Electro-optic Display Assembly via Apertured Adhesive and Detachable Tabs

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Solution Overview

Problem

Existing methods for assembling solid electro-optic displays, such as encapsulated electrophoretic displays, are costly and not well-suited for mass production, as they require batch processes and can damage thin conductive layers during the formation of electrical connections, leading to potential display failures.

Innovation Solution

A process involving a pre-formed aperture front plane laminate, where an adhesive sub-assembly with apertures is adhered to an electro-optic sub-assembly, allowing for electrical connections without forming apertures through the electro-optic medium, and a detachable tab front plane laminate with weak sections for easy separation, facilitating testing and connection formation without damaging conductive layers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional batch assembly methods are used for electro-optic displays, then manufacturing flexibility is maintained, but production efficiency and cost-effectiveness deteriorate

Engineering Contradiction:

Improvemass production efficiencyVSAvoidassembly process complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The front plane laminate is divided into multiple layers (substrate layer, conductive layer, electro-optic medium layer, adhesive layer) that can be manufactured separately and then assembled. This segmentation enables each layer to be optimized and produced independently, facilitating mass production while maintaining quality control.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The conductive layer is formed on the substrate before the electro-optic medium is applied. This preliminary action allows electrical connections to be established early in the manufacturing process, enabling more efficient assembly and testing procedures that support mass production.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If apertures are formed through the electro-optic medium for electrical connections, then electrical connectivity is achieved, but the thin conductive layers are damaged

Engineering Contradiction:

Improvedisplay functionalityVSAvoiddamage to conductive layers

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The aperture formation process is extracted from the electro-optic medium layer and relocated to the substrate layer. By forming apertures only in the substrate (not through the electro-optic medium), the harmful mechanical stress and potential damage to the thin conductive layers are eliminated while still achieving the necessary electrical connectivity.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The substrate acts as an intermediary layer that bears the mechanical stress of aperture formation. By positioning apertures in the substrate rather than in the electro-optic medium, the substrate absorbs the harmful effects of the drilling process, protecting the conductive layers and electro-optic medium from damage.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If conventional assembly methods are used, then manufacturing simplicity is maintained, but production cost and time increase

Engineering Contradiction:

Improveassembly simplicityVSAvoidassembly time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

Multiple functions are merged into the front plane laminate structure: the substrate provides mechanical support, the conductive layer provides electrical connectivity, the electro-optic medium provides display functionality, and the adhesive layer provides bonding. This integration allows all components to be assembled simultaneously in a single manufacturing step, reducing both time and complexity.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS7843624B2Electro-optic displays, and materials and methods for production thereof

Publication Date: 2010.11.30 E INK CORP

AI summary

A first sub-assembly useful in an electro-optic display is produced by: providing an electro-optic sub-assembly comprising a layer of electro-optic medium; providing an adhesive sub-assembly comprising an adhesive layer, the adhesive layer being larger than the layer of electro-optic medium and having one or more apertures; adhering the adhesive sub-assembly to the electro-optic sub-assembly so that a part of the adhesive layer adheres to the layer of electro-optic medium but the aperture(s) are spaced from the layer of electro-optic medium. A second sub-assembly comprises a conductive layer and a layer of electro-optic medium. The conductive layer has a main section covered by the electro-optic medium, an exposed section free from the electro-optic medium, and a weak section connecting the main section and the exposed section, so that the exposed section can be manipulated to rupture the weak section, thus separating the exposed section from the main section without substantial damage.