Thin-Glass Display Stack for Precise Alignment and Low Thickness
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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 moving 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 a thin substrate (for display quality and thinness) and a separate thick support substrate (for mechanical strength). These are stacked together to form a composite structure that provides both thinness and structural integrity during manufacturing and operation.
Solution Approach 2:
The patent uses a composite substrate structure combining a thin substrate and a thick support substrate with different mechanical properties. The thin substrate enables thin display device design while the thick support substrate provides the necessary mechanical strength and stability during transport and processing.
2Length of moving 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 alignment function is segmented from the thin substrate to the thick support substrate. The support substrate provides a stable platform for precise alignment of color filters and display elements, while the thin substrate maintains the overall thinness of the display device.
Solution Approach 2:
The composite substrate structure allows the thick support substrate to provide dimensional stability and flatness for high-precision alignment, while the thin substrate layer maintains the thin display device profile. This division of functional roles resolves the contradiction between thinness and alignment accuracy.
3Length 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 substrates after manufacturing to reduce thickness, the patent preliminarily selects and uses thin substrates from the beginning. This preliminary action approach avoids the need for subsequent polishing steps, thereby maintaining high manufacturing yield while achieving thin display devices.
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.