Display Sealing Substrate Light Pattern Layer for Durability
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Solution Overview
Problem
Conventional flat panel display apparatuses face limitations in durability due to inadequate bonding characteristics between the substrate and the sealing substrate, often resulting in defects and reduced reliability.
Innovation Solution
A display apparatus design featuring a light pattern layer on the sealing substrate with distinct patterns for the first and second sealing members, including a light blocking unit, and a method of manufacturing that uses a laser beam to melt and cure these members without an additional mask, enhancing bonding and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional bonding methods are used between substrate and sealing substrate, then manufacturing process is simple, but bonding characteristics are inadequate resulting in poor durability
Solution Approach 1:
The sealing members are preliminarily disposed on the substrate before the sealing substrate is attached. This preliminary positioning allows the laser beam to selectively melt and cure only the sealing member regions when the sealing substrate is bonded, improving bonding characteristics without requiring complex additional masking steps during the bonding process itself.
Solution Approach 2:
The patent replaces conventional thermal bonding methods with laser beam-based selective melting and curing. Instead of using broad thermal fields or mechanical pressure alone, a focused laser beam is used to precisely control the melting and curing of sealing members made of laser-responsive materials, achieving superior bonding characteristics through optical energy conversion.
2Manufacturing precision
If additional mask is used for laser beam processing, then manufacturing precision is improved, but device complexity and manufacturing time increase
Solution Approach 1:
The sealing members are preliminarily disposed on the substrate in their final positions before bonding. This preliminary action eliminates the need for masks during laser processing, as the sealing members themselves define the treatment zones. The laser beam simply needs to follow the predetermined pattern of sealing member locations, achieving high precision without additional masking complexity.
Solution Approach 2:
The patent extracts and eliminates the mask component from the laser processing system by using the sealing members themselves as the defined treatment targets. Instead of using a mask to define where laser energy should be applied, the sealing members are directly disposed in the desired locations and the laser processes only those areas, removing the mask from the system entirely.
3Reliability
If uniform laser beam is used for curing, then processing is simple, but bonding characteristics are inadequate
Solution Approach 1:
The patent implements local quality by creating a light pattern layer with spatially varying optical properties. The light pattern layer includes light blocking units positioned to prevent laser energy from reaching non-sealing areas, while allowing full transmission to sealing member regions. This local differentiation of light transmission ensures that laser energy is concentrated exactly where needed for bonding, improving bonding characteristics through localized energy delivery.
Solution Approach 2:
The light pattern layer serves as an intermediary between the uniform laser beam source and the sealing members. This intermediate layer modifies the uniform laser beam by selectively blocking and transmitting light, creating a non-uniform energy distribution that matches the sealing member pattern. The light pattern layer mediates the transformation from uniform to localized energy delivery without requiring direct mechanical positioning of the laser beam.
4Reliability
If multiple sealing members are disposed close to display unit, then sealing effectiveness is improved, but durability is reduced due to inadequate bonding
Solution Approach 1:
The patent replaces conventional thermal or adhesive bonding methods with laser-induced melting and curing of the sealing members. This substitution enables precise control of the bonding process, allowing multiple sealing members to be reliably bonded even in close proximity to the display unit. The laser beam can be precisely directed to treat each sealing member individually, ensuring adequate bonding characteristics and durability for multiple closely-spaced sealing members.
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 improves the bonding characteristics between the substrate and the sealing substrate, enhancing the durability of the display apparatus while simplifying the manufacturing process and reducing defects.
Implementation Method 1
irradiating a laser beam onto an upper surface of the sealing substrate to melt and cure the first and second preliminary sealing members
Implementation Method 2
melt and cure the first and second preliminary sealing members
Implementation Method 3
melt and cure the first and second preliminary sealing members
Data Source
AI summary
Present embodiments provide a display apparatus including a substrate; a sealing substrate facing the substrate; a display unit between the substrate and the sealing substrate; a first sealing member between the substrate and the sealing substrate to be spaced apart from the display unit, so as to bond the substrate and the sealing substrate to each other; a second sealing member between the substrate and the sealing substrate to be spaced apart from the display unit and the first sealing member, so as to bond the substrate and the sealing substrate to each other; and a light pattern layer on a surface of the sealing substrate opposite to a surface facing the display unit, so as to adjust light intensity transmitted through the sealing substrate. The light pattern layer includes a first pattern corresponding to the first sealing member and a second pattern corresponding to the second sealing member.