Getter Encapsulation Sheet for Flat Panel Displays
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Solution Overview
Problem
The existing methods for mounting a getter in flat panel display devices to prevent moisture penetration are complex and time-consuming, and can lead to contamination due to outgassing from binder materials.
Innovation Solution
A method involving an encapsulation sheet with a getter and sealant, where the getter is formed on one sheet and the sealant with a corresponding space is formed on another sheet, allowing them to be folded together and attached to a substrate, simplifying the process and avoiding vacuum coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If getter paste is coated around the display unit by dispensing or screen printing in a vacuum, then the getter can be mounted to absorb moisture, but the process becomes complicated and time consuming
Solution Approach 1:
The encapsulation sheet is divided into multiple layers: a first sheet with the getter formed thereon, and a second sheet with sealant. This segmentation allows the getter to be pre-formed on the first sheet in a simple process, avoiding complex vacuum coating while maintaining moisture absorption functionality.
Solution Approach 2:
The getter is pre-formed on the first sheet before final assembly. By preparing the getter in advance on the encapsulation sheet rather than coating it in situ during vacuum processing, the method simplifies the overall mounting process and reduces time consumption while ensuring proper getter placement.
2Ease of manufacture
If getter paste with binder is used for coating, then the getter can be applied to the display unit, but outgassing from the binder contaminates the display unit
Solution Approach 1:
The harmful binder component is extracted from the getter application process. Instead of using getter paste that requires binder, the invention forms the getter directly on the first sheet through deposition or other binder-free methods, eliminating outgassing and contamination while maintaining ease of manufacture.
Solution Approach 2:
The first sheet acts as a disposable carrier that holds the getter during manufacturing. The getter is formed on this temporary substrate and then transferred to the final device, allowing the use of simple, low-cost materials for the first sheet that can be discarded after serving their purpose.
3Productivity
If a simple getter mounting method is used, then the process becomes faster and less complex, but the getter may not be securely attached
Solution Approach 1:
The getter mounting process is merged with the encapsulation sheet formation process. The getter is formed on the first sheet during encapsulation sheet manufacturing, and the sealant on the second sheet simultaneously provides both sealing and secure attachment functions, achieving reliable mounting without additional complex steps.
Solution Approach 2:
The encapsulation sheet combines multiple materials with different functions: the first sheet provides a substrate for getter formation, the getter provides moisture absorption, and the sealant provides sealing and bonding. This composite structure ensures secure attachment while maintaining simple, fast manufacturing.
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 simplifies the getter mounting process, reduces contamination risks, and effectively absorbs moisture, enhancing the stability of the display unit without the need for complex vacuum coating.
Implementation Method 1
a getter that surround the display unit to absorb moisture
Data Source
AI summary
An encapsulation sheet, a flat panel display device, and a method of manufacturing a flat panel display device are disclosed. The method includes: forming a getter on a first sheet; forming a sealant having a space corresponding to the shape of the getter on a second sheet; forming an encapsulation sheet by folding the first sheet and the second sheet to enter the getter into the space; and attaching the encapsulation sheet on a substrate on which a display unit is formed. When the flat panel display device is manufactured using the above method, the folded sealant and the getter are simultaneously mounted on the substrate, and thus, a complicated conventional process of mounting the getter in a vacuum state is unnecessary.