Bending LCD Stack for Zero-Bezel Displays
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Solution Overview
Problem
Existing LCD display technologies face challenges in reducing bezels and manufacturing curved displays due to manufacturing, yield, and reliability issues, particularly in achieving zero-border and curved designs while maintaining display quality and functionality.
Innovation Solution
The implementation of an LCD display stack that bends around the edge of the backlight, with a liquid crystal cell and edge seal extending beyond the active display area, allowing for lateral movement of the substrate and cover layer, and incorporating integrated gate drive circuitry and light-blocking layers to enhance flexibility and reduce light leakage, along with a flexible substrate that can be notched and folded to create a zero-bezel or curved display.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the LCD display stack bends around the edge of the backlight with the complete liquid crystal cell, then the bezel is reduced and curved display is achieved, but the manufacturing complexity and reliability challenges increase
Solution Approach 1:
The display stack is segmented into flexible and rigid portions, with the liquid crystal cell and edge seal forming a flexible segment that can bend around the backlight edge, while the backlight itself remains a separate rigid component. This segmentation allows the flexible portion to be manufactured and assembled independently, reducing overall manufacturing complexity.
Solution Approach 2:
The display stack is configured to bend in the third dimension around the edge of the backlight, transitioning from a flat two-dimensional arrangement to a three-dimensional curved configuration. This dimensional change enables curved display designs while maintaining the functional integrity of the liquid crystal cell.
2Area of stationary object
If the LCD display stack bends around the edge of the backlight, then zero-border display is achieved, but the yield and reliability issues worsen
Solution Approach 1:
The liquid crystal cell and edge seal are pre-configured and pre-assembled in their final curved configuration before being integrated with the backlight and housing. This preliminary action ensures that the flexible display stack maintains its structural integrity and sealing effectiveness, thereby improving reliability while achieving zero-border display.
Solution Approach 2:
The liquid crystal cell is constructed with flexible substrate and thin-film components that can withstand bending around the backlight edge without compromising the sealing or display quality. This use of flexible materials and thin-film technology ensures reliability in the curved, zero-border configuration.
3Adaptability or versatility
If the edge seal lies beyond the active display area, then lateral movement of substrate and cover layer is enabled, but the manufacturing precision requirements increase
Solution Approach 1:
The edge seal acts as an intermediary component positioned beyond the active display area, providing a sealing interface that allows the substrate and cover layer to move laterally relative to each other. This intermediary positioning reduces the direct coupling between the moving parts, thereby enabling lateral movement while maintaining acceptable manufacturing precision.
4Strength
If the LCD display stack is bent through 180 degrees, then robust attachment is achieved, but the stress within the stack increases
Solution Approach 1:
Instead of bending the entire display stack through a full 180 degrees, only the flexible portion containing the liquid crystal cell and edge seal is bent through a partial angle. This partial action achieves robust attachment of the flexible stack to the backlight while minimizing the stress accumulated in the liquid crystal material and sealing structures.
Data Source
AI summary
An LCD display, comprising an active display area, a backlight to illuminate the active display area, and an LCD display stack. The LCD display stack may comprise a substrate, a liquid crystal layer over the substrate, and liquid crystal cover layer. The substrate, the liquid crystal layer, and the liquid crystal cover layer define a liquid crystal cell. The LCD display stack has an edge seal extending between the substrate and the liquid cover layer, and extends over the active display area and beyond the active display area to bend around an edge of the backlight, such that the edge seal lies beyond the active display area.