LED Panel Optical Film Bonding for Bubble-Free Flat Displays
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Solution Overview
Problem
Existing light-emitting diode panels face issues with surface flatness and air bubble generation during optical film attachment, leading to poor display quality and reduced reliability in high-temperature and high-humidity environments due to adhesive layer thickness variations.
Innovation Solution
A display apparatus design featuring a first adhesive layer covering light-emitting units and extending into interspaces, with a second adhesive layer having varying thicknesses to eliminate air bubbles, and incorporating a light reduction film to enhance display contrast and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the thickness of the adhesive layer is increased to improve surface flatness, then air bubble generation is reduced, but reliability performance in high temperature and high humidity environment deteriorates
Solution Approach 1:
The adhesive layer is designed with different thicknesses at different locations: a first adhesive layer with smaller thickness (5-15 μm) positioned at the light-emitting unit area, and a second adhesive layer with larger thickness (15-30 μm) positioned at the non-light-emitting unit area. This local differentiation allows the non-light-emitting area to provide surface flatness while the light-emitting area maintains thin adhesive for reliability.
2Device complexity
If a single adhesive layer is used to bond the optical film, then the structure is simple, but air bubbles are likely to be generated affecting display quality
Solution Approach 1:
The adhesive layer is segmented into two distinct parts: a first adhesive layer and a second adhesive layer, each with different thicknesses and positions. This segmentation allows optimization of each layer's function - the thinner first layer prevents bubbles at critical areas while the thicker second layer provides overall surface flatness.
3Manufacturing precision
If the adhesive layer thickness is uniformly increased, then air bubble generation is reduced, but the reliability performance deteriorates
Solution Approach 1:
The adhesive layer is designed with different thicknesses at different locations: a first adhesive layer with smaller thickness (5-15 μm) positioned at the light-emitting unit area, and a second adhesive layer with larger thickness (15-30 μm) positioned at the non-light-emitting unit area. This local differentiation allows the non-light-emitting area to provide surface flatness while the light-emitting area maintains thin adhesive for reliability.
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 design prevents air bubble formation, improves surface flatness, and enhances display apparatus reliability in high-temperature and high-humidity conditions by using adhesive layers with differential thicknesses and a light reduction film.
Implementation Method 1
The first adhesive layer is disposed between the light reduction film and the light-emitting units, and extends into multiple interspaces between the light-emitting units. The second adhesive layer is disposed between the first adhesive layer and the light reduction film, and connects the first adhesive layer.
Data Source
AI summary
A display apparatus including a circuit substrate, a plurality of light-emitting units, an optical film, a first adhesive layer and a second adhesive layer is provided. The light-emitting units are electrically bonded to the circuit substrate. The optical film overlaps the light-emitting units that are disposed between the optical film and the circuit substrate. The optical film includes a light reduction film overlapping a light-emitting surface of the light-emitting units away from the circuit substrate. The first adhesive layer is disposed between the light reduction film and the light-emitting units, and extends into interspaces between the light-emitting units. The second adhesive layer is disposed between the first adhesive layer and the light reduction film. The second adhesive layer has a first portion overlapping the light-emitting units and a second portion overlapping the interspaces. A thickness of the first portion is different from a thickness of the second portion.