Display Wire Insulating Layer Geometry to Prevent Chipping Defects
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Solution Overview
Problem
During the manufacturing process of display apparatuses, foreign substances can remain in the display area, leading to defective light emission due to impurities generated during the formation of various components.
Innovation Solution
The display apparatus incorporates a substrate with a wire extending along its edges, covered by a first and second insulating layer, where the distance and curvature of the insulating layers' ends are strategically designed to minimize the occurrence of defects by optimizing the adhesion and prevention of chipping during air spraying, thereby reducing the likelihood of impurities being dislodged and remaining in the display area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating layers are formed to cover wires during manufacturing, then adhesion and protection are improved, but chipping may occur during air spraying causing defects
Solution Approach 1:
The insulating layer is designed with a curved surface that has a specific radius of curvature (R1) at the portion covering the wire. This curvature prevents the insulating layer from chipping during air spraying by distributing stress evenly, while still maintaining proper adhesion to the wire. The curved design eliminates sharp corners that would be prone to chipping.
Solution Approach 2:
The patent specifies precise dimensional parameters for the insulating layer, including the radius of curvature (R1) ranging from 1/10 to 1/5 of the wire width, and the distance (L1) from the corner of the insulating layer to the wire edge. By optimizing these parameters, the design achieves both strong adhesion and resistance to chipping during air spraying.
2Area of stationary object
If the insulating layer extends closer to the wire edge, then coverage and protection are improved, but the risk of chipping and defect formation increases
Solution Approach 1:
The patent defines an optimal distance (L1) from the corner of the insulating layer to the wire edge, where L1 is between 1/20 to 1/10 of the wire width. This parameter optimization allows the insulating layer to extend sufficiently close to the wire edge for maximum coverage while maintaining a safe distance that prevents chipping during air spraying, thus achieving both high coverage and defect-free manufacturing.
Solution Approach 2:
The curved surface design with radius R1 allows the insulating layer to approach the wire edge more closely without creating sharp corners that would chip. The curvature provides a gradual transition that maintains structural integrity even when the layer extends further toward the wire edge.
3Object-affected harmful factors
If the insulating layer is positioned further from the wire edge, then chipping is reduced, but coverage and adhesion are compromised
Solution Approach 1:
The patent determines the optimal distance (L1) from the corner of the insulating layer to the wire edge as between 1/20 to 1/10 of the wire width. This optimized distance is sufficient to prevent chipping during air spraying while being close enough to maintain strong adhesion and effective coverage of the wire.
Solution Approach 2:
The curved surface with radius R1 (1/10 to 1/5 of wire width) allows the insulating layer to extend closer to the wire edge without compromising adhesion, while the curvature itself prevents chipping by eliminating stress concentration points.
Data Source
AI summary
A display apparatus includes a substrate, a wire having an inner edge including first and second portions, a first insulating layer covering a portion of the substrate, and a second insulating layer. The portion of the substrate covered by the first insulating layer is closer to a center of the substrate than the wire, the first insulating layer covers a part of the first portion of the wire and a part of the second portion of the wire, and a first end of the first insulating layer is disposed on the wire. The second insulating layer covers the first insulating layer and has a second end disposed on the wire. A distance between the first end and the second end covering the first portion of the wire is different from a distance between the first end and the second end covering the second portion of the wire.