Electro-optic Display Adhesive Alignment for Mass Production

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Solution Overview

Problem

The long-term image quality of electro-optic displays, particularly electrophoretic displays, is compromised due to particle settling, which limits their widespread adoption, and existing manufacturing methods are not well-suited for mass production of solid electro-optic displays.

Innovation Solution

A process involving a sub-assembly with a front sheet, a layer of electro-optic medium, and an adhesive layer, where apertures are formed in the adhesive layer to facilitate alignment and mounting on a backplane, allowing for precise positioning and integration of electronic circuit devices, enabling efficient mass production of electro-optic displays.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If electrophoretic displays are used, then low power consumption and good brightness are achieved, but particle settling occurs leading to poor long-term image quality

Engineering Contradiction:

Improvepower consumptionVSAvoidimage quality stability

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The display medium is divided into multiple discrete microcapsules, each containing electrophoretic particles suspended in fluid. This segmentation prevents particle settling across the entire display area by confining particles within individual capsules, thereby maintaining long-term image quality while preserving the low power consumption characteristics of electrophoretic displays.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Electrophoretic particles are nested within microcapsules that contain suspending fluid. This nested structure allows the particles to remain suspended in a controlled environment within each capsule, preventing settling while maintaining the electro-optic functionality of the display medium.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Ease of manufacture

If existing manufacturing methods are used, then electro-optic displays can be produced, but mass production efficiency is poor

Engineering Contradiction:

Improvemanufacturing feasibilityVSAvoidmass production efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent forms a sub-assembly with the electro-optic medium layer and adhesive layer before final mounting on the backplane. Apertures are pre-formed in the adhesive layer to facilitate alignment and positioning. This preliminary assembly approach streamlines the manufacturing process and enables more efficient mass production.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces traditional mechanical alignment and attachment methods with a chemical bonding approach using adhesive layers. The adhesive layer with pre-formed apertures allows for precise positioning and secure attachment of the electro-optic medium to the backplane, simplifying the manufacturing process and improving production efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If alignment and integration processes are simplified, then mass production efficiency improves, but alignment precision may be compromised

Engineering Contradiction:

Improvemass production efficiencyVSAvoidalignment precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The adhesive layer serves as an intermediary between the electro-optic medium and the backplane. It provides both the alignment function through pre-formed apertures and the bonding function, eliminating the need for separate mechanical alignment and attachment steps. This intermediary approach maintains alignment precision while significantly improving manufacturing efficiency.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 enhances the alignment and integration of electro-optic displays, improving their image stability and enabling cost-effective mass production, addressing the issues of particle settling and manufacturing inefficiencies.

Implementation Method 1

an adhesive layer, the adhesive layer being larger in at least one dimension than the layer of electro-optic material

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS9554495B2Electro-optic displays, and materials and methods for production thereof

Publication Date: 2017.01.24 SAMSUNG ELECTRONICS CO LTD

AI summary

An electro-optic display is produced using a sub-assembly comprising a front sheet, an electro-optic medium; and an adhesive layer. An aperture is formed through the adhesive layer where the adhesive layer is not covered by the electro-optic medium, and the sub-assembly is adhered to a backplane having a co-operating member with the aperture engaged with a co-operating member, thus locating the sub-assembly relative to the backplane. In another form of electro-optic display, a chip extends through an aperture in the electro-optic medium and adhesive layer. In a third form, the aforementioned sub-assembly is secured to a backplane and then a cut is made through both backplane and sub-assembly to provide an aligned edge.