Curved Cover Window Hard Coating Molding
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Solution Overview
Problem
Existing cover windows for flexible display devices are prone to breaking or damage, especially when forming curved portions, due to insufficient hardness and structural integrity during the molding process.
Innovation Solution
A method of manufacturing a cover window with a hard coating layer of polysilsesquioxane, having a thickness of 20 μm to 50 μm, applied on a window substrate composed of polycarbonate and polymethyl methacrylate layers, which is then molded to include both flat and curved portions, enhancing the substrate's hardness and reducing the risk of damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a hard coating layer is formed on the window substrate before molding, then the scratch resistance and hardness are improved, but the risk of breaking or damage during the molding process increases
Solution Approach 1:
The patent applies parameter changes by carefully controlling the thickness of the hard coating layer within a specific range (20-50 μm) and adjusting the molding temperature (120-130°C) and time (3-5 minutes) to achieve the desired balance between scratch resistance and breakage prevention
Solution Approach 2:
The patent uses composite materials by forming a hard coating layer (polysilsesquioxane) on the window substrate (polycarbonate and polymethyl methacrylate layers), creating a composite structure that combines the hardness of the coating with the flexibility and impact resistance of the substrate
2Adaptability or versatility
If the window substrate is molded to include curved portions, then the flexibility and adaptability are improved, but the structural integrity and resistance to breaking deteriorate
Solution Approach 1:
The patent applies segmentation by dividing the window substrate into multiple layers (polycarbonate layer and polymethyl methacrylate layer) with a hard coating layer on top, where each layer contributes different properties: the polycarbonate provides flexibility for curvature, the PMMA layer enhances rigidity, and the hard coating provides scratch resistance
Solution Approach 2:
The patent uses flexible shells and thin films by employing a polycarbonate-based window substrate that can be molded into curved portions while maintaining structural integrity, combined with a thin hard coating layer that provides surface protection without compromising flexibility
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 significantly improves the bending properties and scratch resistance of the cover window, preventing or reducing cracks and breaking during the molding process, while maintaining high light transmittance and mechanical properties.
Implementation Method 1
forming a hard coating layer having a thickness of about 20 μm to about 50 μm on a first surface of a window substrate
Implementation Method 2
The molding process of the window substrate, on which the hard coating layer is formed, may include thermally forming the window substrate at a temperature of about 120° C. to about 130° C. and for about three minutes to about five minutes
Data Source
AI summary
Methods of manufacturing a curved cover window of the disclosure prevent or reduce damage to a window substrate of the curved cover window. Methods include manufacturing methods in which a hard coating layer is formed on a window substrate, and optionally molding the window substrate on which the coating layer is formed in a manner as to minimize or reduce breaking or damage to the window substrate. By using a hard coating layer which is harder than the window substrate and which may include a first polycarbonate layer, a second polymethyl methacrylate layer, and polysilsesquioxane; and thermally molding the window substrate and hard coating layer at a temperature of about 120° C. to about 130° C. and for about three minutes to about five minutes; rupture of the window substrate during the molding process can be reduced.