Curved Display Support Member Bending via Thermal Segmentation
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Solution Overview
Problem
Existing display devices face challenges in manufacturing partially curved structures with reduced defects, particularly in ensuring the integrity and alignment of curved portions during the assembly of cover, panel, and support members.
Innovation Solution
The use of a specialized manufacturing apparatus comprising multiple jig portions that linearly move and heat components to bend support members, allowing for precise control over curvature and attachment to a cover member and panel member, ensuring accurate alignment and reduced defect rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a partially curved structure is used to increase display device size and flexibility, then adaptability and user experience are improved, but manufacturing complexity and defect rates increase
Solution Approach 1:
The support member is divided into multiple regions (first region, second region, third region) with different curvature characteristics. Each region can be independently controlled during manufacturing, allowing complex curved shapes to be achieved by managing simpler segments separately, thus reducing overall manufacturing complexity while maintaining curved display adaptability
Solution Approach 2:
Different regions of the support member are given different structural properties - the first region has a specific curvature radius while the second and third regions have different curvature radii. This local differentiation allows each region to be optimized for its specific function, making the overall curved structure more manageable during manufacturing while achieving the desired adaptability
2Adaptability or versatility
If curved portions are created during assembly, then display device flexibility is improved, but alignment precision and structural integrity deteriorate
Solution Approach 1:
The support member is pre-formed with curved regions before final assembly. The first, second, and third regions are shaped to their final curvature during the support member manufacturing process, rather than attempting to bend them into shape during assembly. This preliminary formation ensures precise alignment and maintains structural integrity while achieving the required display flexibility
Solution Approach 2:
Instead of using mechanical force to bend the support member during assembly (which would compromise alignment precision), thermal energy is applied to heat the support member material above its glass transition temperature, making it pliable for shaping. This substitution of mechanical with thermal processing allows curved portions to be created without damaging the alignment precision or structural integrity
3Adaptability or versatility
If support members are bent during assembly, then curved display configuration is achieved, but risk of damage and defect rates increase
Solution Approach 1:
The material temperature parameter is changed during the forming process. The support member is heated to above its glass transition temperature, which fundamentally changes its mechanical properties from rigid and brittle to pliable and formable. This parameter change allows the support member to be shaped into curved configurations without risk of damage, maintaining structural integrity while achieving the desired curved display configuration
Solution Approach 2:
Thermal energy is used to replace mechanical force in the bending process. Instead of applying mechanical force that would risk damaging the support member, heat is applied to make the material pliable, and then shaping forces are applied when the material is in its softened state. This substitution eliminates the risk of damage during bending while achieving the curved display configuration
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 enables the production of display devices with reduced defects by ensuring precise curvature and alignment of components, enhancing the structural integrity and reducing the risk of damage during assembly.
Implementation Method 1
a first heating portion arranged inside the first support portion
Implementation Method 2
a first temperature measuring portion arranged inside the first support portion to measure a temperature of the first support portion
Implementation Method 3
a second heating portion arranged inside the second pressing portion
Implementation Method 4
a second temperature measuring portion arranged inside the second pressing portion
Implementation Method 5
heating the support member with the first heating portion to a first temperature greater than a glass transition temperature of the support member
Data Source
AI summary
A display device includes a cover member which is at least partially bent, a panel member arranged along a surface of the cover member, where the panel member displays an image, and a support member arranged on another surface of the panel member different from the surface of the panel member on which the cover member is arranged.