Bending Protection Layer Formation for Curved Display Panels
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Solution Overview
Problem
Existing display devices with curved portions face challenges in reducing dead space and minimizing defects during manufacturing.
Innovation Solution
A method of manufacturing a display device involves forming a display panel with a bending area, applying a base bending protection layer, followed by a second bending protection layer using a pressing part with a flat bottom surface, and removing a portion of the base support layer to minimize dead space and defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a curved display panel is manufactured without a bending protection layer, then the manufacturing process is simpler, but the display panel suffers from defects and reduced reliability in the bending area
Solution Approach 1:
The bending protection layer is formed on the display panel before the bending process occurs. This preliminary protective measure prevents defects during bending while maintaining a relatively simple manufacturing process. The layer is applied in advance to protect against future stress and damage.
Solution Approach 2:
The bending protection layer acts as a cushioning layer that absorbs and distributes stress before it can damage the display panel during bending. This beforehand cushioning prevents defects by providing mechanical protection in the bending area before stress is applied.
2Area of stationary object
If the base support layer is completely removed to minimize dead space, then the visibility and aesthetic appearance are improved, but the structural support and stability are reduced
Solution Approach 1:
The base support layer is selectively removed from the bending area where it is not needed, while potentially retaining it in other areas where structural support is still required. This extraction minimizes dead space in the critical bending region while preserving necessary structural integrity elsewhere.
Solution Approach 2:
The support structure is made non-uniform by removing the base support layer only in specific locations (the bending area) where it would create dead space or interfere with curvature, while maintaining support in areas where structural strength is needed. This local modification optimizes both aesthetics and functionality.
3Reliability
If a pressing part with a complex non-flat bottom surface is used to form the bending protection layer, then the adhesion is improved, but the manufacturing complexity and defect risk increase
Solution Approach 1:
The base bending protection layer is formed first as a preliminary layer that provides initial adhesion and protection. This layer is applied before the pressing step, ensuring proper bonding to the display panel while maintaining manufacturing simplicity with a flat pressing surface.
Solution Approach 2:
The pressing part uses a flat bottom surface that applies uniform pressure across the bending protection layer, ensuring homogeneous thickness and properties. This homogeneous pressing approach avoids the defects and complexity associated with non-flat pressing surfaces while maintaining reliable adhesion through the previously applied base layer.
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 method reduces dead space and defect rates in curved display devices by enhancing adhesion and stress management, ensuring the bending protection layer remains intact while maintaining visibility and structural integrity.
Implementation Method 1
forming a first bending protection layer by pre-curing the base bending protection layer
Implementation Method 2
forming a second bending protection layer by pressing the first bending protection layer
Data Source
AI summary
A method of manufacturing a display device includes forming a display panel including a first area, a second area spaced apart from the first area in a first direction, and a bending area located between the first area and the second area, where the display panel includes a first surface and a second surface, which are opposite to each other, forming a base bending protection layer on the first surface of the display panel, forming a base support layer on the second surface of the display panel, forming a first bending protection layer by pre-curing the base bending protection layer, forming a second bending protection layer by pressing the first bending protection layer, and removing at least a portion of the base support layer. The base bending protection layer is formed before the removing the at least a portion of the base support layer.