Stacked-Substrate Display Assembly for Thin Touch Panels
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Solution Overview
Problem
Existing display devices with integrated touch sensors face challenges in reducing thickness while maintaining high display quality and productivity, due to difficulties in aligning thin substrates and preventing breakage during processing.
Innovation Solution
The use of stacked substrates with a thin substrate and a thicker support substrate, where the touch sensor and display element layers are attached with adhesive layers, allowing for high alignment accuracy and separation to achieve a thin, reliable, and high-resolution display device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If a thin substrate is used to reduce display device thickness, then the total thickness is reduced, but the substrate deflects and breaks during transport and processing
Solution Approach 1:
The substrate system is segmented into multiple layers: a thin substrate (10-200 μm) for the display device and a separate thick support substrate (200-500 μm) for mechanical strength. This segmentation allows the thin substrate to achieve the desired thinness while the support substrate provides the necessary structural integrity during manufacturing and transport.
Solution Approach 2:
The thin substrate is nested within or alongside the thick support substrate, forming a composite structure where the thin substrate carries the display elements while the thick support substrate provides mechanical strength. This nested arrangement allows the thin substrate to function without bearing the full mechanical load.
2Length of stationary object
If a thin substrate is used to reduce display device thickness, then the total thickness is reduced, but alignment accuracy between color filter and display element deteriorates
Solution Approach 1:
The substrate system is segmented into a thin substrate for display elements and a separate thick support substrate for mechanical stability. This segmentation ensures that the thin substrate does not deflect during alignment processes, maintaining high alignment accuracy between the color filter and display element while still achieving the desired thin final product.
3Length of stationary object
If polishing is used to reduce substrate thickness after manufacturing, then the display device thickness is reduced, but manufacturing yield decreases
Solution Approach 1:
Instead of polishing substrates after manufacturing elements (which reduces yield), the invention performs the thickness reduction action in advance by selecting and using inherently thin substrates (10-200 μm) from the beginning. This preliminary approach to thickness control eliminates the need for post-manufacturing polishing, thereby maintaining high manufacturing yield while achieving the desired thin display device.
4Length of stationary object
If substrate thickness is reduced to achieve thin display device, then portability is improved, but substrate breakage during processing increases
Solution Approach 1:
The mechanical support function is segmented from the display substrate, with a separate thick support substrate (200-500 μm) providing structural integrity during processing and transport. This allows the display substrate to be extremely thin (10-200 μm) for portability while the support substrate prevents breakage through its superior mechanical strength.
Solution Approach 2:
The thick support substrate acts as an intermediary that protects the thin substrate during manufacturing and transport. The support substrate absorbs mechanical stresses and impacts that would otherwise cause the thin substrate to break, enabling the use of ultra-thin substrates without increasing breakage risk.
Data Source
AI summary
The thickness of a display device including a touch sensor is reduced. Alternatively, the thickness of a display device having high display quality is reduced. Alternatively, a method for manufacturing a display device with high mass productivity is provided. Alternatively, a display device having high reliability is provided. Stacked substrates in each of which a sufficiently thin substrate and a relatively thick support substrate are stacked are used as substrates. One surface of the thin substrate of one of the stacked substrates is provided with a layer including a touch sensor, and one surface of the thin substrate of the other stacked substrate is provided with a layer including a display element. After the two stacked substrates are attached to each other so that the touch sensor and the display element face each other, the support substrate and the thin substrate of each stacked substrate are separated from each other.