Flat Panel Display Glass Film Substrate Cost Reduction
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Solution Overview
Problem
The high cost of glass substrates in flat panel displays, particularly due to their expense and the increased costs associated with larger sizes, necessitates the development of a substitute material or manufacturing technologies to reduce these costs.
Innovation Solution
A flat panel display is manufactured using a glass film formed by depositing and hardening glass powder or glass paste over a substrate, eliminating the need for a separate upper glass substrate and simplifying the manufacturing process by integrating the glass film directly onto the lower substrate, thereby reducing material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two glass substrates are used in flat panel display manufacturing, then structural integrity and display quality are maintained, but manufacturing costs increase significantly
Solution Approach 1:
The invention extracts the upper glass substrate from the display structure and replaces it with a glass film formed directly on the lower substrate. This eliminates the need for a separate upper substrate while maintaining the protective and structural functions, thereby reducing material costs and simplifying the manufacturing process.
Solution Approach 2:
The invention merges the functions of the upper substrate with the glass film layer. The glass film is formed directly on the lower substrate using screen printing or deposition techniques, combining the protective function previously provided by a separate upper substrate with the display structure itself, reducing the number of components and assembly steps.
2Area of stationary object
If larger glass substrates are used for bigger displays, then display area increases, but material costs and handling difficulty increase
Solution Approach 1:
The invention segments the upper substrate function into a thin glass film that can be deposited directly on the lower substrate. This allows the display area to be increased without proportionally increasing material costs, as the glass film uses significantly less material than a complete upper substrate would require.
3Reliability
If traditional two-substrate assembly process is used, then display quality is maintained, but manufacturing complexity and time increase
Solution Approach 1:
The invention merges the upper substrate attachment process with the glass film formation process. The glass film is formed directly on the lower substrate using screen printing or deposition, eliminating the need for separate alignment, bonding, and sealing operations required in traditional two-substrate assembly, thereby reducing manufacturing complexity and cycle time.
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 significantly reduces manufacturing costs by eliminating the need for two glass substrates and simplifies the production process, making it more economical, especially for larger displays.
Implementation Method 1
depositing glass powder over the substrate, including the array, melting the deposited glass powder over the array and hardening the deposited glass powder over the array
Implementation Method 2
melting the deposited glass powder over the array
Implementation Method 3
hardening the deposited glass powder over the array
Data Source
AI summary
A flat panel display includes a substrate, an array on the substrate, and a glass film formed by depositing glass powder over the substrate, including the array, melting the deposited glass powder over the array and hardening the deposited glass powder over the array.