Curved Display Metal Pattern for Stress Relief
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Solution Overview
Problem
Display devices with curved portions are prone to cracking and stress concentration during manufacturing, leading to reliability issues due to laser processing and warping, which can result in scratches and reduced performance.
Innovation Solution
A display device design featuring a resin layer with inorganic insulating films and a metal pattern formed between the curved portion and the display region, where the metal pattern is electrically disconnected from the wiring lines and tapers towards the edges, reducing stress concentration and crack propagation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a curved portion is provided at a corner portion of the outer shape portion, then the display device achieves a modern aesthetic design and improved light distribution, but laser light easily concentrates at the curved corners during manufacturing causing small cracks and scratches that reduce reliability
Solution Approach 1:
The patent applies local quality by providing a filling portion specifically at the curved corner portion with different properties than the surrounding regions. This filling portion has a refractive index matching the resin layer and is positioned to prevent laser light concentration, thereby protecting the curved corner from cracking while maintaining the overall curved aesthetic design.
Solution Approach 2:
The filling portion acts as an intermediary element between the curved corner structure and the laser light during manufacturing. By having a refractive index that matches the resin layer, it serves as a mediator that prevents harmful light concentration at the curved corner while allowing the curved design to be maintained.
2Manufacturing precision
If the outer shape portion is fully cut by laser light during manufacturing, then the display device achieves precise outer dimensions and clean edges, but stress concentrates in the curved portions causing small cracks that can extend into large cracks
Solution Approach 1:
The filling portion is provided in advance before the laser cutting process to prevent the concentration of laser light at curved corners. This preliminary protective measure stops the formation of small cracks before they can occur during the precise outer shape cutting process.
Solution Approach 2:
The filling portion serves as a cushioning element that absorbs or redistributes laser light energy before it can concentrate at the curved corner. This beforehand cushioning prevents the initiation and propagation of cracks during the manufacturing process.
3Shape
If the display device includes curved portions for aesthetic design, then the display device achieves improved appearance and light distribution, but the curved portions become stress concentration points that reduce overall device reliability
Solution Approach 1:
The filling portion provides localized reinforcement at the curved corner portion without affecting the overall curved aesthetic design. It specifically addresses the stress concentration issue at the corner while maintaining the desired curved shape and appearance of the display device.
Solution Approach 2:
The filling portion creates a composite structure at the curved corner by combining materials with specific refractive index properties. This composite approach strengthens the curved portion against stress concentration while maintaining the aesthetic curved design.
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 enhances the reliability of display devices with curved shapes by minimizing crack extension and stress release directions, thereby improving the overall performance and durability of the device.
Implementation Method 1
laser light easily concentrates at curved corners, and thus a small crack (or scratch) is generated in partition processing
Implementation Method 2
when the display device 101 subjected to singulation warps, stress easily concentrates in the curved portions C, and thus a small crack (or scratch) is generated
Implementation Method 3
at a place at which a small crack (or scratch) is generated, film stress is released in a direction in which curvature increases, and such a crack extends in a film stress releasing direction and becomes a large crack
Data Source
AI summary
A display device includes a display region, a frame region, and a curved portion. The display device includes a resin layer, a plurality of inorganic insulating films, and a metal layer. A metal pattern formed with the metal layer is formed between an edge portion of the curved portion and the display region in the frame region along a curved shape of the edge portion of the curved portion and along at least a portion of corresponding two sides of the display device. The metal pattern is electrically disconnected from a wiring line of the display region, and a width of the metal pattern decreases toward both end portions.