Curved Display Lamination with Aligned Edge Cutting
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Solution Overview
Problem
Existing methods for producing curved display and sensor devices on flexible plastic support films face challenges in achieving mechanical stability, particularly during the lamination and cutting processes, which can lead to delamination when the devices are flexed away from their curved configuration.
Innovation Solution
A method involving the formation of a flexible assembly with a stack of layers defining electrical control circuitry, where components are laminated in stressed curved configurations, and cutting through these components to produce aligned edges, specifically using a curved window/cover component and encapsulation films, while the assembly is in a curved configuration, to enhance mechanical stability and prevent delamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If components are laminated in stressed curved configurations to form flexible display devices, then the devices can achieve curved configurations and flexibility, but mechanical stability deteriorates and delamination occurs when flexed away from curved configuration
Solution Approach 1:
The patent applies preliminary action by cutting through the laminated components to create aligned edges while the assembly is in its curved configuration, before any flexing occurs. This pre-cutting establishes stress relief pathways and aligned boundaries that prevent delamination during subsequent flexing operations, resolving the mechanical stability issue while maintaining the curved shape capability
Solution Approach 2:
The patent segments the laminated assembly by making cuts through the stacked components, dividing the continuous structure into sections with aligned edges. This segmentation creates discrete stress zones and prevents stress propagation across the entire assembly, thereby improving mechanical stability during flexing while preserving the overall curved configuration
2Adaptability or versatility
If components are laminated together in stressed configurations to create flexible assemblies, then flexibility and curved shape are achieved, but manufacturing precision deteriorates due to alignment difficulties during cutting
Solution Approach 1:
The patent performs the cutting operation while the assembly is held in its curved configuration, establishing precise aligned edges before any flexing occurs. This preliminary cutting at the correct geometry ensures that subsequent flexing does not compromise edge alignment, thereby maintaining manufacturing precision while achieving flexibility
Solution Approach 2:
The patent changes the physical state and geometric parameters of the assembly during manufacturing by maintaining the curved configuration throughout the lamination and cutting processes. By controlling the assembly in its stressed curved state during fabrication, precise alignment is achieved, and this aligned structure then provides the desired flexibility when flexed
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 improves the mechanical stability of curved devices by creating aligned edges during the lamination process, reducing the risk of delamination when the devices are flexed away from their curved configuration, thus ensuring the structural integrity and functionality of the devices.
Implementation Method 1
comprises at least first and second components laminated together in stressed configurations
Data Source
AI summary
A manufacturing process for forming a flexible assembly suitable for a curved sensor or display including a stack of layers defining electrical control circuitry is presented. The flexible assembly has a curved configuration and comprises at least first and second components (4, 8) laminated together in a stressed configuration due to their curvature. While the assembly is in said curved configuration at least the first and second components (4, 8) are cut to obtain one or more edges which are aligned to each other.