Curved Display Strain Reduction via Carrier Layer
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Solution Overview
Problem
Forming curved display devices on windows with curved profiles is challenging due to excessive strain, which can lead to damage and mura (uneven coloration) in the display layers, particularly when applying displays to glass or polymer substrates with compound curvature.
Innovation Solution
A carrier layer with modified regions and a convex mold are used to distribute and reduce strain on the display, along with a liner to decouple the display from the carrier, minimizing friction and ensuring even strain distribution across the display.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a display is applied directly to a curved window substrate, then the display conforms to the curved shape, but excessive strain causes damage and mura in the display layers
Solution Approach 1:
A carrier layer is introduced as an intermediary between the display and the curved window substrate. The carrier layer has a curvature radius larger than the window substrate, allowing the display to be formed on a gentler curve that reduces strain. This mediator enables the display to eventually conform to the window's curved shape while preventing damage during the forming process.
Solution Approach 2:
The display is first formed on the carrier layer before being transferred to the final window substrate. This preliminary formation on a less curved surface prevents strain-induced damage, and subsequent steps transfer the pre-formed display to the highly curved window while maintaining integrity.
2Shape
If the display is formed with high curvature to match the window, then the display conforms to the window profile, but strain distribution becomes non-uniform causing mura
Solution Approach 1:
The carrier layer incorporates regions with different curvature radii to create non-uniform strain distribution that compensates for the high curvature of the window. By having different sections of the carrier layer with different curvature properties, the strain is distributed more uniformly across the display during formation, preventing mura while still achieving the required curvature match to the window.
3Stability of the object's composition
If friction between display and carrier is high during forming, then the display adheres to the carrier, but excessive friction increases strain on the display
Solution Approach 1:
The friction characteristics between the display and carrier layer are modified by changing physical or chemical parameters of the interface. This adjustment reduces friction to an optimal level that provides sufficient adhesion during forming while minimizing strain on the display layers, preventing both delamination and strain-induced damage.
Data Source
AI summary
A transparent structure may have layers with curved cross-sectional profiles. The transparent structure may have inner and outer layers with curved portions formed by bending the layers. A display may be applied to one or more of the inner and outer layers. To reduce the strain applied to the display while being bent into a desired curvature, a carrier film may be used during bending operations. The carrier film may be modified with a patch or openings distribute the strain evenly across the display. Additionally or alternatively, a convex mold may be used to further decrease the strain on the display while being formed into the desired curvature.