Display Device Alignment Marks for Lamination Precision
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Solution Overview
Problem
Display devices in electronic devices often experience high failure rates and errors during the lamination process, particularly due to misalignment issues between the display panel and the window, which can be exacerbated by the complex shapes and materials used.
Innovation Solution
A display device design featuring a window with light-transmissive main alignment marks and a transmission area of different shapes, along with a method for aligning the display panel and window using these marks, and optionally a sub-alignment mark and test mark to correct for errors, ensuring accurate coupling and reducing failure rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional lamination process without alignment marks is used, then manufacturing process is simpler, but misalignment between display panel and window occurs leading to high failure rates
Solution Approach 1:
Alignment marks are pre-defined in the window before the lamination process, allowing the display panel to be accurately positioned and aligned during assembly. This preliminary preparation of reference markers enables precise alignment without adding complexity to the actual lamination operation.
Solution Approach 2:
Light-transmissive alignment marks serve as intermediary reference elements between the window and display panel. These marks provide visual or detectable references that mediate the alignment process, enabling accurate positioning without direct mechanical intervention or complex alignment mechanisms.
2Manufacturing precision
If multiple alignment marks are added to the window, then alignment precision improves, but manufacturing complexity and process time increase
Solution Approach 1:
Multiple alignment marks are pre-defined in the window at specific positions (including curved corner areas) before lamination. This preliminary placement of multiple reference points enables comprehensive alignment verification without requiring time-consuming manual measurement or adjustment during the assembly process.
Solution Approach 2:
The alignment process replaces mechanical measurement and adjustment systems with optical or visual alignment marks. By using light-transmissive marks that can be detected optically, the system eliminates the need for complex mechanical alignment tools and manual measurement procedures, thereby maintaining high precision while improving manufacturing efficiency.
3Manufacturing precision
If alignment marks are placed at all vertices of the display panel, then complete alignment coverage is achieved, but the window design becomes more complex and materials are wasted
Solution Approach 1:
Alignment marks are strategically pre-positioned at specific vertices and curved corner areas of the display panel in the window design phase. This preliminary planning ensures that critical alignment points are covered without requiring marks at every possible location, optimizing the balance between alignment coverage and window structure simplicity.
Solution Approach 2:
Different regions of the window receive different treatment regarding alignment marks. Curved corner areas and critical vertex positions are equipped with alignment marks, while other areas maintain simple window structure. This localized approach ensures alignment precision where needed while avoiding unnecessary complexity in regions where alignment marks are not required.
Data Source
AI summary
A display device includes a window and a display panel coupled to a bottom surface of the window. The display panel has a substantially regular tetragonal shape or a substantially rectangular shape in a plan view, and the window includes a base member and a bezel layer on a bottom surface of the base member. Between one and three light-transmissive main alignment marks and a transmission area having a different shape than that of the display panel are defined in the bezel layer, and each of the main alignment marks is arranged at a position corresponding to a vertex of the display panel or at a position corresponding to a vertex of an imaginary regular tetragon or of an imaginary rectangle that has the same center point as the display panel and that is larger than the display panel.