Display Panel Edge Chamfer Encapsulation for Warping Control
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Solution Overview
Problem
Narrow-bezel or bezel-less display panels face issues with edge warping and encapsulation failure due to insufficient space for film layers, particularly in large outdoor public information displays formed by splicing multiple panels, which affect the display effect.
Innovation Solution
A display panel design with chamfers on its edges, filled with adhesives of varying viscosities, where a first chamfer is filled with a lower viscosity adhesive to prevent bubble formation and a second chamfer with a higher viscosity adhesive to ensure complete encapsulation, enhancing the encapsulation quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single adhesive is used to fill the chamfer, then the manufacturing process is simple, but the encapsulation quality is insufficient leading to edge warping
Solution Approach 1:
The chamfer filling process is segmented into two distinct stages: first filling with a low-viscosity adhesive to reach the corner regions, then filling with a high-viscosity adhesive to provide strong encapsulation. This segmentation allows each adhesive to perform its optimal function without compromising the other.
Solution Approach 2:
Different regions of the chamfer are assigned different adhesive properties: the corner regions (hard to reach) receive low-viscosity adhesive for easy penetration, while the main body regions receive high-viscosity adhesive for strong bonding and encapsulation stability.
2Reliability
If high-viscosity adhesive is used first, then strong encapsulation is achieved, but bubble formation occurs reducing yield
Solution Approach 1:
The low-viscosity adhesive is applied first to perform the preliminary action of filling the corner regions and establishing initial adhesion. This preliminary action creates a foundation that prevents bubble formation before the high-viscosity adhesive is applied for strong encapsulation.
Solution Approach 2:
The viscosity parameter of the adhesive is changed between the two filling stages. The first adhesive has low viscosity for easy flow and bubble-free filling, while the second adhesive has high viscosity for strong encapsulation. This parameter change optimizes both yield and strength.
3Productivity
If low-viscosity adhesive is used alone, then complete filling is achieved, but encapsulation stability is insufficient causing edge warping
Solution Approach 1:
The encapsulation system uses a composite adhesive structure with two different adhesives having complementary properties. The low-viscosity adhesive provides complete filling capability, while the high-viscosity adhesive provides encapsulation stability. Together they form a composite system that achieves both objectives.
Solution Approach 2:
The low-viscosity adhesive is nested within the high-viscosity adhesive system. The first adhesive fills the corners and is then overlaid and reinforced by the second adhesive, creating a nested structure where each layer contributes its specific function to the overall encapsulation quality.
Data Source
AI summary
A display panel includes a base substrate and a display functional layer located on one side of the base substrate. The display panel includes at least one first edge. At the first edge, the base substrate includes a first chamfer and a second chamfer. In a first direction, the first chamfer at least overlaps with a first filling adhesive, and a non-chamfered region or the second chamfer at least overlaps with a second filling adhesive. The viscosity of the second filling adhesive is greater than the viscosity of the first filling adhesive. The first direction is parallel to the plane of the base substrate and intersects the first edge.