Flexible Display Coating with a Removable Release Frame
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Solution Overview
Problem
The challenge in manufacturing display devices arises when a second layer with a larger planar area is directly formed on a first layer with a smaller area, leading to difficulties in processing the unsupported portions of the second layer.
Innovation Solution
A method involving the formation of a release frame exposing the uppermost surface of a display stack, application of a first curable resin, and subsequent curing to create a flexible coating layer, with the release frame supporting the unsupported areas of the second layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If a second layer with larger planar area is directly formed on a first layer with smaller area, then the area of the second layer can be increased, but the process difficulty increases due to unsupported portions
Solution Approach 1:
A release frame is introduced as an intermediary support structure between the first layer and the second layer. The release frame provides temporary support for the unsupported portions of the second layer during the coating process, enabling the formation of larger area layers without increasing process difficulty. After coating, the release frame is removed, leaving the second layer with its intended larger planar area.
2Area of moving object
If a flexible coating layer with larger area is formed on a second stack with smaller area, then the coating area is increased, but process complexity increases
Solution Approach 1:
The release frame serves as a temporary intermediary platform that extends the effective support area during the coating process. This allows the coating apparatus to deposit material over a larger area than the second stack itself, without requiring complex positioning or support systems. The release frame is subsequently removed, achieving the desired large-area coating with simple process equipment.
3Ease of manufacture
If a release frame is used to support unsupported areas, then process complexity is reduced, but additional manufacturing steps are required
Solution Approach 1:
The release frame is designed as a temporary, disposable component that is discarded after serving its support function. This approach simplifies the overall manufacturing process by eliminating the need for complex, reusable support structures, while the additional steps of attaching and removing the release frame are straightforward operations that do not significantly impact productivity.
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 approach simplifies the process of forming a flexible coating layer with a larger area on a second stack by using a release frame to support the unsupported areas, reducing process complexity and ensuring the coating's integrity.
Implementation Method 1
the first curable resin may be a UV curable resin
Data Source
AI summary
A method of manufacturing a display device includes forming a release frame exposing an uppermost surface of a display stack, wherein the display stack includes a first stack and a second stack sequentially stacked, and the uppermost surface of the display stack is an upper surface of the second stack, applying a first curable resin on the upper surface of the second stack and the release frame adjacent thereto, forming a flexible coating layer on the second stack by curing the first curable resin, and removing the release frame.