Single-Substrate Display Panel with Removable Polarizing Plate
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Solution Overview
Problem
Conventional liquid display apparatuses with two substrates are heavy and costly, and single-substrate designs face challenges in reworking and attaching polarizing plates, affecting their strength and manufacturing efficiency.
Innovation Solution
A display panel with a single substrate featuring a thin film transistor, a first electrode, an image displaying layer, a second electrode, a protective layer, and an upper polarizing plate that can be easily attached and detached, along with a method of manufacturing that includes forming a tunnel-shaped cavity and using a sacrificial layer to improve reworkability and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a two-substrate design is used, then the display panel can be manufactured with conventional methods, but the weight and manufacturing cost increase
Solution Approach 1:
The invention extracts and removes one substrate from the conventional two-substrate liquid crystal display structure, retaining only the lower substrate while integrating all necessary components (liquid crystal layer, polarizing plates, encapsulation layers) directly onto or around the single substrate. This extraction eliminates the upper substrate and reduces overall weight while maintaining display functionality.
Solution Approach 2:
The invention merges multiple components and functions into the single substrate structure. The lower substrate integrates the liquid crystal layer, upper and lower polarizing plates, encapsulation layers, and electrode structures into one unified assembly, eliminating the need for a separate upper substrate while achieving the same display function.
2Reliability
If a two-substrate design is used, then the display panel structure is complete, but the manufacturing cost increases
Solution Approach 1:
The invention extracts the upper substrate from the conventional structure, eliminating the need to manufacture and assemble two separate substrates. This reduction in component count directly lowers manufacturing costs while the integrated single-substrate design maintains structural reliability through proper encapsulation and layer integration.
Solution Approach 2:
The invention discards the upper substrate component entirely, recovering the manufacturing resources and costs that would have been spent on producing and assembling that substrate. The functionality previously requiring the upper substrate is achieved through the integrated lower substrate design with encapsulation layers and direct component attachment.
3Weight of moving object
If a single substrate design is used, then the weight and cost are reduced, but the reworkability of polarizing plates becomes difficult
Solution Approach 1:
The invention segments the polarizing plates and encapsulation layers into independently removable components attached to the single substrate. The lower encapsulation layer and polarizing plates are designed to be detachable from the lower substrate, allowing rework and replacement without damaging the substrate itself, thus improving repairability despite the single-substrate design.
Solution Approach 2:
The invention creates a dynamic, reconfigurable single-substrate structure where polarizing plates and encapsulation layers can be attached and detached as needed. This dynamic attachment system allows the display panel to be reworked, repaired, or upgraded by replacing specific components rather than the entire panel, overcoming the rigidity typically associated with single-substrate designs.
4Ease of manufacture
If a single substrate design is used, then the manufacturing cost is reduced, but the strength of the display panel decreases
Solution Approach 1:
The invention uses composite material structures in the single substrate design, combining the lower substrate with encapsulation layers, polarizing plates, and liquid crystal layers in an integrated assembly. This composite structure provides enhanced mechanical strength and structural integrity comparable to two-substrate designs, while maintaining the cost and weight advantages of the single-substrate approach.
Solution Approach 2:
The invention incorporates encapsulation layers and protective structures in advance during the single-substrate manufacturing process. These preemptive protective elements strengthen the display panel against mechanical stress, handling damage, and environmental factors, ensuring adequate strength without requiring a second substrate for structural support.
Data Source
AI summary
A display panel including a substrate on which a switching element is disposed, a first electrode connected to the switching element, an image displaying layer disposed under the first electrode, a second electrode disposed under the image displaying layer and insulated from the first electrode, a protective layer disposed under the second electrode and surrounding a lower surface and side surfaces of the image displaying layer, and an upper polarizing plate disposed on the substrate, and making contact with the substrate.