Display Panel Adhesive Bonding with Sprinkled Gap Members
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Solution Overview
Problem
The existing methods for manufacturing display devices face 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 the application of adhesive to both the display panel and the color separation element, followed by sprinkling a gap member of a specific size on one surface and then bonding them together with the adhesive in between, ensuring a consistent distance for optimal light focusing without mixing the gap member into the adhesive, thus preventing voids and foreign matter entry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the gap member is mixed with the adhesive, then the gap member can be positioned between the display panel and color separation element, but foreign matter may be mixed into the adhesive and air voids may remain even after defoaming process, decreasing adhesive force
Solution Approach 1:
The process is divided into separate steps: first applying adhesive to the display panel, then sprinkling gap members on the adhesive layer, and finally bonding the color separation element. This segmentation prevents mixing of gap members with adhesive while ensuring proper positioning, resolving the contradiction between positioning precision and adhesive force.
Solution Approach 2:
The adhesive is applied to the display panel before the gap members are sprinkled. This preliminary action ensures that the gap members are placed on top of the adhesive layer rather than being mixed into it, preventing foreign matter contamination and air void formation while maintaining adhesive force.
2Strength
If the gap member is sprinkled on the adhesive after application, then adhesive force is maintained, but the process complexity increases
Solution Approach 1:
The gap members are sprinkled on the adhesive layer and automatically positioned by gravity and adhesion to the adhesive surface. The adhesive itself serves as the positioning medium, eliminating the need for complex positioning mechanisms while maintaining adhesive force.
Solution Approach 2:
The adhesive layer acts as an intermediary between the display panel and gap members. By sprinkling gap members on the adhesive rather than mixing them, the adhesive serves as a mediator that maintains bonding strength while allowing gap member positioning through a simple sprinkling action.
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 method enhances the adhesive force and prevents voids and foreign matter entry, maintaining the adhesive's effectiveness and ensuring consistent light focusing for improved display device performance.
Implementation Method 1
the color separation element dispersing light from a light source and emitting a plurality of rays of separated light with wavelengths different from each other
Implementation Method 2
sticking together a board surface of a color separation element and the opposite surface of the display panel on which the gap member has been sprinkled, with the adhesive between the board surface and the opposite surface
Data Source
AI summary
A method for manufacturing a display device includes applying an adhesive to a display panel having a display surface where an image is displayed and an opposite surface on an opposite side of the display surface, on the opposite surface, sprinkling a gap member of a given size on the opposite surface of the display panel to which the adhesive has been applied, and sticking together a board surface of a color separation element and the opposite surface of the display panel on which the gap member has been sprinkled, with the adhesive between the board surface and the opposite surface, the color separation element dispersing light from a light source and emitting a plurality of rays of separated light with wavelengths different from each other.