Display Panel Pre-Forming for Bent Cover Window Adhesion
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Solution Overview
Problem
Existing methods for manufacturing display devices with bent or curved parts face challenges in reliably attaching flexible display panels to cover windows with angled or curved surfaces, often resulting in poor adhesion and increased defect rates.
Innovation Solution
A method and apparatus that pre-forms the display panel to match the shape of the cover window using a guide film and push members, with a seating pad and clamps to ensure precise contact and uniform pressure, allowing for reliable attachment even to surfaces with complex geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the display panel is directly attached to the cover window with bent parts, then the manufacturing process is simple, but the adhesion quality is poor and defect rates increase
Solution Approach 1:
The display panel is pre-formed to match the bent shape of the cover window before attachment. The pre-forming unit deforms the display panel into a predetermined shape corresponding to the bent part shape, ensuring proper conformity and adhesion when attached to the cover window, thereby resolving the adhesion quality issue while maintaining manufacturing simplicity
2Reliability
If the display panel is pre-formed to match the cover window shape, then the adhesion quality improves, but the device complexity increases
Solution Approach 1:
The manufacturing apparatus is divided into separate functional units: a pre-forming unit that shapes the display panel and an attachment unit that joins it to the cover window. This segmentation allows each unit to perform its specific function efficiently, reducing overall system complexity while maintaining high adhesion quality
Solution Approach 2:
A guide film is introduced as an intermediary element between the display panel and the attachment process. The guide film has a groove that guides the display panel into the correct position and shape, simplifying the attachment process and reducing the complexity of the manufacturing apparatus while ensuring high adhesion quality
3Device complexity
If manual attachment methods are used, then the equipment cost is low, but the productivity and precision are reduced
Solution Approach 1:
The pre-forming unit automatically deforms the display panel into the required shape without manual intervention. The guide film self-aligns the display panel with the cover window during attachment, enabling automated high-precision manufacturing that increases productivity while keeping equipment costs reasonable
Data Source
AI summary
A method of manufacturing a display device includes: preparing a cover window including a bent part on a side surface thereof, and a guide film including a surface on which a display panel and an adhesive layer are arranged; arranging the cover window and the guide film in a face-to-face manner such that the adhesive layer faces the cover window; seating the guide film onto a seating pad of a first jig; pre-forming the display panel by bringing opposite ends of the guide film into close contact with opposite side surfaces of the seating pad using a pair of push members; and joining the display panel with the cover window by bringing the adhesive layer into contact with the cover window.