Dispersed Support Layer for Display Gap Reduction
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Solution Overview
Problem
Large-sized commercial display screens face issues with gaps between glass cover plates and liquid crystal display panels, leading to poor picture quality due to ghost and color halo phenomena, and existing full lamination technologies are costly, complex, and not suitable for mass production.
Innovation Solution
A display device with a support layer comprising dispersedly arranged first support portions between the display panel and cover plate, reducing the separation distance and preventing ghost and color halo issues, while using a simpler fabrication process that significantly reduces production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If full lamination technology is used to bond glass cover plate and liquid crystal display panel, then the gap between them is reduced, but the production cost increases and the fabrication process becomes complex
Solution Approach 1:
The support layer is segmented into multiple discrete support columns distributed across the bonding area, rather than using continuous full lamination. This segmentation reduces material usage and simplifies the fabrication process while still effectively reducing the gap between the cover plate and display panel.
Solution Approach 2:
Instead of uniform full lamination across the entire surface, the patent applies support structures only at specific locations where gap reduction is needed. The support columns are strategically positioned to provide local support, reducing the gap where necessary while maintaining simplicity elsewhere.
2Length of moving object
If full lamination technology is used to bond glass cover plate and liquid crystal display panel, then the gap between them is reduced, but the production cost increases
Solution Approach 1:
The support layer is divided into multiple discrete support columns rather than continuous lamination, reducing material consumption and manufacturing cost while maintaining the gap-reduction effect.
Solution Approach 2:
The patent uses cost-effective support column structures that can be easily manufactured and applied, replacing expensive full lamination technology. These support structures provide the necessary function at a fraction of the cost of complete surface bonding.
3Ease of manufacture
If dispersed support portions are used instead of full lamination, then production cost is reduced, but the gap reduction effect may be compromised
Solution Approach 1:
Instead of applying support structures across the entire surface (excessive action), the patent uses a carefully optimized distribution of support columns at specific locations (partial action). This partial application is sufficient to achieve the desired gap reduction effect while minimizing cost.
Solution Approach 2:
The patent optimizes parameters such as the number, size, spacing, and height of support columns to achieve effective gap reduction. By adjusting these parameters, the solution maintains the gap-reduction function while using fewer materials and reducing production costs compared to full lamination.
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
The solution effectively reduces production costs, eliminates ghost and color halo issues, and increases product yield, achieving a thinner display device with improved image quality, comparable to full lamination processes but at a fraction of the cost.
Implementation Method 1
a support layer, provided between the display panel and the cover plate, the support layer being configured to support the display panel and the cover plate, so that a gap is provided between the display panel and cover plate
Implementation Method 2
bonding the surface of the display panel with the opposed surface of the cover plate
Data Source
AI summary
A display device and a fabrication method thereof are disclosed. A display device, including: a display panel and a cover plate provided opposite to each other; and a support layer, provided between the display panel and the cover plate, the support layer being configured to support the display panel and the cover plate, so that a gap is provided between the display panel and cover plate; the support layer comprising a plurality of first support portions; and the plurality of first support portions are dispersedly arranged and spaced apart from each other.


