Display Panel Packaging Cavity for Uniform Adhesive Thickness
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Solution Overview
Problem
The existing manufacturing methods for mini-LED or micro-LED display devices face challenges in controlling the thickness of the packaging adhesive, leading to thickness differences between display panels, which affect the performance of spliced screens and display devices.
Innovation Solution
A manufacturing method that involves providing a backplane with a light emitting device and a cover with a supporting wall to enclose a cavity, where the packaging adhesive is injected and cured, ensuring a stable film thickness and reducing thickness errors by maintaining a predetermined distance between the backplane and the cover.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If packaging adhesive is directly formed on backplane without supporting structure, then manufacturing process is simple, but thickness of packaging adhesive cannot be controlled and varies between panels
Solution Approach 1:
The patent introduces a supporting wall as an intermediary structure between the backplane and cover. This supporting wall serves as a mediator that defines the cavity space and provides mechanical support, enabling precise control of packaging adhesive thickness while maintaining a relatively simple manufacturing process. The supporting wall acts as the intermediate element that resolves the contradiction between process simplicity and thickness precision.
Solution Approach 2:
The supporting wall is formed on the backplane before the packaging adhesive is applied. This preliminary action establishes the cavity boundaries and thickness reference before the adhesive filling process, ensuring that the subsequent adhesive application results in uniform thickness. By performing the supporting structure creation in advance, the patent achieves precise thickness control without complicating the overall manufacturing process.
2Productivity
If packaging adhesive thickness is not controlled, then manufacturing process is simple, but thickness difference between display panels affects splicing screen performance
Solution Approach 1:
The supporting wall serves as a mediator that ensures consistent packaging adhesive thickness across multiple display panels. By providing a standardized supporting structure on each panel, the patent enables reliable thickness control that ensures consistent optical and mechanical properties when panels are spliced together, thereby maintaining splicing screen performance while preserving manufacturing efficiency.
Solution Approach 2:
The patent controls the thickness parameter of the packaging adhesive by introducing a supporting wall with predetermined height. This changes the thickness parameter from being a variable dependent on application process to being a fixed parameter determined by the supporting wall geometry, ensuring consistent display performance in spliced screens while maintaining efficient manufacturing.
3Device complexity
If packaging adhesive lacks support ability for cover, then structure is simple, but thickness difference of display panels is enlarged
Solution Approach 1:
The supporting wall acts as an intermediary support structure between the backplane and cover. It provides the necessary mechanical support to maintain consistent spacing and prevent cover deformation, thereby controlling display panel thickness consistency. The supporting wall adds minimal structural complexity while effectively solving the thickness consistency problem.
Solution Approach 2:
The supporting wall is prepared in advance on the backplane before assembly with the cover. This preliminary preparation ensures that the support function is already in place to maintain thickness consistency, avoiding the need for complex post-assembly adjustments or additional support structures that would increase device complexity.
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 improves the uniformity of the packaging adhesive thickness across display panels, enhancing the display performance of spliced screens and devices by stabilizing the adhesive film thickness.
Implementation Method 1
injecting a packaging adhesive into the cavity to be injected and curing the packaging adhesive to form the display panel
Data Source
AI summary
A manufacturing method of a display panel, a manufacturing method of a splicing screen, and a display device are provided, which relates to the technical field of manufacturing display devices. In the present disclosure, when a backplane and a cover are packaged, a supporting wall is first disposed so that the supporting wall, the backplane, and cover together enclose a cavity to be injected for accommodating a light emitting device, and then a packaging adhesive is injected. It reduces a thickness error of the packaging adhesive in the display panel, and reduces a thickness difference of the packaging adhesive in different display panels to be spliced.