Stretchable Panel Through-Hole Alignment for Optical Continuity
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Solution Overview
Problem
Conventional manufacturing processes for stretchable panels result in misaligned through holes between the upper and lower panel structures, leading to structural discontinuities and reduced optical performance.
Innovation Solution
A manufacturing method where the upper and lower panel structures are first combined, and then through holes are formed simultaneously through the flexible layers using an etching process, ensuring structural continuity and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the upper panel structure and lower panel structure are etched separately to form through holes, then the manufacturing process can be simplified, but the through holes become misaligned resulting in structural discontinuities
Solution Approach 1:
The patent combines the upper and lower panel structures into a single integrated structure before etching. The support structure connects both panels, allowing simultaneous etching of through holes through the entire assembly, ensuring perfect alignment while maintaining manufacturing efficiency
Solution Approach 2:
The support structure is formed in advance to connect the upper and lower panels before the etching process. This preliminary structural integration ensures that when through holes are etched later, they will be perfectly aligned across both panels, preventing misalignment issues
2Ease of manufacture
If through holes are formed separately in upper and lower panels, then each panel can be processed independently, but optical performance deteriorates due to structural discontinuities
Solution Approach 1:
By merging the upper and lower panels into a single integrated structure with a connecting support, the patent ensures continuous through holes that maintain optical performance while still allowing independent processing of each panel section before final assembly
3Adaptability or versatility
If multiple through holes are formed in separate panels, then assembly flexibility is improved, but structural continuity is lost leading to reduced optical performance
Solution Approach 1:
The support structure is preliminarily formed to connect upper and lower panels before etching, ensuring that when multiple through holes are created, they maintain structural continuity across the entire assembly while preserving assembly flexibility
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 method produces a panel structure with structurally continuous through holes, enhancing optical performance by preventing misalignment and maintaining light transmittance.
Implementation Method 1
The etching barrier layer is used to form multiple through holes simultaneously passing through the first flexible layer, the filler layer, and the second flexible layer
Data Source
AI summary
A panel structure including a stretchable substrate, a first flexible layer, a circuit layer, multiple light-emitting elements, a filler layer, a second flexible layer, and an element layer is disclosed. The first flexible layer includes multiple pixel islands, and the pixel islands are defined by multiple through holes. Each of the through holes passes through the first flexible layer, the filler layer, and the second flexible layer. The display structure has good continuity in structure, and optical performance of the display structure is good. A manufacturing method of a panel structure is also disclosed.