UV-Cured Porous Frame Layer for Display Screens
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Solution Overview
Problem
Conventional display screens with opaque frame layers formed by screen printing suffer from high surface roughness, low light transmissibility, and poor linearity, which can lead to broken transparent conductive lines and increased resistance, especially with white ink materials requiring thicker layers and longer curing times.
Innovation Solution
A display screen apparatus with a light transmissive substrate and a light cured material layer having a peripheral portion with pores, formed using a light curable material that is cured with UV light, creating a thin, opaque, and linear frame with high light transmissibility and low surface roughness, and a reflective layer for enhanced optical density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If screen printing with white ink material is used to form an opaque frame layer, then the frame layer achieves complete opacity, but the surface roughness increases significantly (about 15-20 μm height difference)
Solution Approach 1:
The patent applies porous materials by incorporating inorganic particles (such as titanium dioxide, barium sulfate, or zirconium oxide) with specific size ranges (0.1-10 μm) into the frame layer material. These particles create a porous structure that scatters light effectively to achieve opacity while maintaining a relatively flat surface profile, thus resolving the contradiction between opacity and surface roughness
Solution Approach 2:
The patent changes the particle size parameter of the inorganic materials used in the frame layer to optimize both opacity and surface flatness. By controlling particle size within specific ranges and using multiple sizes in combination, the formulation achieves complete opacity with reduced surface roughness compared to conventional screen printing
2Quantity of substance
If a thicker layer of white ink material is used to achieve complete opacity, then the frame layer becomes fully opaque, but the height difference between frame layer and display screen surface increases
Solution Approach 1:
The porous structure created by inorganic particles provides high light scattering efficiency, enabling complete opacity to be achieved with a thinner layer thickness. This eliminates the need for thick layers that would create excessive height differences, thus resolving the contradiction between opacity and frame height
Solution Approach 2:
The patent uses composite materials combining organic binders with inorganic particles of specific sizes and ratios. This composite formulation achieves optimal opacity-to-thickness ratio, allowing the frame layer to be both fully opaque and thin enough to maintain a small height difference with the display screen surface
3Ease of manufacture
If conventional screen printing is used to form the frame layer, then the manufacturing process is simple, but the linearity at the edge of the frame layer is poor
Solution Approach 1:
The patent replaces the mechanical screen printing process with a coating process that applies the frame layer material followed by UV curing. This substitution maintains manufacturing simplicity while achieving superior edge linearity, as the UV curing process allows for more precise control of material deposition and drying, eliminating the edge irregularities typical of screen printing
4Quantity of substance
If thermoset resin based white ink material is used, then the frame layer achieves good opacity, but the curing time increases significantly
Solution Approach 1:
The patent changes the chemical composition parameter by using UV-curable resin instead of thermoset resin, and by selecting inorganic particles with specific properties. This parameter change enables rapid UV curing while maintaining complete opacity, thus resolving the contradiction between opacity and curing time
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 solution achieves a thin, opaque, and linear frame with low surface roughness, preventing breakage of transparent conductive lines and maintaining high light transmissibility, while eliminating the height difference issues and curing time challenges of conventional methods.
Implementation Method 1
passing a light through a photomask so that a portion of the light curable material layer that is disposed on the peripheral area is irradiated by the light and is converted into a light cured material layer
Data Source
AI summary
A display screen apparatus having a viewing region and a peripheral region surrounding the viewing region includes: a light transmissive substrate having inner and outer surfaces; and a light cured material layer disposed on the inner surface of the light transmissive substrate and having a peripheral portion corresponding in position to the peripheral region of the display screen apparatus. The peripheral portion is formed with a plurality of pores therein.