Display Bonding Apparatus Using Pressure Differential for Bubble-Free Contact
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Solution Overview
Problem
Conventional methods for bonding optical members to display panels, such as using rollers or drums, often result in issues like inferior bonding, bubble formation, wrinkles, detachment, and reduced display quality due to inadequate pressure control and contact mechanisms.
Innovation Solution
A bonding apparatus with vertically and horizontally movable support members that create a pressure difference between the optical member and the panel member, allowing for precise contact and detachment to ensure proper bonding without these issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a roller or drum is used to bond the optical member to the panel member, then the bonding process can be performed with simple equipment, but the bonding quality deteriorates due to inadequate pressure control causing bubbles, wrinkles, and detachment
Solution Approach 1:
The bonding apparatus divides the bonding area into multiple regions with different pressure levels. A first pressing roller applies a first pressure to a first region while a second pressing roller applies a second pressure to a second region, enabling differential pressure control across the bonding surface to eliminate bubbles and wrinkles while maintaining strong adhesion
Solution Approach 2:
Different regions of the bonding interface are subjected to different pressure conditions. The first region receives a first pressure suitable for initial contact and air evacuation, while the second region receives a second pressure optimized for strong bonding, allowing each region to be treated with locally appropriate pressure levels
2Strength
If high pressure is applied uniformly to bond the optical member to the panel member, then strong bonding is achieved, but defects like bubbles and wrinkles increase due to inadequate pressure distribution
Solution Approach 1:
The bonding process is segmented into multiple pressure stages applied to different regions. The first pressing roller applies a first pressure to evacuate air and prevent bubbles, while the second pressing roller applies a second pressure to ensure strong bonding, thereby achieving both high bonding strength and defect-free surfaces through spatial segmentation of pressure application
Solution Approach 2:
The pressure parameter is varied across different regions and stages of the bonding process. By changing the pressure level from a first pressure in the first region to a second pressure in the second region, the system optimizes both bonding strength and defect prevention through parameter differentiation
3Reliability
If the contact portion remains in constant contact with the panel member edge, then positioning is maintained, but detachment of the optical member edge from the panel member occurs due to interference with pressure-driven bonding
Solution Approach 1:
The contact portion is designed to be movable rather than fixed, allowing it to dynamically adjust its position during the bonding process. The contact portion can move in the vertical direction to accommodate the bonding process and in the horizontal direction to detach after bonding, maintaining positioning accuracy while preventing bonding interference
Solution Approach 2:
The contact portion performs periodic actions: first contacting the panel member edge to establish positioning, then moving away to allow pressure-driven bonding to proceed without interference, and finally detaching after bonding is complete. This periodic contact-separation cycle ensures both accurate positioning and strong bonding integrity
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 reduces defects like bubbles, wrinkles, and detachment, thereby enhancing the display quality of manufactured display devices by ensuring a strong and consistent bond between the optical and panel members.
Implementation Method 1
forming a second pressure that is higher than the first pressure, and making the panel member and the optical member come in contact with each other due to a difference between the second pressure on the outside of the optical member and the first pressure between the optical member and the panel member
Data Source
AI summary
A bonding apparatus bonds one member to another member by using the pressure difference between the pressure between the two members and the ambient pressure. After aligning two members close to each other on a chuck and a supporting member in a vacuum chamber, the chamber is vacuumed to form vacuum between the two members. Then, air is supplied to the vacuum chamber to increase the ambient pressure to normal. The increased ambient pressure pushes the one member on the supporting member to the other member on the chuck, bonding both members together.