UV Curable Resin Passivation Layer Direct Contact Substrate
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Solution Overview
Problem
The existing manufacturing processes for display devices require an adhesive layer between the passivation film and the substrate, which complicates the process and does not effectively fill surface irregularities or include carbides formed during substrate separation.
Innovation Solution
A display device with a passivation layer directly contacting the substrate, using UV curable resin applied via an inkjet process, eliminating the need for an adhesive layer and allowing the resin to fill microgrooves and include carbides, thus simplifying the manufacturing process and enhancing substrate surface healing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an adhesive layer is used between the passivation film and substrate, then the bonding strength is improved, but the manufacturing process complexity increases
Solution Approach 1:
The patent merges the adhesive layer function with the passivation layer by making the passivation layer itself adhesive through UV curable resin. This combines the bonding function and passivation function into a single layer, eliminating the need for a separate adhesive layer and simplifying the manufacturing process while maintaining bonding strength.
Solution Approach 2:
The passivation layer is designed to perform multiple functions simultaneously: it provides passivation, acts as an adhesive layer, and fills surface irregularities. The UV curable resin material enables the passivation layer to have adhesive properties while maintaining its passivation function, achieving multi-functionality in a single layer.
2Ease of manufacture
If a traditional passivation film is used, then the process is simple, but surface irregularities and carbides are not effectively filled or included
Solution Approach 1:
The patent changes the physical and chemical parameters of the passivation layer by using UV curable resin instead of traditional passivation film materials. This allows the material to be in a liquid state during application, enabling it to flow into and fill surface irregularities and carbides, and then cure to form a solid, defect-free layer.
Solution Approach 2:
The patent uses composite material approach by incorporating UV curable resin with specific properties that combine adhesive characteristics with passivation capabilities. The resin formulation includes components that enable both surface filling and effective passivation, creating a composite material that addresses multiple requirements simultaneously.
3Device complexity
If an adhesive layer is eliminated, then the manufacturing process is simplified, but the bonding between passivation layer and substrate may be compromised
Solution Approach 1:
The passivation layer performs self-service by providing its own adhesive function through the UV curable resin. The resin is applied directly to the substrate surface and cures to form a bonded interface, eliminating the need for a separate adhesive layer while maintaining bonding strength. The passivation layer essentially adhesives itself to the substrate.
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
This approach simplifies the manufacturing process by eliminating the adhesive layer, effectively filling substrate irregularities, and incorporating carbides, resulting in a more efficient and defect-free passivation layer formation.
Implementation Method 1
forming a passivation layer by curing the resin layer with UV irradiation
Data Source
AI summary
A display device includes: a substrate; a transistor disposed on a first surface of the substrate; and a passivation layer disposed on a second surface of the substrate opposite from the first surface, wherein the passivation layer directly contacts the substrate, and the passivation layer includes a UV curable resin.