Protective Adhesive Layer Design for Bubble-Free Display Modules
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Solution Overview
Problem
Conventional display module manufacturing processes often result in bubbles forming between the polarizer and the protective adhesive layer due to the surface tension of the adhesive, leading to a poor appearance and increased risk of metal wire breakage in the bending area, which complicates the achievement of a narrow bezel.
Innovation Solution
A display module design that includes a protective adhesive layer with a first protection portion covering the bending area and a second protection portion between the first protection portion and the polarizer, ensuring the adhesive layer's surface energy is greater than the adhering layer's, preventing gaps and bubbles, and reducing stress on metal wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protective adhesive layer is provided to cover the bending area, then the breaking risk of metal wires is reduced, but bubbles form between the cover plate and polarizer due to surface tension of the adhesive
Solution Approach 1:
A release film is introduced as an intermediary layer between the protective adhesive layer and the polarizer. This release film prevents the adhesive from directly bonding to the polarizer surface, allowing bubbles to escape during assembly while maintaining the protective function against metal wire breaking.
Solution Approach 2:
The surface energy parameters of the adhesive layer are optimized to control the wetting behavior and bubble formation. By adjusting the surface energy of the protective adhesive layer relative to the adhering layer, the patent prevents gap formation and bubble entrapment while maintaining adequate adhesion for protection.
2Manufacturing precision
If the protective adhesive layer has high surface energy to prevent gaps, then attachment is improved, but bubble formation increases due to surface tension
Solution Approach 1:
The release film serves as a mediator that decouples the relationship between adhesive surface energy and bubble formation. It allows the adhesive to have high surface energy for good attachment while preventing direct contact that would trap bubbles.
Solution Approach 2:
The patent optimizes the surface energy parameters of the protective adhesive layer to be greater than the adhering layer, which prevents gap formation and improves attachment quality, while using the release film to counteract the bubble-forming tendency of high surface energy adhesives.
3Reliability
If the adhesive layer covers the bending area, then metal wire protection is improved, but stress concentration occurs leading to potential breakage
Solution Approach 1:
The protective adhesive layer is designed as a thin film that flexes with the bending area, accommodating the stress and deformation during bending without causing stress concentration that would lead to metal wire breakage.
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 design enhances the attachment of the optical adhesive layer, reduces bubble formation, improves yield, and protects metal wires, allowing for a narrower bezel and better appearance of the display module.
Implementation Method 1
surface energy of the protective adhesive layer is greater than the surface energy of the adhering layer
Data Source
AI summary
A display module, a polarizer assembly, a method for manufacturing a display module, and a display apparatus. The display module includes a display panel, where a non-active area of the display panel includes a bending area; a polarizer, disposed at a first side of the display panel, where at least a part of the polarizer covers an active area of the display panel; and a protective adhesive layer, disposed at the first side of the display panel, where the protective adhesive layer includes a first protection portion and a second protection portion, the first protection portion covers at least a part of the bending area, the second protection portion is located between the first protection portion and the polarizer, and along a thickness direction of the display panel, a maximum dimension of the second protection portion is less than or equal to a dimension of the polarizer.