Mask Layer Integration for Laser Sealing Protection
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Solution Overview
Problem
The manufacturing process of conventional flat panel displays is costly and time-consuming due to the need for expensive sealing masks and alignment systems to protect the driving circuit from laser damage during sealing, as the masks must be larger than the substrates and are only usable for a few months.
Innovation Solution
Integrating a mask layer with the second substrate, where its projection on the first substrate overlaps the driving circuit, eliminating the need for a separate sealing mask and alignment system by using a laser beam that irradiates the sealing material while being reflected by the mask layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate sealing mask is used to protect the driving circuit from laser damage, then the driving circuit is protected, but the manufacturing cost increases and assembly time increases due to alignment requirements
Solution Approach 1:
The patent merges the sealing mask function with the second substrate by forming a mask layer directly on the second substrate. This integration eliminates the need for a separate sealing mask and alignment system, reducing device complexity while maintaining the protection function during laser sealing processes
Solution Approach 2:
The mask layer on the second substrate serves multiple functions: it protects the driving circuit from laser damage and acts as part of the sealing structure itself. This multi-functionality eliminates the need for separate protection components and alignment mechanisms
2Reliability
If a sealing mask larger than the substrate is used, then the driving circuit is fully protected, but the manufacture cost increases due to material waste and short usage life
Solution Approach 1:
The mask layer is formed only on the specific region of the second substrate where protection is needed (the area that will overlap the driving circuit during assembly). This localized approach reduces material usage and manufacturing cost while providing sufficient protection, eliminating the need for oversized masks
3Manufacturing precision
If an alignment system is installed for the sealing mask, then the masking precision is improved, but the assembly time increases
Solution Approach 1:
By integrating the mask layer with the second substrate, the patent eliminates the separate alignment step between mask and substrate. The mask layer is inherently aligned with the substrate since it is formed on it, removing the alignment system and reducing assembly time while maintaining precision
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 approach prevents damage to the driving circuit during the laser process, reduces manufacturing costs, and shortens assembly time by eliminating the need for expensive sealing masks and alignment systems.
Implementation Method 1
using a laser beam that irradiates the sealing material while being reflected by the mask layer
Data Source
AI summary
A display device includes a first substrate, a second substrate and a sealing material. The first substrate includes an active area and a driving circuit. The driving circuit has a first side facing the active area and a second side opposite to the first side. The second substrate includes a mask layer. A projection of the mask layer on the first substrate at least overlaps the driving circuit from the second side to the first side. The sealing material is between the second substrate and the first substrate, used for sealing the second substrate and the first substrate, and located beside the second side of the driving circuit.