Display Panel Step Smoothing Member Design
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Solution Overview
Problem
The manufacturing process of liquid crystal displays faces stress concentration and potential damage due to steps formed by partial adhesion of polarizers on the lower panel, leading to structural instability and risk of damage during panel assembly and handling.
Innovation Solution
A display panel design incorporating a step smoothing member with a melting point above 150°C, matching the thickness of the lower polarizer, positioned under the lower substrate without overlapping the polarizer, and a polymer cushioning material on lateral surfaces to absorb impacts and distribute pressure uniformly, thereby eliminating the step and reducing the risk of damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a polarizer is partially adhered to the lower panel, then the polarizer can be positioned correctly, but a step is formed causing stress concentration and potential damage
Solution Approach 1:
A step smoothing member is introduced as an intermediary component between the lower substrate and the lower polarizer. This member fills the step gap created by partial adhesion, providing a smooth transition surface that eliminates stress concentration points while maintaining the polarizer's correct positioning.
Solution Approach 2:
The step smoothing member is positioned in advance to prevent stress concentration before it can cause damage. By pre-compensating for the step formation, the structure is protected against potential damage during subsequent manufacturing processes and panel assembly.
2Ease of manufacture
If the lower panel area is larger than the upper panel area, then driver and wires can be disposed at the exposed region, but a step is formed between polarizer regions
Solution Approach 1:
The step smoothing member acts as a mediator that bridges the height difference between regions with and without polarizer adhesion. This allows the larger lower panel area to maintain its structural stability while still providing the necessary exposed region for driver and wire placement.
3Manufacturing precision
If the polarizer area is smaller than the lower panel area, then the polarizer can be properly positioned, but stress concentration occurs at the step
Solution Approach 1:
The step smoothing member serves as a protective intermediary that eliminates the sharp step transition. This prevents stress concentration at the boundary between polarizer-adhered and non-adhered regions, thereby improving the panel's reliability and resistance to damage during manufacturing and handling.
Solution Approach 2:
By pre-installing the step smoothing member, the structure is protected against stress concentration before damaging forces are applied. This beforehand cushioning ensures that the panel maintains its integrity throughout the manufacturing process.
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 effectively prevents stress concentration and damage by smoothing the step caused by polarizer adhesion, ensuring stable panel assembly and reducing the likelihood of lateral impact damage during manufacturing processes.
Implementation Method 1
a step smoothing member compensating for a step due to partial adhesion of a polarizer to the lower panel
Implementation Method 2
a polymer cushioning material disposed at a lateral surface of the upper substrate and the lower substrate
Data Source
AI summary
A display panel includes: an upper substrate, a lower substrate disposed under the upper substrate, a lower polarizer disposed under the lower substrate, and a step smoothing member disposed under the lower substrate and not overlapping with the lower polarizer.