Bent Display Panel Assembly for High-Curvature Circuit Integration

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Solution Overview

Problem

Manufacturing displays with bent or curved portions is challenging due to the difficulty in handling strain on components like indium tin oxide conductive traces, which can break under curvature, limiting the achievable curvature and potentially resulting in visible seams when cutting the display panel to alleviate strain.

Innovation Solution

A method where a display panel is partially formed in a planar state and then molded to have desired curvature, with additional susceptible components added later, and a flexible printed circuit is formed directly on the panel using precise deposition, allowing for high curvature without applying substantive pressure and avoiding front-of-screen artifacts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If a display panel is bent to increase curvature magnitude, then the display can achieve desired curved shape, but conductive traces formed from indium tin oxide may break due to strain

Engineering Contradiction:

Improvecurvature magnitudeVSAvoidconductive trace integrity

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

The patent applies preliminary action by forming the flexible printed circuit layer-by-layer directly on the display panel before the bending process. This ensures that the conductive material is already deposited and bonded to the panel surface, eliminating the risk of breakage during subsequent bending operations. The conductive layers are created in advance when the panel is still planar and accessible, allowing precise deposition without strain.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces traditional mechanical lamination processes with precise deposition of conductive material. Instead of applying substantive pressure through mechanical means that could cause artifacts or damage, the conductive material is deposited directly onto the panel surface using vapor deposition or similar techniques. This substitution eliminates mechanical stress on the conductive traces during the bonding process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If lamination pressure is applied to attach flexible printed circuit, then electrical connections are made, but front-of-screen artifacts may occur

Engineering Contradiction:

Improveelectrical connectionVSAvoidfront-of-screen artifacts

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces mechanical lamination pressure with a deposition-based attachment method. The flexible printed circuit is formed by precisely depositing conductive material directly onto the display panel surface, eliminating the need for substantive pressure application. This substitution ensures that electrical connections are made without causing front-of-screen artifacts that would result from mechanical compression or lamination processes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If display panel is cut to alleviate strain, then conductive traces are protected from breaking, but visible seams are created

Engineering Contradiction:

Improveconductive trace integrityVSAvoiddisplay continuity

Core Design Contradiction:

ReliabilityVSShape

Solution Approach 1:

The patent applies preliminary action by forming all conductive layers and the flexible printed circuit before the bending process. This eliminates the need for subsequent cutting operations to relieve strain, as the conductive material is already properly bonded and positioned. The display panel can be bent to the desired curvature without creating visible seams, maintaining both structural integrity and visual continuity.

Inventive Principle:

Principle #10Preliminary action

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

Enables the creation of displays with increased curvature, including compound curvature, without damaging sensitive components like indium tin oxide traces, allowing for more aggressive bending without breaking and maintaining structural integrity, while preventing visible seams and artifacts.

Implementation Method 1

A flexible printed circuit may be formed directly on the display panel using precise deposition of conductive material

Methodology Applied

Scientific EffectPhysical Vapour Deposition: Physical Vapour Deposition

Data Source

PatentUS20230352497A1Methods of Forming Bent Display Panels

Publication Date: 2023.11.02 APPLE INC

AI summary

A display may have one or more bent portions. To increase the magnitude of curvature in a display and/or to allow for compound curvature in the display, a display panel may be partially formed in a planar state. The partial display panel is then bent to have desired curvature. After the partial display panel is bent, additional display components that are susceptible to damage during the bending process may be added to complete the display panel. A flexible printed circuit may be formed directly on the display panel using precise deposition of conductive material. By forming the flexible printed circuit layer-by-layer directly on the display panel, no substantive pressure needs to be applied to the display panel. Electrical connections may therefore be made to the display panel in regions of the display with high levels of curvature and/or with compound curvature without causing front-of-screen artifacts for the display panel.