Inkjet Cover Window Fabrication with Integrated Panel Bonding
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Solution Overview
Problem
Existing methods for manufacturing cover windows for display devices often require separate processes for fabrication and bonding, which can lead to inefficiencies and potential defects.
Innovation Solution
A method that integrates the fabrication of a cover window and its bonding to a display panel using an inkjet technique, allowing for simultaneous production of a desired 3D shape, with precuring and high-energy curing to enhance adhesion, and optionally incorporating a printed pattern to define non-display areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If separate processes are used for cover window fabrication and bonding, then process flexibility is maintained, but manufacturing efficiency decreases and potential defects increase
Solution Approach 1:
The patent combines the cover window fabrication process and bonding process into a single integrated operation. The inkjet printing system simultaneously deposits window material and bonding adhesive in one pass, eliminating the need for separate fabrication and bonding steps. This merging of processes directly improves manufacturing efficiency while the automation of the integrated system manages the complexity.
Solution Approach 2:
The inkjet printing system performs multiple functions simultaneously: it acts as both the window material deposition system and the bonding adhesive application system. This multi-functionality allows a single piece of equipment to accomplish what previously required separate specialized processes, thereby improving productivity without proportionally increasing device complexity.
2Manufacturing precision
If inkjet technique is used for window material deposition, then manufacturing precision and 3D shape capability are improved, but process complexity increases
Solution Approach 1:
The patent replaces traditional mechanical window fabrication methods (such as stamping, molding, or manual assembly) with an inkjet printing system. This substitution enables precise digital control over material deposition, allowing for complex 3D shapes and high manufacturing precision. The digital nature of inkjet printing simplifies process control compared to mechanical systems, managing the complexity through software rather than mechanical complexity.
Solution Approach 2:
The inkjet printing system allows for dynamic adjustment of deposition parameters such as material viscosity, deposition speed, layer thickness, and curing conditions. These parameter changes enable the system to achieve high manufacturing precision for various 3D window shapes while maintaining process flexibility. The ability to programmatically control parameters reduces the need for physical reconfiguration, managing complexity through digital control.
3Strength
If precuring is performed before bonding, then adhesion strength is enhanced, but manufacturing time increases
Solution Approach 1:
The patent applies a preliminary curing step to the bonding adhesive immediately after deposition but before final bonding. This partial curing (precuring) enhances the adhesive's tack and initial bond strength, improving overall adhesion. The precuring is performed rapidly using UV or other appropriate energy sources integrated into the printing system, minimizing the time added to the process while achieving significant adhesion improvement.
Solution Approach 2:
The patent maintains continuous operation by integrating the precuring step directly into the bonding workflow without interruption. The inkjet system deposits material, the precuring unit immediately treats the adhesive, and bonding follows seamlessly. This continuous flow eliminates idle time between steps, ensuring that the precuring enhancement to adhesion strength does not significantly increase total manufacturing 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 integrated approach minimizes defects and enhances the manufacturing efficiency by allowing for simultaneous fabrication and bonding, resulting in a robust and precise cover window attachment.
Implementation Method 1
In the ejecting of the window raw material, the window raw material is ejected into the mold by an inkjet technique
Implementation Method 2
curing the precured window raw material
Data Source
AI summary
A method of manufacturing a display device, the method including ejecting a window raw material into a mold, precuring the ejected window raw material, molding a cover window by placing the precured window raw material onto a display panel and curing the precured window raw material, and separating the mold from the cover window.