Flat Panel Display UV Curing via Diffusion Ink
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Solution Overview
Problem
In flat panel display apparatuses, the bonding between the window and the panel is often defective due to incomplete curing of the resin layer, particularly in regions with a flexible printed circuit board (FPCB), as UV rays are blocked by the black matrix and FPCB, leading to incomplete curing and potential product defects.
Innovation Solution
A black matrix with a black ink part for blocking UV rays and a diffusion ink part, made of carbon black and UV-transmitting materials like acrylic resin, cyclohexanone, and aromatic hydrocarbon solvent, is used to allow UV rays to penetrate and cure the resin layer effectively, even in areas with FPCB, by forming the diffusion ink part at positions corresponding to the FPCB and in the image region.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If UV rays are irradiated from above the window to cure the resin layer, then the bonding between window and panel is achieved, but the resin layer below the black matrix is not cured well due to UV ray blocking
Solution Approach 1:
The patent introduces a new dimension for UV ray irradiation by adding side irradiation sources that illuminate the resin layer from the lateral direction through the black matrix regions. This multi-directional approach allows UV rays to reach previously shadowed areas below the black matrix, ensuring complete curing of the resin layer while maintaining effective bonding between the window and panel.
Solution Approach 2:
The patent segments the UV irradiation process into multiple independent irradiation zones: top irradiation for general curing and side irradiation for targeted curing of regions blocked by the black matrix. This segmentation allows each irradiation source to focus on specific areas, ensuring comprehensive coverage and complete curing throughout the entire resin layer.
2Manufacturing precision
If UV rays are irradiated from sides of the window to eliminate blocked regions, then curing improves in black matrix areas, but FPCB blocks UV rays and prevents complete curing
Solution Approach 1:
The patent applies local quality by positioning side UV irradiation sources specifically at regions where the black matrix blocks UV rays, while avoiding direct irradiation through the FPCB area. The irradiation intensity and angle are optimized for local curing needs in the black matrix region without being obstructed by the flexible printed circuit board, achieving selective curing where needed.
Solution Approach 2:
The patent uses the window structure itself as an intermediary medium that allows UV rays to reach the resin layer at its edges and sides. By irradiating from the sides of the window, UV rays can curve through the resin layer and reach areas below the black matrix without being blocked by the FPCB, which is positioned elsewhere in the assembly.
3Shape
If a black matrix is formed to cover the edge of the image region, then aesthetic appearance is improved, but UV ray transmission is blocked causing bonding defects
Solution Approach 1:
The patent resolves the contradiction by adding a lateral irradiation dimension that bypasses the UV-blocking function of the black matrix. Side-mounted UV sources illuminate the resin layer from the edges, allowing UV rays to penetrate through or around the black matrix and cure the resin in previously inaccessible areas, thus maintaining both the aesthetic edge coverage and bonding reliability.
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 solution ensures complete curing of the resin layer, enhancing the bonding between the window and the panel, thereby reducing the likelihood of defects and improving the manufacturing process efficiency.
Implementation Method 1
a resin layer that is UV curable and is configured to bond the panel and the window
Implementation Method 2
a black ink part for blocking UV rays
Implementation Method 3
a diffusion ink part for transmitting UV rays
Data Source
AI summary
A flat panel display apparatus includes a panel including an image region on which an image is realized, a window covering the panel, a black matrix formed in the window along a side edge of the image region, and a resin layer that is ultraviolet (UV) curable and that bonds the panel and the window. The black matrix includes a black ink part for blocking UV rays, and a diffusion ink part for transmitting UV rays. In the flat panel display apparatus, the resin layer for window bonding is sufficiently cured in all regions, including a region thereof under the black matrix, so that a bonding defect in the window due to insufficient curing of the resin layer is significantly decreased.