Display Device Reinforcement Layer Segmentation for Adhesion

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Solution Overview

Problem

Existing display devices face challenges in achieving strong adhesion between the reinforcement layer and the functional layer, often resulting in separation issues due to non-flat surfaces and inefficient manufacturing processes.

Innovation Solution

The display device incorporates a method of fabricating module layers with a flat reinforcement layer surface by cutting a base module layer, which includes a reinforcement layer, an adhesive layer, and a functional layer, along scribing lines, thereby eliminating bump and slope shapes that can weaken adhesion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the reinforcement layer is formed continuously from edge to edge, then the structural strength is improved, but the surface becomes non-flat with bumps and slopes that weaken adhesion

Engineering Contradiction:

Improvestructural strengthVSAvoidsurface flatness

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The reinforcement layer is segmented into multiple sections separated by grooves, which allows each section to be formed independently with flat surfaces while maintaining overall structural strength through the adhesive layer connections

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The problematic bump and slope portions are extracted/removed by forming grooves that separate the reinforcement layer into distinct flat sections, eliminating the non-flat surfaces that cause adhesion failures

Inventive Principle:

Principle #2Taking out (Extraction)

2Productivity

If multiple module layers are produced from a single base module layer, then manufacturing productivity is improved, but the complexity of the fabrication process increases

Engineering Contradiction:

Improvemanufacturing productivityVSAvoidfabrication process complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The base module layer is prepared in advance with pre-formed grooves and adhesive layers positioned ready for separation, allowing multiple module layers to be produced through a single cutting operation without requiring additional preparation steps

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The complex multi-step mechanical assembly process is replaced by a single laser cutting operation that simultaneously separates multiple module layers from the base module layer, simplifying the fabrication process

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 approach enhances the adhesion between the functional layer and the reinforcement layer, improving the structural integrity of the display device and reducing manufacturing time by allowing multiple module layers to be produced from a single base module layer.

Implementation Method 1

cutting the base module layer by irradiating a laser beam to the base module layer along the scribing line

Methodology Applied

Scientific EffectLaser heating: Laser

Data Source

PatentUS20250160173A1Display device and method for fabricating the same

Publication Date: 2025.05.15 SAMSUNG DISPLAY CO LTD

AI summary

A display device includes: a substrate; a first electrode on the substrate; a pixel defining layer on the first electrode; a light emitting layer on the first electrode and the pixel defining layer, a second electrode on the light emitting layer; an encapsulation layer on the second electrode; an adhesive layer on the encapsulation layer, a reinforcement layer on the adhesive layer, and a functional layer on the reinforcement layer.