Display Panel Protective Layer for Moisture-Resistant Bonding
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Solution Overview
Problem
Current display devices face challenges in enhancing reliability, particularly in the fabrication process, where ensuring the integrity and protection of the display panel and circuit board interfaces while minimizing moisture and corrosion is difficult.
Innovation Solution
A display device design that includes a protective layer with a protrusion having an island shape, where the optical layer is aligned with the display panel and circuit board, and a resin is applied through a hole in the optical layer to form a protective layer between the optical layer and the circuit board, ensuring alignment and preventing moisture ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protective layer is formed between the optical layer and the display panel, then moisture protection and corrosion prevention are improved, but the fabrication complexity increases due to additional alignment and bonding steps
Solution Approach 1:
The protective layer is divided into multiple protrusions that are separately formed and then bonded to the display panel. Each protrusion can be independently positioned and aligned, allowing for modular assembly that reduces overall fabrication complexity while maintaining comprehensive moisture protection coverage.
Solution Approach 2:
The protrusions are pre-formed on the protective layer before bonding to the display panel. This preliminary formation allows for precise positioning and alignment markings to be created in advance, simplifying the subsequent bonding process and reducing alignment complexity during final assembly.
2Strength
If the optical layer is precisely aligned with the display panel, then bonding integrity is improved, but manufacturing precision requirements increase
Solution Approach 1:
The protrusions serve as intermediary elements between the optical layer and the display panel. These protrusions include alignment markings that facilitate precise positioning during bonding, acting as a mediator that guides the alignment process and reduces the overall precision requirements for the bonding operation.
Solution Approach 2:
Instead of requiring precise alignment across the entire optical layer, the alignment is achieved through localized alignment markings on the protrusions. This partial alignment approach focuses precision requirements on specific critical points rather than the entire surface, reducing overall manufacturing precision demands.
3Strength
If resin is applied through a hole in the optical layer, then bonding between layers is improved, but the risk of moisture ingress through the hole increases
Solution Approach 1:
The optical layer is designed with a flexible membrane structure that can be sealed around the hole after resin application. This thin film approach allows the hole to be opened for resin injection while maintaining the ability to seal it afterward, preventing moisture ingress while preserving the bonding benefits of resin application.
Solution Approach 2:
The hole is temporarily created and used for resin application, then removed or sealed after the resin is applied. This extraction approach allows the resin bonding function to be achieved while eliminating the persistent vulnerability of an open hole that would allow moisture ingress.
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 solution enhances the reliability of the display device by forming a robust protective layer that prevents moisture and corrosion, while also ensuring proper alignment and bonding between the optical layer and the circuit board, thereby improving the overall durability and performance.
Implementation Method 1
applying a resin solution between the mold and the display panel through a hole formed in the mold, forming a protective layer between the mold and the display panel by curing the resin solution
Data Source
AI summary
A display device includes a display panel including a display area in which pixels are provided, and a non-display area located on a side of the display area, a circuit board bonded to the display panel in the non-display area, and electrically connected to the pixels, an optical layer provided on the display panel in the display area, and a protective layer disposed on the display panel in the non-display area. A top surface of the protective layer includes a protrusion having an island shape, or a trace formed by removing at least a portion of the protrusion.