Curved Display Assembly via Pre-Curved Window and Adhesion
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Solution Overview
Problem
Curved displays often experience reduced viewing quality due to the laminating process, which can lead to potential issues in viewing quality, especially in highly directional lighting conditions, and reflections at the display's outer surface.
Innovation Solution
A method involving forcibly flexing and adhering display components to a curved surface, including touch sensor components, polariser sheets, liquid crystal cells, and light-emitting diode units, while applying surface treatments like coatings and thermoforming to enhance viewing quality and reduce reflections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If components are laminated in a naturally flat configuration and then forcibly flexed to conform to a curved surface, then the display device can be assembled efficiently, but viewing quality is reduced in certain regions and under directional lighting conditions
Solution Approach 1:
The patent applies preliminary action by pre-curving the window/cover component before assembling other display components. This ensures that subsequent components are assembled on a already-curved surface, maintaining their curved configuration and preventing flat-film-induced distortions, thereby preserving viewing quality while enabling efficient assembly.
Solution Approach 2:
The patent inverts the conventional lamination sequence by first forming the curved window/cover component and then assembling other components to it, rather than laminating all components flat and then flexing the entire assembly. This inversion prevents the introduction of flat-film stresses that degrade viewing quality.
2Strength
If the display device is assembled with multiple components laminated together, then structural integrity is achieved, but reflections at the outer surface increase in curved configurations
Solution Approach 1:
The patent applies local quality by selectively applying anti-reflective coatings or surface treatments to specific regions of the window/cover component, particularly to the outer curved surface where reflections are most problematic. This maintains structural integrity while locally reducing reflections to improve viewing quality.
Solution Approach 2:
The patent employs surface treatments such as anti-reflective coatings that modify the optical properties of the outer surface. These treatments change the surface's interaction with light, reducing reflections and improving viewing quality under directional lighting conditions while maintaining the component's structural integrity.
3Shape
If components are forcibly flexed to conform to a curved surface, then the display device achieves the desired curved shape, but internal stresses are introduced that may affect reliability
Solution Approach 1:
The patent applies preliminary action by pre-curving the window/cover component to the desired curved configuration before assembling other components. This eliminates the need to forcibly flex the entire multi-component assembly, thereby achieving the desired shape while minimizing internal stresses and improving reliability.
Solution Approach 2:
The patent segments the assembly process into distinct stages: first forming the curved window/cover component, then sequentially assembling other components to it. This segmentation allows each component to be formed or assembled in its final curved configuration independently, reducing cumulative internal stresses and improving overall reliability.
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 viewing quality in curved displays by minimizing reflections and maintaining high performance in directional lighting, ensuring uniform thickness and protection against moisture ingress, thus enhancing the overall display experience.
Implementation Method 1
a liquid crystal cell comprising liquid crystal material contained between two containing films
Implementation Method 2
adhering the first component in a forcibly flexed configuration to the curved surface of the curved component
Data Source
AI summary
Described are methods for assembling a display device by forcibly flexing a first component to conform to a curved surface, adhering the first component to the curved surface, forcibly flexing a second component to conform to an outer surface of the first component and adhering the second component to the first component. The first and second components each comprise at least one of: i) a touch sensor component or a component film of a touch sensor component; ii) at least one pair of orthogonal polariser sheets; iii) a liquid crystal cell comprising liquid crystal material contained between two containing films; iv) at least one encapsulation film; v) at least one diffuser sheet; vi) a backlight component; vii) a light-emitting diode unit; and viii) a circular polariser component, or a component film thereof, for use with a light-emitting diode unit.