Dot-like Adhesive Coating Pattern for Flat Display Bonding
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Solution Overview
Problem
The existing methods for attaching a protective plate to a liquid crystal display panel using a UV-curable adhesive coating solution face challenges in minimizing the thickness of the bonding layer while preventing air bubbles and adhesive spread, leading to potential image quality deterioration and increased manufacturing costs.
Innovation Solution
A method involving the formation of a wall pattern and dot-like adhesive coating patterns on the protective plate and display panel, with ventilation holes to control the spread of the adhesive, allowing for uniform bonding layer formation without air bubbles and reduced thickness, using a two-way Y-shaped line pattern and specific area ratios for the adhesive patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the protective plate and bonding layer are pressed to adjust the thickness of the bonding layer, then the thickness is minimized and made uniform, but the adhesive coating solution may run out of the space and adhere to the display panel, leading to deterioration of image quality
Solution Approach 1:
The adhesive coating solution is applied in a dot-like pattern rather than uniformly across the entire bonding region. This creates areas of high adhesive concentration (dots) separated by areas with no adhesive, allowing the adhesive to spread locally to fill gaps and form a uniform bonding layer without overflowing onto the display panel.
Solution Approach 2:
The bonding region is divided into multiple discrete dot-like adhesive coating areas. This segmentation allows controlled local spreading of adhesive while preventing continuous overflow. The dots are strategically positioned and sized to ensure complete coverage when spread, eliminating the need for excessive pressing that would cause adhesive to run out.
2Object-affected harmful factors
If the protective plate and bonding layer are weakly pressed to allow natural spread of adhesive, then adhesive overflow is prevented, but the bonding layer thickness cannot be further reduced and air bubbles may form
Solution Approach 1:
The adhesive is applied in dot-like patterns with predetermined size, spacing, and distribution before the bonding process. This preliminary configuration ensures that when mild pressing is applied, the adhesive dots spread naturally to fill the bonding space uniformly without requiring strong pressure that would cause overflow, while still achieving minimal and uniform thickness.
Solution Approach 2:
The adhesive coating is applied in a dot-like pattern with specific area ratios (5-20% of total bonding area) rather than uniform coating. This parameter change in coating distribution allows the adhesive to spread efficiently under mild pressure, filling voids and eliminating air bubbles while maintaining controlled thickness without overflow.
3Stability of the object's composition
If a uniform adhesive coating is applied across the entire bonding region, then complete coverage is achieved, but the adhesive may form air bubbles and the bonding layer thickness increases
Solution Approach 1:
Instead of applying adhesive uniformly across the entire bonding region, the adhesive is applied as discrete dot-like patterns. These segmented adhesive dots are distributed across the bonding area with specific spacing and area ratios. When pressed, the dots spread to fill the space between the protective plate and display panel, achieving complete coverage without trapping air bubbles that would occur with continuous uniform coating.
Solution Approach 2:
The adhesive is concentrated in specific dot-like locations rather than distributed uniformly. This local concentration allows the adhesive to flow and spread efficiently from high-concentration dots to low-concentration areas under mild pressure, ensuring complete coverage while minimizing the total amount of adhesive used and preventing air bubble formation that occurs with uniform thick coating.
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 enables sufficient bonding without adhesive overflow, prevents air bubbles, and allows for a thinner, uniform bonding layer, resulting in high-quality image display and reduced manufacturing costs.
Implementation Method 1
a UV-curable adhesive coating solution is dropped to one of the protective plate and the bonding layer to attach the protective plate and the bonding layer to each other before the UV-cure of the solution
Data Source
AI summary
According to one embodiment, a method for manufacturing a flat display includes applying a dot-like adhesive coating pattern in a region to be bonded on the surface of one of a display panel and a protective plate after forming a wall pattern along the outer circumference of the region to be bonded.