Anti-Reflection Layer Cover Tape Attachment in Flexible Displays
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Solution Overview
Problem
Existing display devices face challenges in easily attaching a cover tape to an anti-reflection layer, particularly in the manufacturing process of flexible display panels with bending areas, which can lead to difficulties in protecting the anti-reflection layer and ensuring proper alignment and attachment of components like the cover tape and window.
Innovation Solution
A method involving a display panel with distinct areas, including a bending area, where an anti-reflection layer is attached and a cover tape is strategically positioned on the driving IC, with precise removal sections of releasing films and laser cutting to facilitate easy attachment and protection of the anti-reflection layer, ensuring it covers only the necessary areas and is not damaged during the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cover tape is attached to an anti-reflection layer in a flexible display panel, then the anti-reflection layer is protected from foreign substances, but the attachment process becomes difficult due to the bending area and releasing film structure
Solution Approach 1:
The releasing film is divided into a first removal section and a second removal section, allowing selective removal in different areas. The first removal section is removed to enable cover tape attachment, while the second removal section remains to protect the anti-reflection layer in the bending area, resolving the contradiction between protection and attachability
Solution Approach 2:
The releasing film is pre-applied to the anti-reflection layer before the cover tape attachment process. This preliminary protective layer is then selectively removed in the first removal section, enabling easy cover tape attachment while maintaining protection in other areas, thus improving ease of manufacture without compromising reliability
2Reliability
If the anti-reflection layer extends to the second area to be covered by cover tape, then protection is provided, but alignment and attachment precision becomes challenging
Solution Approach 1:
The first removal section of the releasing film acts as an intermediary element that facilitates precise alignment. By removing this specific section, a clean attachment surface is created with well-defined boundaries, allowing the cover tape to be accurately positioned and attached without alignment challenges, while the anti-reflection layer continues to extend for full coverage
3Manufacturing precision
If laser cutting is used to cut the releasing film boundary, then precise cutting is achieved, but the anti-reflection layer may be damaged by laser irradiation
Solution Approach 1:
The releasing film is segmented into distinct removal sections with clear boundaries. The laser beam is used to cut only the releasing film along these predefined boundaries, not the anti-reflection layer underneath. This segmentation allows precise cutting of the releasing film while protecting the anti-reflection layer from laser damage
Solution Approach 2:
The releasing film serves as a disposable sacrificial layer that is selectively removed by laser cutting. This temporary element absorbs the laser energy and cutting action, protecting the valuable anti-reflection layer from direct laser exposure while enabling precise boundary definition for cover tape attachment
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 method allows for efficient and precise attachment of the cover tape to the anti-reflection layer, protecting it from foreign substances and ensuring proper alignment, thereby enhancing the manufacturing process and reducing defects in the display device.
Implementation Method 1
cutting a first boundary between the first removal section and the second removal section of the first releasing film by irradiating a laser beam to the first boundary
Data Source
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AI summary
A method for manufacturing a display device (DD) includes preparing a display panel (DP) that includes a first area (AA1), a bending area (BA) extending from the first area (AA1), and a second area (AA2) extending from the bending area (BA), attaching an anti-reflection layer (RPL) to the display panel (DP), removing a first removal section (RPT1) of a first releasing film (RFL1) disposed on the anti-reflection layer (RPL), the first removal section (RPT1) overlapping the second area (AA2) of the display panel (DP) in a plan view, and providing a cover tape (CTP) onto a first section (RPT1) of the anti-reflection layer (RPL) that overlaps the second area (AA2) of the display panel (DP) in a plan view.