Display Module Sealing with Variable Width Metal and Sealant
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Solution Overview
Problem
Existing display module manufacturing methods face challenges in maintaining the reception sensitivity of antennas while ensuring strong bonding between substrates, as the metal layer's width variation affects the sealing member's curing process, leading to potential stress and damage.
Innovation Solution
A method involving a metal layer with varying widths on a display module, where a first portion has a constant width and a second portion with a reduced width, and a sealing member with different forming and sealing widths, is used to minimize the difference in sealing widths after curing, ensuring stable bonding and antenna sensitivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the metal layer has a uniform width to ensure strong bonding, then the bonding strength between substrates is improved, but the antenna reception sensitivity deteriorates due to interference with the antenna structure
Solution Approach 1:
The metal layer is designed with different widths in different regions: a first width in the first region (away from antenna) and a second width in the second region (overlapping antenna), where the second width is less than the first width. This local variation allows the metal layer to provide sufficient bonding strength in non-antenna areas while minimizing interference with the antenna in the overlapping region, thus resolving the contradiction between bonding strength and antenna reception sensitivity.
2Reliability
If the sealing member is formed with a large width to ensure complete sealing, then the sealing reliability is improved, but the stress concentration increases causing potential damage to the display module
Solution Approach 1:
The sealing member is designed with different forming widths in different regions: a first forming width in the first region and a second forming width in the second region, where the second forming width is greater than the first forming width. This local variation allows the sealing member to provide adequate sealing in critical areas while reducing stress concentration in regions where less sealing is needed, thus resolving the contradiction between sealing reliability and stress concentration.
3Strength
If the sealing member width is uniformly large to prevent stress, then the mechanical strength is improved, but the antenna reception sensitivity deteriorates due to increased interference with the antenna
Solution Approach 1:
The sealing member is designed with different forming widths in different regions: a first forming width in the first region (away from antenna) and a second forming width in the second region (overlapping antenna), where the second forming width is greater than the first forming width. This local variation allows the sealing member to provide adequate mechanical strength in non-antenna areas while minimizing interference with the antenna in the overlapping region, thus resolving the contradiction between mechanical strength and antenna reception sensitivity.
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 approach maintains antenna reception sensitivity and increases the mechanical strength of the display module by controlling the sealing member's width variation during the curing process, preventing stress and damage.
Implementation Method 1
The sealing member may be melted and cured by a laser beam emitted onto the sealing member.
Data Source
AI summary
A method of manufacturing a display device includes forming on a first substrate a display element and a metal layer surrounding the display element, the metal layer including a first portion having a first width and a second portion having a second width less than the first width, forming on a second substrate a sealing member surrounding the display element, the sealing member including a first sealing portion having a first forming width and a second sealing portion having a second forming width greater than the first forming width, arranging the first substrate and the second substrate such that the sealing member on the second substrate faces the first substrate, the first sealing portion overlaps the first portion of the metal layer, and the second sealing portion overlaps the second portion of the metal layer, and sealing the first and second substrates by melting and curing the sealing member.