Touch Sensor Dam Structure for Fewer Display Manufacturing Masks
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Solution Overview
Problem
Existing display device manufacturing processes require a large number of masks, complicating the manufacturing process and increasing costs.
Innovation Solution
The display device design incorporates a reduced number of masks by omitting one touch organic layer and utilizing dams made from organic layers of the display panel to prevent overflow, simplifying the stacking structure and reducing the number of manufacturing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional touch sensor layer structure is used, then the touch sensor layer can be properly formed, but the number of masks increases and manufacturing complexity increases
Solution Approach 1:
The patent merges the dam structure and touch organic layer formation into a single manufacturing process. By forming the dam and touch organic layer in one step using the same material deposition process, the need for separate masks for each structure is eliminated, thereby reducing the total number of masks and simplifying the manufacturing process
Solution Approach 2:
The patent employs a universal material and process that serves multiple functions: the deposited material forms both the dam structure and the touch organic layer, while the same process step creates both the protective barrier and the conductive touch sensor elements, eliminating the need for separate specialized processes
2Reliability
If multiple organic layers are used to form the touch sensor layer, then the touch sensor layer can be properly formed, but the manufacturing process becomes more complex
Solution Approach 1:
The patent extracts and eliminates one of the multiple organic layers from the conventional touch sensor layer structure. By removing the redundant layer, the manufacturing process is simplified while the essential touch sensor functionality is maintained through the optimized remaining layer configuration
Solution Approach 2:
The patent segments the touch sensor layer into distinct functional regions (conductive regions and insulating regions) within a single organic layer, allowing different functions to be achieved without requiring multiple separate organic layer deposits, thereby reducing process complexity
Data Source
AI summary
A display device includes a base substrate including a display area including a plurality of pixels, and a non-display area adjacent to the display area, a first dam on the non-display area of the base substrate, a second dam on the non-display area of the base substrate, the second dam between the first dam and the display area, a touch conductive layer between the first dam and the second dam, and a touch sensor layer including a touch organic layer, the touch organic layer on the touch conductive layer, wherein the touch organic layer ends inside the first dam without extending past an end of the first dam, and the first dam and the second dam include a same material.