Display Panel Edge Sealing With Laser-Melted Metal
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Solution Overview
Problem
As the bezel size of display devices is reduced, side-surface sealing defects can occur due to variations in parts and process deviations, leading to potential moisture penetration into the display panel.
Innovation Solution
A meltable metal is disposed in a trimming region of the display device and cut using a laser, sealing the side surface of the display device as the metal melts from the cutting heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the bezel size is reduced, then the display device achieves a more compact and modern appearance, but side-surface sealing defects occur due to variations in parts and process deviations, leading to moisture penetration
Solution Approach 1:
The patent changes the physical state of the sealing member from solid to liquid by heating it above its melting point, allowing it to flow and fill sealing gaps. This parameter change (temperature) enables the sealing material to adapt to dimensional variations and ensure reliable sealing even when bezel size is reduced and tolerances are tighter.
Solution Approach 2:
The patent employs a composite sealing structure consisting of a sealing member (meltable material) and a support member. This composite approach combines the flowability and sealing capability of the meltable material with the structural support of the support member, creating a robust sealing system that can accommodate reduced bezel dimensions while maintaining sealing reliability.
2Reliability
If a traditional sealing member is used, then the side surface is sealed, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The patent merges the sealing function with the cutting process by positioning the meltable sealing member at the cutting line. The laser cutting operation simultaneously performs both cutting and sealing functions - cutting the display device while melting the sealing member to seal the side surface. This consolidation of operations reduces manufacturing steps and complexity.
Solution Approach 2:
The sealing member is designed to be self-activating through the laser cutting process. The heat generated during laser cutting automatically melts the sealing member, which then flows and seals the side surface without requiring separate sealing equipment or additional processing steps. The process uses the energy already present in the cutting operation to achieve sealing.
3Area of stationary object
If the sealing member coating area is reduced due to smaller bezel size, then the device becomes more compact, but the coating thickness falls below the lower limit, causing sealing defects
Solution Approach 1:
The patent changes the temperature parameter of the sealing member to above its melting point, transforming it from a rigid coating to a flowable material. This allows the sealing member to extend beyond the reduced coating area and flow into gaps and crevices, ensuring adequate sealing coverage and thickness even when the initial coating area is minimized due to smaller bezel dimensions.
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 effectively prevents moisture penetration into the display panel while simplifying the manufacturing process by sealing the side surfaces during the cutting process.
Implementation Method 1
melting the meltable metal pattern by heat of the laser, to form a sealing member configured to seal a side surface of the display panel
Implementation Method 2
irradiating a central portion of the meltable metal pattern formed in the trimming region with a laser, thereby cutting a resultant structure into unit display panel regions and, simultaneously, melting the meltable metal pattern by heat of the laser
Data Source
AI summary
A display device and a method of manufacturing the same which are capable of effectively preventing side-surface moisture penetration while achieving simplification of a process are disclosed. The display device includes a back plate, a display panel bonded onto the back plate, a cover glass bonded onto the display panel, and a sealing member configured to seal a side surface of the display panel and formed of a meltable metal.