Display Device Edge Structure for Smaller Non-Display Areas
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Solution Overview
Problem
Existing display devices face challenges in minimizing the non-display area and improving mechanical strength while reducing substrate thickness during the manufacturing process.
Innovation Solution
The display device incorporates a substrate with a specific edge design featuring inclined surfaces and dams, an encapsulating layer, and a heat dissipation layer, along with a manufacturing process using laser irradiation and etching to minimize the non-display area and enhance structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the substrate thickness is reduced to minimize the non-display area, then the aesthetic appeal and immersion are improved, but the mechanical strength of the substrate deteriorates
Solution Approach 1:
The substrate is divided into multiple thin layers (first substrate layer, second substrate layer, third substrate layer) with different orientations and properties. This segmentation allows each layer to contribute differently to the overall mechanical strength, enabling the use of thinner substrates without compromising strength. The layered structure distributes stress across multiple interfaces, preventing catastrophic failure that would occur in a single thin substrate.
Solution Approach 2:
The patent employs composite substrate structures where multiple layers with different materials and orientations are combined. The first substrate layer has a first orientation, the second substrate layer has a second orientation different from the first, and the third substrate layer has a third orientation. This composite approach creates a structure with enhanced mechanical properties that exceed the sum of individual layers, allowing reduced thickness while maintaining or improving strength.
2Area of stationary object
If the non-display area is minimized to improve aesthetics, then the display area ratio is improved, but the space for manufacturing processes and structural integrity deteriorates
Solution Approach 1:
The patent incorporates a first inclined surface and a second inclined surface on the substrate before final assembly. These pre-formed structural features serve as guides and support structures during the manufacturing process, particularly during laser cutting and etching operations. The inclined surfaces are created in advance to facilitate precise cutting while maintaining substrate integrity, ensuring reliable manufacturing even with minimized non-display areas.
3Manufacturing precision
If laser irradiation is used for cutting the substrate, then manufacturing precision is improved, but heat generation causes substrate deformation
Solution Approach 1:
The patent introduces a first cutting auxiliary layer and a second cutting auxiliary layer as intermediary materials between the laser source and the substrate. These auxiliary layers act as heat sinks and protective barriers during laser cutting operations. They absorb excess heat and prevent direct thermal exposure to the substrate, thereby maintaining substrate shape stability while still allowing precise cutting to occur. The auxiliary layers are removed or integrated after the cutting process.
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 effectively reduces the non-display area and enhances the mechanical strength of the display device, improving manufacturing efficiency and aesthetic appeal.
Implementation Method 1
forming a cutting line along the periphery of the display cell by irradiating a laser from the other surface opposite to the one surface of the mother substrate
Implementation Method 2
separating the substrate on which the display cells are formed by etching the mother substrate along the other surface and the cutting line
Data Source
AI summary
A display device includes: a substrate including a display area and a non-display area surrounding the display area; a light emitting element layer on the display area on the substrate and including a plurality of light emitting elements; and an encapsulating layer on the light emitting element layer and on a portion of the display area and the non-display area; and wherein the substrate comprises an upper surface on which the light emitting element layer is located, a bottom surface opposite to the upper surface, a side surface connected to the upper surface and not parallel to the upper surface, and a first inclined surface connected to the side surface and the bottom surface and not parallel to the side surface and the bottom surface, wherein an edge area of the upper surface of the substrate adjacent to an edge of the substrate, in which a processing trace remains.