Electro-Optic Device Resin Layering for Frame Reduction
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Solution Overview
Problem
Existing electro-optic devices face challenges with a large frame region and uneven resin material distribution, leading to variations in device shape and potential bubbles between resin layers, due to the use of sealing members and low-viscosity resin materials, especially when manufacturing on large-scale mother substrates.
Innovation Solution
The electro-optic device incorporates a casing that overlaps the optical elements along the outer periphery, with a first resin layer forming inside the casing and a second resin layer adhering to the casing, controlling the film thickness and viscosity to suppress wet-spreading and ensure uniform bonding, thereby reducing the frame region and preventing bubbles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sealing member is disposed on the outside of the light-emitting element region, then stress and impact are alleviated, but the frame region increases in size
Solution Approach 1:
The patent removes the sealing member from the configuration, extracting the harmful element that caused both the frame region expansion and the stress concentration issues. Instead, it uses a resin material layer to provide stress relief without requiring a separate sealing member structure
Solution Approach 2:
The patent merges the stress relief function into the resin material layer that is already present in the device structure. By combining the stress relief function with the existing resin layer rather than adding a separate sealing member, the frame region is minimized while still providing necessary stress protection
2Shape
If the resin material has low viscosity to form a flat surface, then surface flatness is improved, but wet-spreading occurs beyond the necessary range
Solution Approach 1:
The patent changes the viscosity parameter of the resin material to a specific range (100-10,000 cP) that balances surface flatness formation with wet-spreading control. This parameter optimization allows the resin to flow sufficiently to fill unevenness while preventing excessive spreading beyond the intended area
Solution Approach 2:
The patent applies a controlled amount of resin material that is sufficient to achieve the desired surface flatness and stress relief functions, but not excessive enough to cause unwanted wet-spreading. The application process is designed to deposit the precise amount needed without over-application
3Reliability
If a first resin layer is applied to cover light-emitting elements and then a second resin layer is applied to adhere the counter substrate, then adhesion is improved, but variation in wet-spreading occurs depending on elapsed time
Solution Approach 1:
The patent segments the resin material application into two distinct layers with different functions: a first resin layer for stress relief and surface formation, and a second resin layer specifically for adhesion. This segmentation allows each layer to be optimized independently, with the second layer applied immediately before counter substrate bonding to ensure consistent adhesion properties
Solution Approach 2:
The patent performs preliminary action by applying the first resin layer and allowing it to form a stable base structure before applying the second resin layer. This preliminary formation of the first layer creates a consistent foundation that reduces variation in the subsequent second layer application and ensures uniform adhesion properties
4Area of stationary object
If the resin material volume is decreased to suppress wet-spreading, then frame region is reduced, but insufficient stress relief may occur
Solution Approach 1:
The patent applies local quality by creating a resin material layer with locally optimized thickness and distribution. The resin layer is configured to have sufficient volume and thickness specifically in the regions where stress relief is needed, while maintaining a compact overall structure that minimizes the frame region. The resin material is strategically positioned to provide maximum stress relief with minimum material volume
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 configuration effectively minimizes the frame region, reduces resin material variation, and prevents bubble formation between resin layers, enhancing the reliability and light transmission efficiency of the electro-optic device.
Implementation Method 1
a second resin layer that is disposed on the first resin layer
Data Source
AI summary
An electro-optic device includes: a first substrate that includes a first surface; an optical element that is disposed in a first region on the first surface; a casing that is disposed to overlap with a part of the optical element along an outer periphery of the first region on the first surface and includes first and second end portions; a first resin layer that is disposed on an inside of the second end portion of the casing on the first surface and is installed to overlap with at least a part of the optical element; a second resin layer that is disposed on the first resin layer; and a second substrate that faces the first surface and is disposed on the second resin layer.