Curved Display Panels with Strain-Adjusted Substrates

The display area edge is transformed from a straight line to a curved shape, specifically with a radius of curvature between 50-200 micrometers. This curvature allows the display area to extend closer to the substrate edge while maintaining structural integrity, as the curved transition distributes stress more effectively than a sharp corner would. The curved edge profile enables the display area proportion to increase without compromising the mechanical strength of the substrate at the boundary regions.

The substrate thickness is varied locally by creating grooves at specific positions, particularly at the corners and along the curved edge. These grooves reduce the substrate thickness in localized regions where the curvature is most pronounced, allowing the curved display edge to flex and adapt to the reduced non-display area width. This local thinning maintains overall structural integrity while enabling the aesthetic curved boundary.

The substrate is divided into multiple layers with grooves created at specific depths in each layer. Rather than attempting to create a complex three-dimensional curved shape in a single substrate, the curvature is achieved through segmented grooving operations that remove material in controlled steps. This segmentation of the substrate structure into layered regions with varying thickness makes the manufacturing process more manageable and precise.

The grooves are formed in the substrate before the final display elements are assembled or before the device is put into service. By pre-forming the curved edge geometry and thickness variations in the substrate manufacturing stage, the subsequent assembly processes are simplified. The preliminary grooving action establishes the curved profile that guides subsequent bonding and assembly operations.