Display Module Base Film Structure for Sensor Alignment
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Solution Overview
Problem
Existing display modules are prone to defects during manufacturing due to added functions, which can lead to damage and inefficiencies.
Innovation Solution
A display module design featuring a display panel with a groove or through-hole, a base film with specific indentation portions and an adhesive layer, and a sensor insertion mechanism to reduce manufacturing defects by precise alignment and protection of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additional functions are added to the display module, then the functionality and versatility are improved, but the manufacturing precision and reliability deteriorate due to increased complexity
Solution Approach 1:
The base film is divided into a first portion and a second portion, with the first portion positioned over the groove/through-hole and the second portion extending to the edge. This segmentation allows the adhesive layer to be applied only to the first portion, simplifying the bonding process and improving manufacturing precision while maintaining the additional functions provided by the sensor assembly.
Solution Approach 2:
The adhesive layer is extracted and applied only to the first portion of the base film that overlaps the groove or through-hole, rather than covering the entire base film. This extraction of the adhesive application area simplifies the manufacturing process and reduces the risk of misalignment, thereby improving manufacturing precision while preserving the enhanced functionality.
2Adaptability or versatility
If a sensor is inserted into the groove or through-hole, then the functionality is improved, but the probability of component damage during manufacturing increases
Solution Approach 1:
The base film is pre-formed with a first portion positioned over the groove or through-hole before the adhesive layer is applied. This preliminary positioning creates a protective structure that prevents damage to the sensor during subsequent manufacturing steps, while still allowing the sensor to be integrated into the display module with enhanced functionality.
Solution Approach 2:
The first portion of the base film acts as an intermediary protective layer between the adhesive layer and the sensor in the groove/through-hole. This intermediary structure protects the sensitive sensor elements from damage during the bonding process and subsequent manufacturing, while enabling the sensor integration that enhances device functionality.
3Strength
If the adhesive layer covers the entire base film, then the bonding strength is improved, but the alignment precision and manufacturing accuracy deteriorate
Solution Approach 1:
The adhesive layer is applied locally only to the first portion of the base film that overlaps the groove or through-hole, rather than uniformly across the entire base film. This local quality approach concentrates the bonding strength where it is most needed (at the groove/through-hole interface) while improving alignment precision by reducing the overall bonding area and minimizing misalignment risks.
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
Enhances manufacturing precision and reduces the likelihood of component damage during assembly by ensuring accurate alignment and protection of sensitive elements.
Implementation Method 1
an adhesive layer bonding the first portion to the display panel
Data Source
AI summary
A display module includes: a display panel including a substrate, a transistor layer disposed on the substrate and including transistors, and a display layer disposed on the transistor layer and including a display element, where the display panel defines a groove or a through-hole therein; a base film including a first portion disposed on the display panel so that a portion of the first portion overlaps the groove or the through-hole, and a second portion connected to the first portion, wherein the base film defines a first indentation portion between the first portion and the second portion; and an adhesive layer bonding the first portion to the display panel.