Curved Vehicle Display Bubble Removal via Stepped Support Cover
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Solution Overview
Problem
The existing manufacturing processes for curved display devices for vehicles are inefficient due to high process time and costs associated with the autoclave process for removing bubbles, which often results in incomplete bubble removal and increased defective rates.
Innovation Solution
A curved display device design featuring a stepped structure in the support cover with through-holes for bubble discharge, combined with double injection molding of thermoplastic resins and an optical adhesive composition, simplifies the bonding process and reduces bubble formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an autoclave process is used to remove bubbles between the panel and adhesive, then bubble removal is attempted, but process time and costs increase and bubbles are not completely removed
Solution Approach 1:
The patent extracts the harmful bubbles from the adhesive layer by providing dedicated discharge paths (through-holes in the dam structure) that allow bubbles to escape during the bonding process itself, eliminating the need for subsequent autoclave processing to remove bubbles
Solution Approach 2:
The patent performs preliminary bubble discharge action by incorporating through-holes in the dam structure before bonding occurs, allowing bubbles to escape during the bonding process rather than requiring a separate post-bonding autoclave process
2Ease of manufacture
If a dam structure is formed along the rim of the cover member to prevent adhesive flow, then adhesive containment is improved, but process complexity increases
Solution Approach 1:
The patent merges the dam structure with the support cover by forming the dam structure as an integrated part of the support cover itself, rather than as a separate component, thereby maintaining adhesive containment functionality while reducing overall structural complexity
Solution Approach 2:
The support cover serves multiple functions: it provides structural support, contains the adhesive through its integrated dam structure, and facilitates bubble discharge through holes in the dam structure, eliminating the need for separate dedicated components
3Strength
If the adhesive layer is applied between the panel assembly and support cover, then bonding is achieved, but bubbles are generated that increase defective rate
Solution Approach 1:
The patent converts the harmful effect of bubbles (which would normally increase defective rate) into a beneficial outcome by providing controlled discharge paths that allow bubbles to escape during bonding, transforming the bonding process from one that traps bubbles to one that actively removes them
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
This approach simplifies processes, enhances productivity, reduces defective rates, and improves design freedom while maintaining excellent display visibility and transmittance.
Implementation Method 1
an adhesive layer which is formed between a window region corresponding to the display region and the panel assembly
Implementation Method 2
at least one through-hole for discharging bubbles generated between the adhesive layer and the panel assembly is formed at the interface between the first region and the second region
Implementation Method 3
the window and the support cover may be manufactured by double injection molding of different thermoplastic resins
Implementation Method 4
The optical adhesive composition may include one or more of an optical clear adhesive (OCA) composition and an optical clear resin (OCR) composition
Data Source
AI summary
The present invention relates to a curved display device for a vehicle and a manufacturing method thereof. In one embodiment, the curved display panel for the vehicle includes: a cover member which comprises a transparent window having a curved shape and a support cover formed on the lower side of the window, and which comprises a display region defined by an opening formed in the support cover, and a non-display region excluding the display region; and a panel assembly bonded to a lower side of the support cover.