Thin-Substrate Display Assembly for Touch Sensor Alignment
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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, as the stacking of touch sensors and display elements on substrates leads to deflection and breakage issues, and alignment accuracy is compromised, affecting pixel resolution and reliability.
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 precise alignment and separation to achieve a thin, high-resolution display device with improved reliability and productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a thin substrate is used for the display device, then the total thickness is reduced, but substrate deflection and breakage occur during transport and processing
Solution Approach 1:
The substrate system is segmented into a thin substrate (for display quality and thinness) and a separate support substrate (for mechanical strength). The thin substrate carries the display elements while the support substrate provides structural integrity during handling and processing, resolving the contradiction between thinness and reliability.
Solution Approach 2:
A support substrate acts as an intermediary carrier that temporarily supports the thin substrate during manufacturing and transport. This intermediary structure allows the thin substrate to maintain its thin profile for display quality while the support substrate prevents deflection and breakage during handling.
2Length of moving object
If polishing is used to reduce substrate thickness, then the display device thickness is reduced, but manufacturing yield decreases
Solution Approach 1:
Instead of polishing thin substrates after element formation (which causes breakage and low yield), the invention preliminarily selects appropriately thin substrates before element formation. This preliminary action avoids the need for subsequent thickness reduction processes that would compromise yield.
3Manufacturing precision
If thin substrates are used for color filter and display element alignment, then display quality is improved, but alignment accuracy decreases due to substrate deflection
Solution Approach 1:
The alignment function is segmented between the thin substrate (which provides the display surface) and the support substrate (which provides dimensional stability). The support substrate prevents deflection during alignment operations, ensuring high alignment accuracy for color filters and display elements, while the thin substrate maintains the desired thin profile for display quality.
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.