Minimizing Display Border via Edge Cutting and Sealing
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Solution Overview
Problem
Conventional display devices face manufacturing challenges in reducing the size of electronic devices while maintaining the display area, particularly due to the large borders around the display edges that house internal components like LEDs or liquid crystal pixels.
Innovation Solution
A method involving a display unit with a minimized border is achieved by cutting a section at the edge to remove portions of the encapsulation layer and substrate, ensuring no display active area is compromised, and sealing the cut section with a transparent cover and sealant to protect the area and maintain the display's integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the border around the display edges is reduced to minimize device size, then the overall device size is reduced, but the manufacturing precision and reliability deteriorate due to challenges in positioning internal components close to the edge
Solution Approach 1:
The display device is divided into a display area and a non-display area, with the encapsulation layer extending into the non-display area to provide structural support and component mounting space. This segmentation allows the display active area to be maximized while maintaining adequate border space for manufacturing and component placement.
Solution Approach 2:
The encapsulation layer is extended in the lateral dimension beyond the display active area into the non-display area. This dimensional extension provides a functional border region that maintains manufacturing precision requirements while minimizing the visible border from the front view.
2Length of stationary object
If the border around the display edges is reduced to minimize device size, then the overall device size is reduced, but the reliability deteriorates due to challenges in protecting internal components near the edge
Solution Approach 1:
The encapsulation layer is extended into the non-display area to form a protective barrier that seals internal components from environmental contaminants. This extended encapsulation provides reliable protection while maintaining a minimized visible border.
Solution Approach 2:
The device is segmented into display and non-display areas, with the encapsulation layer providing protective coverage in both regions. The non-display area serves as a protective buffer zone that enhances reliability without increasing the front-visible device size.
3Length of stationary object
If internal components are positioned closer to the edge to reduce device size, then the overall device size is reduced, but the manufacturing complexity increases
Solution Approach 1:
By dividing the device into display and non-display areas with the encapsulation layer extending into the non-display area, the patent creates distinct functional zones. This segmentation simplifies manufacturing by providing clear boundaries for component placement and assembly processes.
Solution Approach 2:
The encapsulation layer is extended into the non-display area during the manufacturing process to pre-establish protective barriers and structural frameworks. This preliminary action simplifies subsequent assembly steps and reduces manufacturing complexity.
Data Source
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AI summary
Display devices with a minimized border and methods of manufacturing display devices are described herein. In one example, a display unit (400) is provided, the display unit (400) having a display active area (204) disposed between an encapsulation layer (202) and a substrate (206) such that the encapsulation layer (202) encloses the display active area (204) between a surface of the encapsulation layer (202) and a surface of the substrate (206). A section of the display unit is cut at one edge (304) of the display unit such that a portion of the encapsulation layer (202) and a portion of the substrate (206) are removed from the display unit while no display active area (204) is removed. The cut section of the display unit is then sealed.