Display Panel Adhesive Bonding with Segmented Gap Control
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Solution Overview
Problem
The existing display device manufacturing process faces a decrease in adhesive force due to foreign matter and air voids in the adhesive, which affects the bonding between the liquid crystal display panel and the color separation element.
Innovation Solution
A method involving a first adhesive with gap members applied to the display panel, followed by a second adhesive applied around the perimeter of the panel and color separation element, ensuring a secure bond and preventing foreign matter entry through discontinuous portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If a gap member is mixed with the adhesive to maintain the given distance between the display panel and color separation element, then the gap distance is maintained, but foreign matter and air voids are introduced into the adhesive, decreasing adhesive force
Solution Approach 1:
The adhesive bonding structure is divided into two segments: a first adhesive portion containing the gap member for maintaining distance, and a second adhesive portion free of foreign matter for providing strong bonding. This segmentation allows each portion to fulfill its specific function without compromising the other.
Solution Approach 2:
Different regions of the adhesive bonding structure are assigned different qualities: the first adhesive portion (inner region) contains the gap member for precise spacing control, while the second adhesive portion (outer region) is free of foreign matter to maximize adhesive force. This local differentiation resolves the contradiction between maintaining gap distance and ensuring bonding strength.
2Strength
If the display panel and color separation element are bonded with adhesive, then the components are secured together, but air mixed into the adhesive remains as voids even after defoaming, decreasing adhesive force
Solution Approach 1:
The adhesive is segmented into two portions with different compositions: the first adhesive portion contains the gap member and may contain some voids, while the second adhesive portion is specifically designed to be free of foreign matter and air voids. This segmentation ensures that the critical bonding regions have maximum adhesive force.
Solution Approach 2:
The harmful elements (foreign matter and air voids) are extracted from the second adhesive portion, which is applied after the first adhesive portion. By applying the second adhesive portion over the perimeter and ensuring it is free of contaminants, the bonding strength is maximized in the critical bonding regions.
3Manufacturing precision
If a first adhesive containing a gap member is applied to bond the display panel and color separation element, then the gap distance is controlled, but the adhesive may split and foreign matter may be mixed in, reducing bonding reliability
Solution Approach 1:
The bonding process is segmented into two adhesive application steps: the first adhesive portion is applied with the gap member for precise distance control, and the second adhesive portion is applied afterward to seal and protect the first adhesive portion, preventing splitting and foreign matter contamination. This two-stage approach ensures both precision and reliability.
Solution Approach 2:
The first adhesive portion containing the gap member is applied first to establish the precise gap distance before the second adhesive portion is applied. This preliminary action ensures that the critical spacing is set before the final sealing adhesive is applied, preventing subsequent contamination or splitting.
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 configuration enhances the adhesive force by preventing adhesive splitting and maintaining a consistent bond, thereby improving the display device's performance and reliability.
Implementation Method 1
a color separation element configured to disperse light from a light source and to emit, to the display panel, a plurality of rays of separated light with wavelengths different from each other
Implementation Method 2
an outer adhesive portion that bonds a side surface of the display panel and the color separation element to each other over an entire perimeter of the display panel
Data Source
AI summary
A display device includes a display panel, a color separation element configured to disperse light from a light source and to emit, to the display panel, a plurality of rays of separated light with wavelengths different from each other, and an outer adhesive portion that bonds a side surface of the display panel and the color separation element to each other over an entire perimeter of the display panel.