Ultra-Thin Touch Display Fabrication with Shared Substrate Alignment
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Solution Overview
Problem
Conventional touch display apparatus fabrication methods result in thick and heavy devices due to the use of glass substrates, with limited alignment accuracy between touch and display panels, making it unsuitable for high-resolution and 3D touch displays.
Innovation Solution
A method involving a first substrate, a second substrate acting as a common substrate for both display and touch panels, and a third substrate with a touch sensing layer, where the second substrate is ultra-thin and directly aligned with the first substrate's alignment mark, allowing for reduced thickness and improved alignment accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional glass substrates are used for both display and touch panels, then structural strength is maintained, but thickness and weight increase significantly
Solution Approach 1:
The patent replaces conventional thick glass substrates with ultra-thin substrates (thickness of 0.1mm or less) for both the display panel and touch panel. These thin substrates are sufficiently strengthened through the lamination structure and bonding processes to maintain structural integrity while dramatically reducing weight and thickness of the final apparatus.
Solution Approach 2:
The patent merges the substrate structures of the display panel and touch panel by making them share common substrates. Specifically, the second substrate serves as both the upper substrate of the display panel and the lower substrate of the touch panel, eliminating redundant substrate layers and reducing overall thickness and weight.
2Manufacturing precision
If separate alignment marks are used for display and touch panels, then alignment of each panel is achieved, but alignment accuracy between panels deteriorates to 70-80 μm tolerance
Solution Approach 1:
The patent makes the alignment marks on the first and second substrates serve dual purposes: they align both the display panel components and the touch panel components simultaneously. By positioning these common alignment marks at overlapping locations, a single alignment operation achieves both alignments with high precision (less than 5 μm tolerance), eliminating the need for separate alignment procedures.
3Length of stationary object
If substrates are thinned after assembly, then some thickness reduction is achieved, but further thinning becomes impossible and initial thickness remains limited
Solution Approach 1:
The patent performs substrate thinning before the assembly of display and touch panels. The first and second substrates are thinned to ultra-thin specifications (0.1mm or less) while still on their respective carriers, allowing subsequent assembly and carrier removal without compromising structural integrity. This preliminary thinning enables achieving record-low thickness that would be impossible if thinning were attempted after assembly.
4Manufacturing precision
If conventional fabrication methods are used, then production cost and yield are maintained at standard levels, but alignment accuracy for high-resolution displays deteriorates
Solution Approach 1:
The patent makes the alignment marks on the first and second substrates serve dual purposes: they align both the display panel components and the touch panel components simultaneously. By positioning these common alignment marks at overlapping locations, a single alignment operation achieves both alignments with high precision (less than 5 μm tolerance), eliminating the need for separate alignment procedures.
Data Source
AI summary
A method of fabricating a touch display apparatus is provided which includes: forming a first substrate on a first carrier; forming an assembly part on a second carrier, wherein the assembly part includes a second substrate, a third substrate and a touch sensing layer interposed therebetween, and the third substrate is relatively near a side of the second carrier; assembling the first substrate and the assembly part such that a display layer is formed between the first substrate and the assembly part; and at least removing the first carrier. In addition, a touch display fabricated from the above method is also provided.