Silicon OLED Array Substrate Edge Extension for Cover Plate Protection

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Solution Overview

Problem

Silicon-based OLED display devices face issues with glass cover plate breakage during positioning and locking in AR/VR devices, and the manufacturing process of cutting glass cover plates leads to uneven edges and damage to cutting machines.

Innovation Solution

A display device design where the array substrate extends beyond the cover plate at its edges, allowing for non-contact positioning and fixing, and the cover plate is not cut during manufacturing, preventing damage and improving bonding precision and mechanical strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the glass cover plate is cut during manufacturing to fit the array substrate, then the bonding precision can be improved, but the glass cover plate edges become uneven and prone to breakage

Engineering Contradiction:

Improvebonding precisionVSAvoidglass cover plate strength

Core Design Contradiction:

Manufacturing precisionVSStrength

Solution Approach 1:

Instead of cutting the glass cover plate to match the array substrate dimensions, the patent inverts the approach by making the array substrate smaller than the glass cover plate. The array substrate's orthographic projection is contained within the glass cover plate's orthographic projection, allowing the glass cover plate to extend beyond the array substrate edges. This eliminates the need for cutting the glass cover plate while maintaining proper bonding and alignment.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent segments the device structure into distinct regions: the array substrate region, the glass cover plate region, and an extended region where the glass cover plate protrudes beyond the array substrate. This segmentation allows each component to maintain its optimal dimensions and properties independently, with the glass cover plate retaining its full size and strength while the array substrate is positioned within its boundaries.

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If the glass cover plate is cut during manufacturing, then the bonding area can be optimized, but the cutting machine may be damaged and production efficiency decreases

Engineering Contradiction:

Improvebonding area optimizationVSAvoidproduction efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent eliminates the cutting step by inverting the dimensional relationship between components. Instead of reducing the glass cover plate to match the array substrate, the array substrate is positioned within the glass cover plate boundaries. This removes the harmful cutting operation entirely, preventing machine damage and maintaining high production efficiency while achieving optimal bonding area.

Inventive Principle:

Principle #13The other way round (Inversion)

3Ease of operation

If the array substrate is positioned to extend beyond the cover plate edges, then the positioning and fixing operation becomes easier, but the risk of glass cover plate breakage increases

Engineering Contradiction:

Improvepositioning and fixing easeVSAvoidglass cover plate integrity

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent inverts the positioning relationship by ensuring the array substrate remains within the glass cover plate boundaries rather than extending beyond them. This allows positioning and fixing operations to be performed on the array substrate without contacting the glass cover plate edges, eliminating the risk of breakage while maintaining ease of operation.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent uses the non-display region of the array substrate as an intermediary for positioning and fixing operations. This intermediary region allows external fixtures and tools to interact with the array substrate without transmitting force to the glass cover plate, thereby facilitating ease of operation while protecting glass cover plate integrity.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Volume of moving object

If the cover plate size matches the array substrate exactly, then the device structure is compact, but the positioning and fixing operations cause glass cover plate breakage

Engineering Contradiction:

Improvedevice compactnessVSAvoidglass cover plate durability

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The patent inverts the size relationship by making the glass cover plate larger than the array substrate rather than matching its dimensions exactly. The glass cover plate's orthographic projection contains the array substrate's orthographic projection, creating a protective margin that prevents breakage during positioning and fixing while maintaining overall device compactness through optimized spatial arrangement.

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentUS11563192B2Display device having some edges of cover plate that do not overlap with the underlying array substrate and method for manufacturing the same

Publication Date: 2023.01.24 BOE TECHNOLOGY GROUP CO LTD

AI summary

A display device and a method for manufacturing a display device are provided. The display device includes an array substrate and a cover plate. The array substrate is a silicon-based organic light-emitting diode array substrate. An orthographic projection of the array substrate in a plane parallel to the array substrate covers an orthographic projection of the cover plate in the plane, the orthographic projection of the array substrate includes a plurality of edges, the orthographic projection of the cover plate includes a plurality of edges, the plurality of edges of the array substrate are in one-to-one correspondence to the plurality of edges of the cover plate. At least two edges of the orthographic projection of the array substrate do not overlap with corresponding edges of the orthographic projection of the cover plate and are located outside the orthographic projection of the cover plate.