Display Substrate Bending Structures for Dense Cell Separation
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Solution Overview
Problem
The challenge in fabricating display devices is to increase the number of display cells on a mother substrate while minimizing the spacing between them, which affects the overall efficiency and aesthetics of the display device.
Innovation Solution
A method involving a first substrate with specific edge and corner configurations, including obtuse angles and undercuts, and a second substrate with similar features, allowing for a single process to separate display cells and minimize spacing by intersecting cell-cut lines with bending patterns during fabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the spacing between display cells is reduced to increase the number of display cells on the mother substrate, then the productivity and density of display cells are improved, but the manufacturing precision and structural integrity become more difficult to maintain
Solution Approach 1:
The substrate is divided into multiple display cells separated by bending areas. The cell-cut lines are designed to intersect with the bending patterns, creating distinct segments that can be independently controlled. This segmentation allows for reduced spacing between cells while maintaining individual cell integrity through the bending area structures.
Solution Approach 2:
The bending areas and cell-cut lines are pre-designed and positioned before the final assembly. The bending patterns are formed in advance to create the necessary spacing and structural support. This preliminary action ensures that when display cells are arranged on the mother substrate, the spacing is controlled and consistent, enabling higher density without compromising manufacturing precision.
2Area of stationary object
If the non-display area is reduced to increase the display area ratio, then the aesthetics and immersion are improved, but the ease of manufacture and fabrication complexity increase
Solution Approach 1:
The bending areas and cell-cut lines are merged into a single integrated structure that serves multiple functions: they define the display cell boundaries, create the necessary spacing, and maintain structural integrity. This merging reduces the need for separate manufacturing steps and simplifies the fabrication process while achieving the desired display area ratio.
Solution Approach 2:
The bending areas serve multiple purposes: they act as spacing elements between display cells, provide structural support for the substrate, and define the boundaries of the display area. This multi-functionality reduces the overall complexity of the device structure and simplifies manufacturing by eliminating the need for separate components for each function.
3Ease of manufacture
If the cell-cut lines intersect the bending patterns to separate display cells in a single process, then the ease of manufacture is improved, but the manufacturing precision and structural integrity become more difficult to maintain
Solution Approach 1:
The bending areas act as intermediary structures between adjacent display cells. The cell-cut lines are designed to intersect with these bending patterns, which serve as mediators that facilitate the separation process. This intermediary structure enables single-process separation while maintaining precision, as the bending areas provide a controlled interface where the cut lines can be positioned accurately.
Solution Approach 2:
The bending patterns are pre-formed and positioned before the cell separation process. The cell-cut lines are designed to intersect with these pre-existing bending patterns at predetermined locations. This preliminary action ensures that when the separation process occurs, the intersection points are accurately controlled, maintaining manufacturing precision while enabling ease of manufacture through single-process operation.
Data Source
AI summary
A display device includes a first substrate including a first sub-substrate in line with a main area; and a second substrate including a second sub-substrate in line with a pad area and spaced apart from the first sub-substrate with the bending area between the first sub-substrate and the second sub-substrate, the first sub-substrate includes an edge portion at an edge surrounding the first sub-substrate in plan view, the edge portion includes a first side surface facing the bending area, a second side surface spaced apart from the first side surface, and a first corner between the first side surface and the second side surface, and the first sub-substrate has a different cross-sectional shapes at the first side surface, the second side surface and the first corner in cross-section.