Sealant Structure for Display Substrate Protection and Cut Straightness
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Solution Overview
Problem
Existing display apparatuses face challenges in achieving both adequate protection of substrates and maintaining the straightness of cut portions during the fabrication of large-size display panels, as excessive or insufficient sealant thickness can compromise the integrity and precision of the cut edges.
Innovation Solution
A display apparatus design featuring a sealant with a connection part, bottom part, and extension part, where the extension part's thickness is controlled to ensure coplanarity with the encapsulation layer and optical film, maintaining a horizontal distance greater than 0 and vertical distance less than or equal to half the substrate thickness, collectively shaped as an L or reversed L, to enhance protection and straightness of the cut portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the sealant has excessive thickness, then the protection capacity of the sealant on the substrate is improved, but the straightness of the cut portion of the sealant deteriorates
Solution Approach 1:
The sealant is divided into three functional parts: connection part (for substrate connection), bottom part (for protection), and extension part (for coplanarity). This segmentation allows each part to be optimized independently - the connection and bottom parts provide protection while the extension part ensures straightness by extending beyond the encapsulation layer boundary.
Solution Approach 2:
The sealant structure extends into a third dimension by creating an extension part that protrudes beyond the encapsulation layer in the vertical direction. This dimensional extension allows the sealant to maintain coplanarity with the encapsulation layer outer surface while providing sufficient thickness for protection in the horizontal direction.
2Manufacturing precision
If the sealant has insufficient thickness, then the straightness of the cut portion is improved, but the protection capacity of the sealant on the substrate deteriorates
Solution Approach 1:
The sealant is segmented into connection part, bottom part, and extension part, allowing the protection function to be distributed across multiple segments rather than relying on a single thick layer. The extension part specifically addresses the coplanarity requirement while other parts provide protection.
Solution Approach 2:
Different parts of the sealant have different thickness characteristics optimized for their specific functions. The extension part has sufficient thickness to ensure coplanarity with the encapsulation layer outer surface, while the connection and bottom parts provide localized protection where needed, eliminating the need for uniformly excessive thickness throughout.
3Strength
If the sealant thickness is increased to protect the substrate during splicing, then the protection capacity is improved, but the coplanarity with the encapsulation layer deteriorates
Solution Approach 1:
The extension part extends in the vertical dimension beyond the encapsulation layer boundary, creating a stepped structure. This allows the sealant to maintain coplanarity with the encapsulation layer outer surface at the critical splicing interface while providing additional thickness in the extension part for protection during splicing operations.
Solution Approach 2:
The sealant is segmented into connection part, bottom part, and extension part, with the extension part specifically designed to extend beyond the encapsulation layer. This segmentation allows the coplanarity function to be separated from the protection function, enabling each to be optimized independently.
Data Source
AI summary
A display apparatus includes a first display module including a substrate, an encapsulation layer, and a sealant. The substrate has a display surface, a bottom surface, and a side surface connected between the opposite display and bottom surfaces. The encapsulation layer is disposed on the display surface. The sealant includes a connection part, a bottom part contacting the bottom surface, and an extension part having an outer surface. The connection part has two opposite ends and opposite first and second surfaces. The bottom part and the extension part are respectively located at the two opposite ends and extended from the first and second surfaces in directions away from each other. The first surface contacts the side surface. The encapsulation layer contacts the connection part and the extension part and is coplanar with the outer surface. A horizontal distance between the outer surface and the second surface is greater than 0.