Display Lamination Resin Layer for Light Shielding Step Cancellation
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Solution Overview
Problem
Conventional methods for manufacturing image display apparatuses face issues with insufficient adhesion and moisture invasion due to incomplete curing of photocurable resin between the light shielding layer and the image display member, requiring additional thermal polymerization steps and reducing storage stability.
Innovation Solution
A method involving coating a liquid photocurable resin composition thicker than the light shielding layer on the light-transmissive cover member or image display member, followed by UV curing to form a light-transmissive cured resin layer, allowing for complete photocuring without thermal polymerization and eliminating the step between the light shielding layer and the cover member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a light shielding layer is disposed around the outer edge of the light-transmissive cover member to improve brightness and contrast, then display image quality is improved, but curing of the photocurable resin composition between the light shielding layer and the image display member does not sufficiently proceed, resulting in insufficient adhesion and potential peeling
Solution Approach 1:
The patent introduces a light-transmissive resin layer as an intermediary substance between the light shielding layer and the image display member. This resin layer fills the gap created by the light shielding layer's thickness, enabling UV light to penetrate through to the image display member for sufficient curing, while also providing adhesive bonding between the components
Solution Approach 2:
The patent adds a new dimensional element (the light-transmissive resin layer) in the vertical dimension between the light shielding layer and the image display member. This resolves the curing issue by creating a pathway for UV light transmission while maintaining adhesion, without modifying the light shielding layer itself
2Reliability
If a thermal polymerization initiator is mixed in the photocurable resin composition to enable heat-curing in addition to photocuring, then adhesion between the light shielding layer and image display member is improved, but initial investment for the thermal polymerization process becomes larger and storage stability of the resin composition is reduced
Solution Approach 1:
The patent extracts the thermal polymerization initiator from the resin composition, eliminating the need for thermal curing equipment and processes. Instead, it relies solely on photocuring through optimized light-transmissive resin formulation, thereby reducing device complexity and initial investment while maintaining adhesion through sufficient UV penetration
Solution Approach 2:
The patent replaces the thermal curing mechanism with a purely photopolymerization-based system. By using a light-transmissive resin that allows UV penetration through the light shielding layer structure, it substitutes thermal energy with optical energy for curing, eliminating the need for thermal polymerization equipment
3Shape
If the photocurable resin composition is coated thinner to avoid elimination from between the light shielding layer and image display member, then the step formation is reduced, but curing of the resin between the light shielding layer and image display member does not sufficiently proceed
Solution Approach 1:
The patent changes the optical parameters of the resin composition by selecting materials with high UV transmittance in the blue region (400-480 nm). This allows the resin to maintain sufficient thickness for filling steps and providing adhesion while still permitting adequate UV light penetration for complete curing
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 ensures sufficient photocuring of the resin layer between the light shielding layer and the image display member, cancels the step formed by the light shielding layer, and prevents air bubble generation and peeling, improving adhesion and image quality.
Implementation Method 1
irradiating UV rays to the resin composition so as to cure into a light-transmissive cured resin layer
Implementation Method 2
coating the surface of the light-transmissive cover member having the light shielding layer formed thereon with the heat- and photocurable resin composition
Implementation Method 3
bonding and laminating the image display member and the light-transmissive cover member via a light-transmissive cured resin layer
Data Source
AI summary
In the method of manufacturing an image display apparatus according to the present invention, a liquid photocurable resin composition that does not contain a thermal polymerization initiator is coated on the surface of a light-transmissive cover member including a light shielding layer or the surface of an image display member in a thickness thicker than that of the light shielding layer, and thereafter UV rays are irradiated in that state for curing to form a light-transmissive cured resin layer. Then, the image display member and the light-transmissive cover member are laminated to each other via the light-transmissive cured resin layer to obtain an image display apparatus.