Semi-Penetration Layer for Uniform Laser Sealing in Displays
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Solution Overview
Problem
The existing sealing units in flat panel display apparatuses, particularly those using glass frit, suffer from non-uniform heating due to the Gaussian profile of laser beams, leading to residual stress and damage during the sealing process, which limits the improvement of sealing characteristics.
Innovation Solution
A semi-penetration layer, made from materials like indium tin oxide (ITO) or zinc oxide, is introduced to absorb a predetermined amount of light, reducing energy concentration at the center of the sealing unit and preventing excessive heating, thereby improving the uniformity of the sealing process and reducing residual stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a laser beam with Gaussian profile is used to melt and harden the glass frit in the sealing unit, then the sealing unit connects the substrate and sealing substrate together, but the center of the sealing unit is excessively heated compared to the edges, resulting in non-uniform heating and limited improvement of sealing characteristics
Solution Approach 1:
The patent applies local quality by introducing a semi-penetration layer with specific light absorption properties at the center of the sealing unit. This layer selectively absorbs excess light energy in the center region where the Gaussian laser beam profile causes excessive heating, while allowing sufficient energy to reach the edges. This creates non-uniform light absorption distribution that compensates for the non-uniform heating pattern, achieving more uniform temperature distribution across the sealing unit.
Solution Approach 2:
The semi-penetration layer acts as an intermediary element between the laser beam and the glass frit. It mediates the energy transfer by absorbing a predetermined amount of light energy before it reaches the glass frit, thereby controlling and uniformizing the heating process. This intermediary layer prevents direct excessive energy transfer to the center region of the glass frit, solving the temperature uniformity problem.
2Ease of manufacture
If the sealing unit is formed by pre-forming material and hardening it by irradiating light, then the sealing process is simplified, but the Gaussian profile of the irradiated light causes the center to be excessively heated, limiting the improvement of sealing unit characteristics
Solution Approach 1:
The semi-penetration layer introduces local quality variation in the sealing structure by having different light absorption characteristics in different regions. The center region contains the semi-penetration layer that absorbs excess light, while the edge regions allow more light transmission. This local differentiation enables uniform heating across the entire sealing unit while maintaining the simplified light-curing process.
Solution Approach 2:
The patent changes the optical parameters of the sealing structure by introducing a layer with specific light absorption properties. By controlling the absorption coefficient and thickness of the semi-penetration layer, the energy distribution parameter is modified to compensate for the Gaussian beam profile, achieving uniform heating without changing the overall manufacturing process.
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
The semi-penetration layer ensures more even energy distribution across the sealing unit, preventing non-uniform expansion and contraction, thus enhancing the durability and sealing characteristics of the sealing unit, and protecting the underlying substrate and thin films from damage.
Implementation Method 1
a semi-penetration layer disposed farther from the substrate than the sealing unit while not deviating from the width of the sealing unit, and absorbing a predetermined amount of light incident on the sealing substrate
Implementation Method 2
absorbing a predetermined amount of light incident on the sealing substrate... preventing excessive heating
Data Source
AI summary
A display apparatus including: a substrate; a display unit disposed on the substrate; a sealing substrate facing the display unit; a sealing unit spaced apart from the display unit and disposed between the substrate and the sealing substrate and connecting the substrate to the sealing substrate; and a semi-penetration layer disposed on the substrate and not protruding from a width of the sealing unit, and absorbing a predetermined amount of light incident on the sealing substrate, thereby improving characteristics of the sealing unit.