Display Edge Cladding Structure to Stop Cutting-Induced Cracks
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Solution Overview
Problem
The durability of flat panel display apparatuses is compromised due to cracking issues during manufacturing, particularly when cutting mother substrates, as external forces or process conditions can damage the films, leading to crack propagation and reduced durability.
Innovation Solution
A display apparatus design featuring a substrate partitioned into central and peripheral areas, with a first insulating layer and a cladding layer that covers slits in the peripheral area, where the cladding layer extends parallel to the substrate edge and includes the same material as the insulating layer, effectively preventing crack propagation and foreign substance movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the mother substrate is cut to separate display apparatuses, then individual display units are obtained, but cracks occur on the films and durability is affected
Solution Approach 1:
A release structure is formed on the substrate before the cutting process. This release structure includes a release layer and a release pattern that are prepared in advance to prevent cracks during subsequent cutting operations. The release structure is positioned in advance at locations where cracks are likely to occur during separation.
Solution Approach 2:
The release structure acts as an intermediary element between the substrate and the cutting process. It includes a release layer that provides a controlled interface for separation, allowing the substrate to be cut into individual display apparatuses without causing cracks to propagate through the films. The release pattern with controlled width and positioning serves as a mediator that manages the stress distribution during cutting.
2Reliability
If the cladding layer covers the slits, then crack propagation is prevented, but the device structure becomes more complex
Solution Approach 1:
The cladding layer is integrated with the existing insulating layer structure. The cladding layer uses the same material as the insulating layer and is formed as an extension of it, covering the slits while maintaining material consistency. This merging approach prevents crack propagation without introducing fundamentally new materials or complex multi-layer structures.
Solution Approach 2:
The cladding layer is positioned specifically at the peripheral area of the substrate where slits are located, rather than covering the entire substrate. The cladding layer has a specific width that is greater than the slit width, providing localized protection at critical areas. This local quality approach prevents crack propagation at vulnerable points without adding complexity to the entire device structure.
Data Source
AI summary
A display apparatus includes a substrate partitioned into a central area and a peripheral area disposed adjacent to the central area. The central area includes a display area; a first insulating layer corresponding to the peripheral area of the substrate; at least one slit corresponding to a region of the first insulating layer; and a cladding layer, which covers the at least one slit, on the first insulating layer.