Display Panel Non-Flat Surface Resin Flow Control
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Solution Overview
Problem
Film detachment occurs in organic electroluminescent (EL) display panels due to resin flow between panel units, leading to reduced luminance and non-light-emission areas, which is a common issue with both non-flowable and flowable resins used in the adhesion process.
Innovation Solution
A display panel design featuring a non-flat surface with specific recess and protrusion configurations, where the sealing resin layer is in contact with both surfaces, and the distances between these features satisfy certain ratios to minimize resin flow and pressure differences, thereby reducing the risk of film detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a resin layer is used to adhere panel units together, then sealing property is improved, but film detachment occurs due to resin flow
Solution Approach 1:
The patent applies preliminary action by forming a protrusion portion on the first panel unit before adhesion. This protrusion creates a mechanical interlocking structure with the resin layer, preventing film detachment that would otherwise occur due to resin flow during the adhesion process. The protrusion is formed in advance to anticipate and counteract the harmful effect of resin flow.
Solution Approach 2:
The patent applies local quality by creating a non-uniform surface structure on the first panel unit, specifically a protrusion portion with controlled dimensions (D1, D2, W, S parameters). This localized structural modification concentrates the resin in specific areas, creating different resin distribution zones that prevent film detachment while maintaining overall sealing effectiveness.
2Object-affected harmful factors
If non-flowable resin is used to prevent air bubbles, then air bubble formation is reduced, but film detachment still occurs
Solution Approach 1:
The protrusion portion is formed on the first panel unit before the adhesion process begins. This preliminary structural feature ensures that when non-flowable resin is applied and air bubbles are prevented, the protrusion still provides mechanical interlocking to prevent film detachment, thus solving both problems simultaneously.
Solution Approach 2:
The patent specifies precise parameter ranges for the protrusion portion (D1, D2, W, S) to optimize its effectiveness. By controlling these geometric parameters, the protrusion creates optimal resin distribution and mechanical interlocking, preventing film detachment even when using non-flowable resin that lacks self-leveling properties.
3Strength
If resin flow is allowed between panel units, then adhesion strength is improved, but film detachment occurs in light-emitting areas
Solution Approach 1:
The protrusion portion creates localized zones of enhanced adhesion strength through mechanical interlocking, while the surrounding areas maintain controlled resin distribution. This local quality approach ensures strong bonding without the harmful resin flow that causes film detachment in light-emitting areas.
Solution Approach 2:
The resin layer acts as a flexible bonding medium that conforms to the protrusion structure. The resin fills the spaces created by the protrusion, creating a flexible yet strong adhesive bond that prevents film detachment while maintaining adhesion strength across the panel units.
Data Source
AI summary
A display panel including an EL panel unit, a CF panel unit, and a sealing resin layer. In the EL panel, a surface of a sealing layer has a non-flat surface as a whole in a Z-axis direction, with recess portions at light-emitting areas corresponding to regions between banks and protrusion portions at non-light-emitting areas corresponding to tops of the banks. D2<0.90×D1 and S>{(0.90×D1)−D2}×W are satisfied, where D1 (D1(R), D1(G), D1(B)) denotes a distance between the EL panel unit and the CF panel unit at a first recess portion, D2 denotes a distance between the EL panel unit and the CF panel unit at a protrusion portion, W denotes a width of a top of the protrusion portion, and S denotes a cross-sectional area of a second recess portion.