Display Device Anti-Reflection Layer Integration for Bending Endurance

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Solution Overview

Problem

Existing display device manufacturing methods face challenges in improving reliability, particularly in terms of bending endurance and service life, while also aiming for reduced process time and improved display quality.

Innovation Solution

A method involving the formation of a display device with specific layers, including a substrate, pixel circuit, light-emitting unit, touch sensing unit, insulating layer, and anti-reflection layer, where the anti-reflection layer is formed directly on the insulating layer using methods like ink-jet printing or coating, reducing overall thickness and bending stress.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the anti-reflection layer is formed separately and attached to the insulating layer, then the manufacturing process is simpler, but the bending endurance and reliability are reduced due to layer separation

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidbending endurance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent combines the anti-reflection layer and insulating layer into a single integrated layer formed simultaneously through one coating process, eliminating the interface between separate layers that would otherwise separate during bending. This merging resolves the contradiction by maintaining manufacturing simplicity while preventing layer separation to improve bending endurance and reliability.

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

If multiple separate layers are used for anti-reflection and insulation, then each layer can be optimized independently, but the overall device thickness increases and bending stress increases

Engineering Contradiction:

Improvelayer optimization flexibilityVSAvoiddevice thickness

Core Design Contradiction:

Adaptability or versatilityVSLength of stationary object

Solution Approach 1:

The patent merges the anti-reflection layer and insulating layer into a single multi-functional layer that performs both functions simultaneously. This integration reduces the overall device thickness by eliminating the cumulative thickness of multiple separate layers and the adhesive layers required to bond them, while still allowing independent optimization of the combined layer's properties.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If multiple separate layers are used, then functional optimization is easier, but the number of process steps increases

Engineering Contradiction:

Improvefunctional optimizationVSAvoidnumber of process steps

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines multiple coating processes into a single integrated process where the anti-reflection and insulating layers are formed together in one step. This reduces the number of process steps and associated alignment operations, while the combined layer structure still enables functional optimization through material composition and thickness control.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS12411566B2Method for manufacturing display device

Publication Date: 2025.09.09 INNOLUX CORP

AI summary

The disclosure provides a method for manufacturing a display device, including the following steps. A substrate is provided. A pixel circuit is formed on the substrate. A light-emitting unit is formed on the pixel circuit. A touch sensing unit is formed on the light-emitting unit. An insulating layer is formed on the touch sensing unit. An anti-reflection layer is formed on the insulating layer. The method for manufacturing the display device of the embodiment of the disclosure can improve reliability.