP, solid content of 30-70%). This composite material approach provides both the necessary adhesive strength to prevent delamination and the flow characteristics to fill gaps, enabling the decoration film to be thinner without sacrificing bonding reliability.
2Reliability
If the adhesive layer is optimized to increase adhesive power, then delamination is reduced, but the viscosity and solid content must be precisely controlled, increasing manufacturing complexity
Solution Approach 1:
The patent defines specific parameter ranges for the adhesive layer (viscosity: 50-200 cP, solid content: 30-70%) that balance adhesive performance with manufacturing ease. Within these ranges, the adhesive provides sufficient bonding strength while maintaining manageable flow characteristics during application, reducing the complexity of process control.
Solution Approach 2:
The patent applies the adhesive layer with specific local properties at the interface between the decoration film and release paper. The adhesive is formulated to have optimal viscosity and solid content specifically at this bonding interface, ensuring strong adhesion without requiring complex control throughout the entire manufacturing process.
3Reliability
If additional adhesive layers are added to improve bonding, then delamination is prevented, but the manufacturing process becomes more complex and costly
Solution Approach 1:
The patent designs a single adhesive layer that performs multiple functions: providing strong adhesive bonding between the decoration film and release paper, filling gaps to prevent bubble formation, and maintaining flexibility. This multi-functional adhesive layer eliminates the need for multiple separate adhesive layers or additional bonding processes, simplifying the manufacturing process while ensuring reliable adhesion.
Solution Approach 2:
The composite adhesive layer combining acrylic and rubber resins provides both high adhesive strength and gap-filling capability in a single layer. This eliminates the need for multiple layers with different functions, reducing manufacturing complexity and cost while preventing both delamination and bubble formation.
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 solution effectively reduces delamination failures, minimizes bubble generation, and enhances economic efficiency by eliminating the need for additional manufacturing steps, while allowing for thinner, more flexible display devices with reduced manufacturing costs.
Implementation Method 1
In the delamination reduction layer, an opposite surface of one surface in contact with the print layer has a higher surface energy than a lowermost layer among the plurality of layers of the print layer
Implementation Method 2
an adhesive layer in direct contact with a lower part of the cover window
Implementation Method 3
the generation of bubbles that may occur when a decoration film and a display panel are bonded to each other can be prevented
Data Source
AI summary
A display device is provided. The display device includes a cover window having a display area and a non-display area surrounding the display area, an adhesive layer in direct contact with a lower part of the cover window, a print layer disposed under the adhesive layer and including a plurality of layers, and a delamination reduction layer disposed under the print layer. In the delamination reduction layer, an opposite surface of one surface in contact with the print layer has a higher surface energy than a lowermost layer among the plurality of layers of the print layer.