Curved Display Panel Fabrication via Substrate Thinning

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Solution Overview

Problem

Conventional liquid crystal display panels are manufactured in a flat shape, making it difficult and costly to produce a curved display panel with flexible substrates, and existing flexible panels have complex and expensive manufacturing processes.

Innovation Solution

A method involving partial thinning of substrates and attaching a reinforcing plate with a curved shape using an adhesive layer to maintain a curved shape, while forming a reinforcing layer and optionally adding polarizers, to create a curved display panel from a conventional flat panel.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If flexible substrates are used to create curved display panels, then curved shape is achieved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvecurved shapeVSAvoidmanufacturing process complexity

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The substrate is divided into different thickness zones through selective removal. Edge portions are thinned to a first thickness to enable bending, while central portions maintain original thickness for structural support. This segmentation allows the panel to achieve curved shape using conventional manufacturing processes without requiring entirely flexible substrates.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the substrate are given different properties: edge portions are made thinner and more flexible to accommodate curvature, while central portions remain thicker and stiffer to maintain structural integrity. This local differentiation resolves the contradiction by applying flexibility only where needed for shaping while preserving rigidity where structural support is required.

Inventive Principle:

Principle #3Local quality

2Shape

If flexible substrates are used to create curved display panels, then curved shape is achieved, but manufacturing cost increases

Engineering Contradiction:

Improvecurved shapeVSAvoidmanufacturing cost

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The substrate thickness is modified in advance during the manufacturing process before final assembly. By selectively removing material from edge portions early in the manufacturing sequence, the panel is pre-conditioned to accept curved shaping without requiring expensive post-processing or specialized flexible substrate materials, thereby reducing overall manufacturing cost.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Instead of investing in expensive flexible substrates and complex curved manufacturing equipment, the invention uses conventional rigid substrates with selectively removed portions. This approach replaces costly specialized materials with standard materials processed in a modified but simpler manner, reducing manufacturing cost while achieving the same curved shape functionality.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Shape

If substrate thickness is reduced to enable bending, then curved shape is achieved, but structural strength decreases

Engineering Contradiction:

Improvecurved shapeVSAvoidstructural strength

Core Design Contradiction:

ShapeVSStrength

Solution Approach 1:

The substrate is segmented into thinned edge portions and intact central portions. The thinned edges provide flexibility for bending into curved shapes, while the intact central portions maintain structural strength. This segmentation allows simultaneous achievement of both curved shape and adequate structural strength.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The final curved display panel structure combines the modified substrate with additional components such as adhesive layers and curved supporting structures. This composite construction compensates for the reduced strength in thinned portions while maintaining the desired curved shape, effectively resolving the strength-thickness contradiction.

Inventive Principle:

Principle #40Composite materials

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 method allows for the simple fabrication of a curved display panel with reduced manufacturing costs and enhanced structural strength, maintaining the desired curved shape while minimizing weight and providing shock absorption.

Implementation Method 1

attaching a reinforcing plate having the same shape with the desired curved shape and light transmitting characteristics to the display panel using an adhesive layer which is formed on at least a portion of edge portions of the display panel

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Data Source

PatentUS9581844B2Method for fabrication of curved-surface display panel

Publication Date: 2017.02.28 TOVIS CO LTD

AI summary

A curved-surface display panel fabrication method for fabricating a curved display panel having a desired curved shape using a flat display panel having a first substrate and a second substrate, includes: paring partially outer surfaces of the first substrate and the second substrate so as to reduce thicknesses thereof to a predetermined thickness; and attaching a reinforcing plate having the same shape with the desired curved shape and light transmitting characteristics to the display panel using an adhesive layer which is formed on at least a portion of edge portions of the display panel in a state that the pared flat display panel is bent to the desired curved shape.