Display Cutout Stress Mitigation via Curved Metal Patterns
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Solution Overview
Problem
Conventional display devices with cutout portions for camera mounting suffer from reliability issues due to stress concentration at corners, leading to small cracks and flaws that expand, compromising the device's integrity.
Innovation Solution
A display device with a resin layer, inorganic insulating films, and a metal pattern formed in the frame region to conform to the cutout portion's shape, ensuring the metal pattern is not electrically connected to the display region's wiring lines, thereby mitigating stress-induced crack expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser light is used to form a cutout portion with sharp corners, then the cutting precision and shape definition are improved, but stress concentration occurs at the corners leading to crack formation and reduced reliability
Solution Approach 1:
The patent applies curvature to the corner portions of the cutout by forming a curved portion with a radius of curvature of 0.3mm or more at the corners where the cutout meets the frame region. This curvature modification eliminates stress concentration points while maintaining the functional shape of the cutout, thereby preventing crack formation and improving device reliability without sacrificing manufacturing precision
2Ease of manufacture
If the cutout portion is formed with small radius of curvature corners, then the cutting process is simplified, but small cracks are formed due to stress concentration during bending and operation
Solution Approach 1:
The patent specifies that curved portions should be formed at corner sections with a radius of curvature of 0.3mm or more. This moderate curvature requirement balances manufacturing simplicity with crack prevention, as it avoids sharp corners that concentrate stress while not requiring excessively complex cutting processes. The curved shape redistributes stress evenly, preventing crack formation during device bending and operation
3Length of moving object
If the inorganic film is made thinner to reduce device thickness, then the device becomes more compact, but the film becomes more susceptible to crack expansion under stress
Solution Approach 1:
The patent applies beforehand cushioning by forming a resin layer that covers the cutout portion and extends into the frame region. This resin layer acts as a cushioning element that absorbs and distributes stress before it can reach and expand cracks in the underlying inorganic film. The cushioning effect protects thinner inorganic films from stress-induced crack expansion, maintaining reliability while allowing for reduced device thickness
4Area of stationary object
If the cutout portion is formed close to the display region, then the frame region can be minimized, but stress from the cutout affects the display region through the inorganic film
Solution Approach 1:
The patent uses the resin layer as an intermediary element between the cutout portion and the display region. The resin layer extends from covering the cutout portion into the frame region, creating a buffer zone that isolates stress from the display region. This intermediary structure allows the cutout to be positioned close to the display region while preventing stress transmission through the inorganic film, thus maintaining display region integrity with minimal frame region
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 solution enhances the reliability of the display device by suppressing crack expansion and maintaining structural integrity despite changes in humidity and temperature, thereby improving the device's overall performance.
Implementation Method 1
a resin layer... are provided; wherein a metal pattern formed from the metal layer is formed, conforming to at least a portion of a shape of the cutout portion, in the frame region between a variant edge portion of the display device forming the cutout portion and the display region
Implementation Method 2
In section A as illustrated in (a) of FIG. 7, when forming the cutout portion K1, the laser light tends to be concentrated at the corner of a section, recessed with a small radius of curvature, cut using the laser light
Implementation Method 3
a resin layer, a plurality of inorganic insulating films formed above the resin layer, and a metal layer formed above and in contact with one inorganic insulating film from among the plurality of inorganic insulating films are provided
Data Source
AI summary
A display device includes a metal pattern formed, in a frame region between a variant edge portion of the display device forming a cutout portion, and a display region. The metal pattern is formed from a metal layer conforming to at least a portion of the shape of the cutout portion.