Multi-Stack Joined Body for Display Devices
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Solution Overview
Problem
Existing methods for joining transparent members in display devices, such as LCDs and OLEDs, face limitations in joining strength and gas permeability, with methods like sealant and glass frit/glass powder techniques offering insufficient strength and vulnerability to foreign substances.
Innovation Solution
A multi-stack joined body structure is introduced, featuring a first and second transparent member with an intermediate layer in between, where the joining region lacks a physical boundary, utilizing materials like silicon oxide, silicon nitride, or metal materials, and formed using laser irradiation to enhance adhesiveness and reduce gas permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If sealant or glass frit/glass powder is used for joining transparent members, then the joining process is simple, but the joining strength is limited (about 6 MPa for sealant, about 10 MPa for glass frit)
Solution Approach 1:
The patent merges the intermediate layer and the joining interface into a unified structure where the intermediate layer protrudes into the glass member to form an integrated joining region. This eliminates the separate interface between the intermediate layer and glass member, creating a continuous material flow that achieves ultra-high joining strength exceeding 100 MPa while maintaining manufacturing simplicity.
2Reliability
If sealant material is used for joining, then the joining process is straightforward, but the sealant is vulnerable to infiltration of foreign substances such as gas and moisture because it includes organic material
Solution Approach 1:
The patent changes the material parameter of the joining interface from organic sealant to inorganic material by forming the intermediate layer that protrudes into the glass member. This material transformation eliminates the vulnerability to gas and moisture infiltration while maintaining ease of manufacture through a single integrated forming process that creates the protruding structure directly.
3Strength
If a physical boundary is maintained at the joining interface, then the structure is simple to manufacture, but the joining strength per unit area is limited
Solution Approach 1:
The patent segments the intermediate layer into two functional portions: a first portion that forms the joining interface with the glass member and a second portion that extends into the glass member. This segmentation creates a protruding structure that increases the effective joining area and eliminates the physical boundary, achieving ultra-high joining strength exceeding 100 MPa while maintaining manufacturing precision through controlled formation of the protruding portion.
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 configuration achieves significantly improved joining strength, exceeding 100 MPa per unit area, and low gas permeability, enhancing the reliability and durability of display devices by eliminating physical interfaces between the members.
Implementation Method 1
forming a joining region in which a physical boundary is not provided between the first transparent member and the intermediate layer and between the second transparent member and the intermediate layer by irradiating the stacked body with a laser
Implementation Method 2
a joining region in which a physical boundary is not provided... by irradiating the stacked body with a laser
Data Source
AI summary
A multi-stack joined body includes a first transparent member, a second transparent member disposed on the first transparent member, and an intermediate layer interposed between the first transparent member and the second transparent member, where a joining region in which a physical boundary is not provided between the first transparent member and the intermediate layer and between the second transparent member and the intermediate layer is provided across the first transparent member, the intermediate layer, and the second transparent member.