Display Panel Mother Substrate Sealing Structure

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Solution Overview

Problem

The manufacturing process of display panels faces challenges in reducing dead space and maintaining bonding performance and cutting accuracy, as decreasing the sealing portion width or cutting margin can lead to reduced bonding strength and increased cutting errors.

Innovation Solution

A mother panel design featuring a second sealing member with unit patterns whose width decreases along a direction away from the first sealing member, which supports the substrates and minimizes cutting errors while maintaining bonding strength by increasing contact areas and reducing overlap with cutting lines.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If the width of the sealing portion is decreased to reduce dead space, then the proportion of the pixel portion is improved, but the bonding performance between substrates deteriorates

Engineering Contradiction:

Improvedead spaceVSAvoidbonding performance

Core Design Contradiction:

Area of stationary objectVSStrength

Solution Approach 1:

The sealing portion is divided into a first sealing portion and a second sealing portion with different functions. The first sealing portion (inner) provides bonding between substrates, while the second sealing portion (outer) provides cutting margin and structural support, allowing each segment to optimize its specific function without compromising the other

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the sealing portion are given different properties: the first sealing portion has properties optimized for bonding (contacting both substrates), while the second sealing portion has properties optimized for cutting margin and error prevention (extending beyond the first sealing portion), allowing each local region to fulfill its specific requirement

Inventive Principle:

Principle #3Local quality

2Area of stationary object

If the cutting margin is decreased to reduce dead space, then the proportion of the pixel portion is improved, but cutting errors and sealing portion performance deterioration occur

Engineering Contradiction:

Improvedead spaceVSAvoidcutting accuracy

Core Design Contradiction:

Area of stationary objectVSManufacturing precision

Solution Approach 1:

The sealing portion is segmented into two functional zones: the first sealing portion for bonding and the second sealing portion specifically designed to provide cutting margin, allowing the cutting margin function to be separated from the bonding function and optimized independently

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The second sealing portion is pre-formed to extend beyond the first sealing portion, creating a built-in buffer zone that anticipates and compensates for potential cutting errors before the cutting process occurs, ensuring cutting accuracy is maintained

Inventive Principle:

Principle #10Preliminary action

3Area of stationary object

If the width of the sealing portion is decreased to reduce dead space, then the proportion of the pixel portion is improved, but bonding strength is reduced

Engineering Contradiction:

Improvedead spaceVSAvoidbonding strength

Core Design Contradiction:

Area of stationary objectVSForce

Solution Approach 1:

The sealing portion is divided into functional segments where the first sealing portion maintains bonding strength by contacting both substrates, while the second sealing portion compensates for reduced width by extending outward to provide structural support and cutting margin

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first and second sealing portions are combined to form an integrated sealing structure that simultaneously provides bonding function and cutting margin function, allowing the overall sealing portion to maintain adequate width for bonding while minimizing dead space through the strategic design of the second sealing portion

Inventive Principle:

Principle #5Merging (Combining)

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 design enhances bonding performance and prevents cutting errors by ensuring consistent contact areas and minimizing overlap with the second sealing member, thus improving the efficiency of the cutting process and reducing dead space in display panels.

Implementation Method 1

bonding a first mother substrate and a second mother substrate by melting and hardening a sealing portion disposed between the first and second mother substrates

Methodology Applied

Scientific EffectBonding: Adhesive

Implementation Method 2

second sealing members comprising unit patterns, wherein a width of each unit pattern in a second direction perpendicular to a first direction decreases along the first direction which is a direction away from each of the first sealing members

Methodology Applied

Scientific EffectGeometric pattern design: Geometry

Data Source

PatentUS9655243B2Display panel and mother panel for manufacturing the same

Publication Date: 2017.05.16 SAMSUNG DISPLAY CO LTD

AI summary

A mother panel including second sealing members which are disposed at an outer side of each of first sealing members which surround display devices between a first mother substrate and a second mother substrate and have a plurality of unit patterns whose width in a second direction which is perpendicular to a first direction which is a direction away from each of the first sealing members decreases along the first direction.