Folded Flexible Display Panel Thermocompression Bonding
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Solution Overview
Problem
The manufacturing of foldable display devices with large flexible display panels poses challenges due to the difficulty in ensuring a sufficiently large mounting stage for the flexible printed circuit substrate, as existing apparatuses are not designed to accommodate the larger size requirements of these devices.
Innovation Solution
A method involving thermocompression bonding between the frame terminal of the flexible display panel and the counter terminal of the flexible printed circuit substrate, where the flexible display panel is folded to allow only the abutting portion to be on the mounting stage, enabling the connection without requiring an auxiliary stage or altering the existing mounting apparatus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If a large flexible display panel is used for foldable display devices, then the display size and functionality are improved, but the mounting stage size required for manufacturing becomes excessively large, making it difficult to use existing manufacturing apparatuses
Solution Approach 1:
The flexible display panel is divided into a display region and a frame region, with the frame region further divided into first and second regions. The first region contains the terminal area for bonding, while the second region can be folded over during mounting. This segmentation allows the panel to be mounted in a folded state on a standard-sized stage, resolving the contradiction between large panel size and limited stage area.
Solution Approach 2:
The mounting process utilizes the folding dimension of the flexible display panel. By folding the panel along a predetermined line, the two-dimensional area requirement on the mounting stage is reduced. The panel is mounted in a folded configuration, allowing standard manufacturing apparatuses to handle large display panels that would otherwise exceed stage dimensions.
2Area of stationary object
If the flexible display panel is folded during mounting, then the mounting stage size requirement is reduced, but the alignment and bonding precision between terminals becomes more difficult to ensure
Solution Approach 1:
The flexible display panel is pre-folded along a predetermined folding line before the bonding process. This preliminary folding action positions the terminal region in a known, stable configuration that facilitates precise alignment with the flexible printed circuit substrate terminals, ensuring bonding precision despite the folded state.
Solution Approach 2:
Thermocompression bonding is used to replace traditional mechanical bonding methods. This thermal process provides more consistent and precise bonding results, ensuring reliable electrical connection between terminals even when the panel is in a folded configuration during mounting.
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 the successful manufacturing of foldable display devices with large display panels using standard manufacturing apparatuses, ensuring effective electrical connection and simplifying the mounting process without the need for additional infrastructure.
Implementation Method 1
the thermocompression bonding is performed in a state in which the flexible display panel is folded
Data Source
AI summary
A method for manufacturing a display device includes a mounting process in which a frame terminal of a flexible display panel and a counter terminal of a flexible printed circuit substrate are electrically connected by thermocompression bonding. In the mounting process, the thermocompression bonding is performed in a state in which the flexible display panel is folded so that the flexible display panel includes an abutting portion abutting on a mounting stage and a folding portion where the flexible display panel is to be folded over the abutting portion in plan view.