Display Cell Resin Filling Structure Without Encapsulation Glass
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Solution Overview
Problem
Existing display device manufacturing processes face challenges in achieving efficient and reliable production, particularly in defining and separating display areas without the need for encapsulation glass and its subsequent cutting processes.
Innovation Solution
A display device design that includes a substrate with defined display and non-display areas, featuring a pad area, a display part with a pixel circuit layer and light emitting elements, a pad part with multiple pads, a dam surrounding the display part, and a filling layer made of transparent curable resin positioned on top of the display part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If encapsulation glass is used to protect and define display areas, then structural support and protection are improved, but manufacturing complexity and production time increase due to additional forming and cutting processes
Solution Approach 1:
The patent extracts the encapsulation glass layer from the display structure, replacing it with a filling layer formed by coating and curing resin material. This eliminates the need for separate glass forming and cutting processes, reducing manufacturing complexity while maintaining structural support through the dam structure and filling layer combination
Solution Approach 2:
The patent changes the material parameter from rigid encapsulation glass to curable resin material that can be applied in liquid form and then cured. This parameter change allows the material to be deposited using coating processes rather than requiring high-temperature glass forming and mechanical cutting, thereby simplifying the manufacturing process
2Reliability
If encapsulation glass is used to protect display cells, then reliability is improved, but manufacturing time increases due to additional processing steps
Solution Approach 1:
The patent merges the protection function with the filling layer that is already required for display cell structure, eliminating the need for separate encapsulation glass processing. The filling layer, formed by coating and curing, provides both structural support and protection simultaneously, reducing manufacturing cycle time while maintaining reliability
Solution Approach 2:
The patent applies the filling layer material in liquid form before curing, allowing the material to be deposited using simple coating processes. This preliminary action in liquid form enables subsequent curing to provide the protective function without requiring time-consuming glass forming and cutting operations
3Manufacturing precision
If dam structure is added to surround display part, then manufacturing precision is improved by defining boundaries, but device complexity increases
Solution Approach 1:
The dam structure serves multiple functions: it defines the display area boundaries for manufacturing precision, provides structural support for the filling layer, and acts as a barrier between different regions. This multi-functionality reduces the need for additional separate structures, thereby limiting the increase in device complexity while achieving improved manufacturing precision
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 design enhances manufacturing efficiency by eliminating the processes of forming and cutting encapsulation glass, while ensuring reliability through the use of a dam and filling layer that provide structural support and protection to the display cells.
Implementation Method 1
a dam and a filling layer which are formed of a curable resin with a certain level or higher of viscosity
Implementation Method 2
The first and second display cells are individually separating by cutting the mother substrate by irradiating a laser beam
Data Source
AI summary
According to an embodiment of the disclosure, a display device may include a substrate where a display area and a non-display area are defined, the non-display area including a pad area, a display part disposed on the substrate and displaying an image, a pad part disposed in the pad area and including a plurality of pads, a dam positioned between the pad part and the display part and surrounding at least one side of the display part, and a filling layer disposed on the display part surrounded by the dam to cover the display part. The filling layer may include a transparent curable resin and is positioned in an uppermost layer in the display area.