Flexible Display Panel Sidewall Sealing via Laser Melted Adhesion

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Solution Overview

Problem

Conventional methods for manufacturing flexible display panels fail to effectively protect the sides of the display film from external moisture, as bended protection films cannot conform to corners, leading to reduced moisture protection and potential damage due to temperature-induced bubble volume variations.

Innovation Solution

A manufacturing method involving thermal melt-able adhesion layers and protection films, where a laser is used to melt and re-solidify the adhesion layers and protection films to form a sidewall structure that completely surrounds the display film, ensuring comprehensive protection against moisture intrusion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If protection films are bended from upper and lower surfaces to side surfaces, then coverage of side surfaces is improved, but conformance to corners is poor and bubbles remain

Engineering Contradiction:

Improvecoverage area of protection filmVSAvoidconformance to corners

Core Design Contradiction:

Area of stationary objectVSManufacturing precision

Solution Approach 1:

The protection structure is divided into two parts: a protection film for the display film and a separate sidewall structure for the corners. The sidewall structure is formed by melting and re-solidifying adhesion layer material to create a dedicated corner protection element that can conform to corner geometries, while the protection film maintains its function on flat surfaces.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The corner protection structure combines multiple materials: the adhesion layer material (which is melted and re-solidified), the protection film material, and the driving substrate material. This composite structure allows the sidewall to conform to corners while maintaining protection against moisture.

Inventive Principle:

Principle #40Composite materials

2Area of stationary object

If protection films are adhered with larger area than driving substrate, then side surface coverage is improved, but thermal expansion causes separation

Engineering Contradiction:

Improvearea of protection filmVSAvoidadhesion stability under thermal changes

Core Design Contradiction:

Area of stationary objectVSReliability

Solution Approach 1:

The adhesion layer material undergoes phase transition from solid to liquid when melted by laser, then re-solidifies to form the sidewall structure. This phase transition allows the material to flow and conform to corner geometries, then solidifies to create a stable, thermally-resistant structure that maintains adhesion under thermal expansion and contraction.

Inventive Principle:

Principle #36Phase transitions

3Object-affected harmful factors

If bended protection films are used, then side surface protection is achieved, but moisture intrusion occurs at corners

Engineering Contradiction:

Improveprotection against moistureVSAvoidcorner coverage

Core Design Contradiction:

Object-affected harmful factorsVSManufacturing precision

Solution Approach 1:

The protection system is segmented into a protection film for flat surfaces and a separate sidewall structure for corner protection. The sidewall structure is specifically formed to address corner coverage, ensuring that moisture cannot intrude at these vulnerable locations while the protection film provides broadside coverage.

Inventive Principle:

Principle #1Segmentation

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

The method effectively prevents external moisture from entering the display panel, extending its lifespan by ensuring complete coverage and sealing of the display film's sides, even under temperature changes.

Implementation Method 1

a laser is used to melt and re-solidify materials to form a sidewall structure around the display film

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

The material of the first adhesion layer is thermal melt-able. The sidewall structure is in contact with a side surface of the display film and includes the material of the first adhesion layer which is melted and re-solidified

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS9632373B2Display panel and manufacturing method of display panel

Publication Date: 2017.04.25 E INK HLDG INC

AI summary

A display panel including a driving substrate, a display film, a first protection film, a first adhesion layer, and a sidewall structure is provided. The display film is disposed on the driving substrate. The first protection film is adhered on the display film through the first adhesion layer. The display film is located between the driving substrate and the first protection film. A material of the first adhesion layer is thermal melt-able. The sidewall structure is in contact with a side surface of the display film and includes the material of the first adhesion layer which is melted and re-solidified. In addition, a manufacture method of the display panel includes irradiating the driving substrate the first protection film and the first adhesion layer with a laser to form the sidewall structure in contact with the side surface of the display film.