Glass Spacer Laser Sintering for LCD Bezel Minimization
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Solution Overview
Problem
Conventional liquid crystal display devices face challenges with bezel area minimization, adhesive reliability, and moisture barrier effectiveness due to the use of double-sided tape and glass frit, which are prone to delamination and moisture penetration.
Innovation Solution
A display device with a spacer made of glass material having a uniform width, attached using laser beams, integrates the display panel and light guide plate, providing a low water vapor transmission rate and enhancing design compatibility and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If double-sided tape is used to attach the display panel to the mold frame, then the attachment process is simple, but the adhesive power is low causing delamination and twisting in hot and humid environments
Solution Approach 1:
The patent changes the material parameters from organic double-sided tape to inorganic glass frit, which has higher thermal stability and adhesive strength. The glass frit maintains its bonding properties in hot and humid environments where polymer-based tapes fail, resolving the reliability issue while keeping the attachment process relatively simple through dispensing and firing.
Solution Approach 2:
The patent uses glass frit as a composite material consisting of glass powder and inorganic binder, combining the advantages of glass (high stability, low WVTR) with binding capabilities. This composite material provides both strong adhesion and moisture barrier properties, overcoming the limitations of single-material solutions.
2Strength
If glass frit is used to attach the light guide plate and display panel, then the bonding force is strong, but it is difficult to control the width and height of the sealant
Solution Approach 1:
The patent performs preliminary actions by pre-forming spacers with precise dimensions before applying the glass frit. These spacers act as physical guides and limits, ensuring that the glass frit is contained within specific width and height boundaries during dispensing. This preliminary structuring solves the dimension control problem while maintaining the strong bonding properties of glass frit.
Solution Approach 2:
The patent introduces spacers as intermediary elements between the glass frit and the final structure. These spacers serve as both structural supports and dimensional control mechanisms, allowing the glass frit to achieve its full bonding potential without the manufacturing precision issues of direct application.
3Strength
If glass frit is melted by heat to achieve attachment, then the bonding is strong, but adjacent optical sheets may be deformed or wavelength conversion layer may be damaged
Solution Approach 1:
The patent segments the heating process into localized zones using laser beams. Instead of applying heat uniformly across the entire assembly, the laser selectively melts the glass frit only at the attachment points between components. This segmented thermal approach achieves strong bonding while preventing thermal damage to adjacent optical sheets and wavelength conversion layers.
Solution Approach 2:
The patent replaces conventional thermal field heating (affects large area) with laser beam heating (localized energy). This substitution of the heating mechanism allows precise control of thermal energy, concentrating it only where needed for glass frit melting while minimizing thermal exposure to sensitive optical components.
4Ease of manufacture
If conventional bonding agents are used, then the attachment is achieved, but they cannot prevent moisture penetration due to high water vapor transmission rate
Solution Approach 1:
The patent employs glass frit as a composite material with inherently low water vapor transmission rate. The glass powder and inorganic binder create a dense, non-porous structure that provides both attachment and moisture barrier functions. This composite approach simultaneously achieves bonding strength and moisture protection, unlike single-material bonding agents.
Solution Approach 2:
The glass frit creates an inert barrier environment between the display panel and external moisture. The fired glass frit forms a hermetic seal that prevents moisture and oxygen penetration, protecting the internal components. This inert barrier property is inherent to the glass material and is enhanced by the sintering process that creates a dense, impermeable structure.
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
The solution minimizes bezel area, ensures reliable attachment, and prevents moisture penetration, thereby improving the longevity and performance of the display device.
Implementation Method 1
a light guide plate and a display panel are integrated with each other by means of a spacer having a uniform width along a thickness direction by melting the spacer having a uniform width along the thickness direction by means of laser beams
Data Source
AI summary
Disclosed herein are a display device and a method of manufacturing the same. The display device includes: a display panel including a first substrate, a second substrate disposed opposite to the first substrate, and a liquid crystal layer disposed between the first substrate and the second substrate; a light guide plate configured to receive light from light sources disposed on a side surface thereof, and to emit the light to the display panel; an optical sheet disposed between the light guide plate and the first substrate; and a spacer disposed and attached between the display panel and the light guide plate. The spacer has a uniform width along a thickness direction.