Flat Display Panel Protection Layer for Structural Strength
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Solution Overview
Problem
The manufacturing process of flat display panels often results in defects such as dimples, scratches, and cracks on the glass substrates, which reduce the structural strength of the panels and lead to failures in bending, squeeze, or pull tests, thereby affecting yield.
Innovation Solution
A flat display panel structure that includes a first and second substrate with a sealant between them, and a protection layer in the space formed by the substrates' edges, enhancing structural strength without compromising display quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the glass substrates are thinned by etching process, then the thickness of the flat display panel is reduced, but defects such as dimples, scratches and cracks are formed on the surfaces
Solution Approach 1:
The invention divides the substrate structure into multiple functional layers: the original glass substrates, sealant layers at the edges, and a protection layer filling the space between substrates. This segmentation allows the thinning process to proceed while the protection layer compensates for surface defects, resolving the contradiction between thickness reduction and surface quality maintenance.
Solution Approach 2:
The protection layer is introduced as a beforehand cushioning measure to compensate for potential defects (dimples, scratches, cracks) that may occur during thinning and manufacturing processes. This layer acts as a buffer that prevents defect propagation and maintains structural integrity, allowing aggressive thinning without compromising final product quality.
2Ease of manufacture
If defects such as dimples, scratches and cracks occur on the glass substrates, then the structural strength of the flat display panel is reduced, but the manufacturing process cannot be simplified
Solution Approach 1:
The invention creates a composite structure by combining the glass substrates with sealant materials and protection layer materials. This composite approach allows the use of standard manufacturing processes (maintaining ease of manufacture) while the combined structure provides enhanced defect tolerance and structural strength that neither component could achieve alone.
Solution Approach 2:
The sealant and protection layer act as intermediary elements between the glass substrates. These intermediaries fill gaps, compensate for defects, and distribute stresses, thereby maintaining structural strength without requiring changes to the core manufacturing process of the glass substrates themselves.
3Length of stationary object
If the etching depth is increased to reduce thickness, then the thickness is reduced to predetermined value, but the number and size of dimples increase
Solution Approach 1:
The invention converts the harmful effect of increased dimpling (caused by deeper etching) into a beneficial structure. The protection layer is specifically designed to fill and compensate for these dimples, transforming what would be defects into a controlled feature that can be systematically addressed. This allows aggressive thinning while the protection layer serves as a corrective measure that actually improves overall uniformity.
Data Source
AI summary
A flat display panel includes a first substrate, a second substrate opposite to the first substrate, a sealant disposed between the first and second substrates. The sealant, the edge of the inner surface of the first substrate, and the edge of the inner surface of the second substrate form a space, and the flat display panel further includes a protection layer disposed inside the space so as to reinforce the structural strength of the flat display panel.