Resin-Filled Layer Alignment for Display Panel Assembly
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Solution Overview
Problem
In display panel manufacturing, achieving high positioning accuracy is challenging due to limitations in reducing hole displacement errors, which affects the alignment of outer edges in mobile devices like smartphones, where a separate member such as a sheet or film is stacked in multiple layers.
Innovation Solution
A display device is designed with layers stacked such that their outer edges coincide in orthogonal directions, and holes across layers communicate with each other, with resin continuously filled and cured over the entirety of the layers, even if holes are displaced, ensuring accurate alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If screws or pins are used to fix multiple layers, then the layers can be assembled together, but the outer edges of the layers are displaced when hole positions are displaced
Solution Approach 1:
A resin layer is introduced as an intermediary substance between the multiple layers. The resin fills the holes and cures to form a bonding medium that connects the layers together, replacing the direct mechanical connection through screws or pins. This intermediary resin compensates for hole position displacements while maintaining outer edge alignment of the layers.
Solution Approach 2:
The invention changes the bonding method from rigid mechanical fastening (screws/pins) to a more flexible chemical bonding approach using resin. The resin's ability to flow and adapt to varying hole positions, then cure to a solid state, provides tolerance for position variations while achieving strong bonding and precise outer edge alignment.
2Area of stationary object
If high accuracy is required for positioning the display panel and outer edges in mobile devices, then the display area can be maximized, but the hole position error cannot be reduced below a certain limit
Solution Approach 1:
The invention converts the harmful effect of hole position displacement into a beneficial feature. Instead of requiring precise hole alignment, the resin is designed to flow and fill holes even when they are misaligned, then cure to provide strong bonding. This transforms the manufacturing challenge of achieving precise hole positioning into an advantage where a range of hole positions are acceptable.
Solution Approach 2:
The resin's physical parameters (viscosity, curing time, expansion characteristics) are optimized to accommodate hole position variations. The resin can flow to fill misaligned holes, then cure to maintain the outer edge alignment of layers, effectively decoupling the precision requirements of hole positioning from outer edge alignment.
3Manufacturing precision
If resin is used to fill holes across multiple layers, then high positioning accuracy is achieved despite hole displacement, but the manufacturing process becomes more complex
Solution Approach 1:
The invention merges the bonding function and the hole-filling function into a single resin application step. Instead of separately aligning holes and then inserting fasteners, the resin is applied to fill holes and simultaneously bond the layers together. This consolidation simplifies the overall manufacturing process while achieving high positioning accuracy.
Solution Approach 2:
The resin application process provides continuous useful action by simultaneously achieving multiple objectives: filling misaligned holes, bonding layers together, and maintaining outer edge alignment. The continuous nature of resin flow and curing eliminates the need for separate adjustment and fastening steps, reducing process complexity.
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 method achieves high positioning accuracy by allowing resin to fill and cure across displaced holes, ensuring the outer edges of the layers align correctly, thereby improving the accuracy of the display panel assembly.
Implementation Method 1
a resin continuously filled in the holes over the entirety of the plurality of layers
Data Source
AI summary
A display device includes a plurality of layers stacked such that outer edges thereof coincide with each other at both ends in at least one of a first direction and a second direction that are orthogonal to each other and each layer including holes communicating in the stacking direction at a plurality of positions, and a resin continuously filled in the holes over the entirety of the plurality of layers. The plurality of layers include a display panel including a display area. The display panel includes the corresponding holes outside the display area. The holes of the plurality of layers are displaced in a plan view, as compared with the matching accuracy of the outer edges.