Concave Convex Insulation Layer for Display Seal Adhesion
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Solution Overview
Problem
Conventional flat panel display devices face issues with adhesion strength between substrates due to the positioning of sealing materials on level surfaces, making them prone to separation under external impacts.
Innovation Solution
The implementation of concave and convex structures with metal and insulation layers in peripheral regions, along with a sealant that contacts the uneven top surface of an upper insulation layer, enhances adhesion strength by increasing the contact interface and distributing stress more effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If sealing material is positioned on a level surface of insulation layer or metal layer, then the structure is simple and easy to manufacture, but the adhesion strength between substrates is insufficient and substrates are easily separated by external impact
Solution Approach 1:
The patent applies curvature by forming concave and convex patterns on the surface of the insulation layer or metal layer in the sealing region. Instead of a flat level surface, the surface is modified with curved undulations that increase the contact area between the sealing material and the underlying layer, thereby enhancing adhesion strength and resistance to external impacts.
Solution Approach 2:
The patent transitions from a two-dimensional level surface to a three-dimensional concave-convex structure by adding surface undulations. This dimensional change increases the surface area and creates mechanical interlocking features that improve the bonding between the sealing material and the substrate, effectively resolving the adhesion strength issue.
2Reliability
If sealing material is positioned on a level surface, then the manufacturing process is simple, but the contact interface area is small leading to poor stress distribution
Solution Approach 1:
By introducing curved concave-convex patterns on the sealing surface, the patent increases the contact interface area between the sealing material and the underlying layer. This curvature-based modification distributes applied stresses more evenly across the expanded contact area, improving reliability and stress distribution while maintaining manufacturing feasibility through standard patterning techniques.
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 configuration significantly improves the adhesion strength between substrates, enhancing the durability and resistance to external impacts of flat panel display devices.
Implementation Method 1
While the laser is irradiated into the sealing region, the phase of the sealing material may be changed from solid to liquid. Then, the phase of the sealing material may be changed from liquid to solid after predetermined time.
Data Source
AI summary
A display device includes a substrate with a major surface and a cover opposing the substrate. An array of light emitting pixels is disposed over a generally central portion of the major surface, and interposed between the substrate and the cover. A seal is disposed over a peripheral portion of the substrate, and interposed between and interconnecting the substrate and the cover. Between the seal and the substrate, a lower insulation layer, an upper insulation layer, and a structure located between the lower and upper insulation layers and including at least one metal layer. The upper insulation layer includes an uneven top surface. A contour of the uneven top surface of the upper insulation layer may conform with or follow that of the top uneven surface of the structure. The seal contacts and is bonded to the uneven top surface of the upper insulation.