Display Encapsulation With Filler Seal for Water and Shock Resistance

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Solution Overview

Problem

Modern electronic devices face challenges in achieving robustness and water resistance without increasing device size or impacting performance, particularly in portable applications where they are exposed to forces, compression, and environmental hazards.

Innovation Solution

The use of a filler material, such as epoxy, is implemented around the periphery of a display component within a frame, creating a seal and acting as a shock absorber and adhesive, while also providing a tortuous leak path to prevent water ingress, with a conformal coating further enhancing sealing and protection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If bulky seals and isolation components are used to improve robustness and water resistance, then reliability is improved, but device size increases

Engineering Contradiction:

Improverobustness and water resistanceVSAvoiddevice size

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent applies a conformal coating layer (thin film) over the filler material and display component assembly. This thin film provides water and dust resistance without requiring bulky seals, thereby improving reliability while maintaining a compact device form factor.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent uses a composite structure combining filler material (epoxy or potting compound) and conformal coating. The filler material provides structural support and initial sealing, while the conformal coating adds an additional protective layer. This composite approach achieves superior water and shock resistance without increasing device volume.

Inventive Principle:

Principle #40Composite materials

2Reliability

If filler material is used to absorb shocks and provide sealing, then reliability is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveshock absorption and sealingVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies the conformal coating after the filler material is positioned, creating a sequential manufacturing process. The conformal coating is applied over the filler material and display component assembly, providing sealing and protection in a final step. This preliminary positioning of the filler material followed by conformal coating simplifies the overall manufacturing process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The conformal coating acts as an intermediary layer between the filler material and the external environment. It provides the sealing function while allowing the filler material to perform its structural and shock-absorption functions. This intermediary approach simplifies manufacturing by allowing the filler material to be positioned first, then sealed by the conformal coating.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If conformal coating is applied to enhance sealing, then water resistance is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improvewater resistanceVSAvoidcoating thickness and uniformity

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The conformal coating is applied as a thin film over the filler material and display component assembly. This thin film approach provides effective water and dust sealing without requiring complex precision manufacturing. The conformal coating conforms to the underlying structure, providing uniform coverage and sealing.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent creates a composite structure where the conformal coating works together with the filler material. The conformal coating provides the water-resistant sealing function, while the filler material provides structural support. This composite approach distributes the functional requirements, reducing the precision demands on individual components.

Inventive Principle:

Principle #40Composite materials

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 solution enhances the durability and water resistance of electronic devices by absorbing shocks and preventing moisture exposure, thereby improving the device's structural integrity and user experience without bulkiness or performance degradation.

Implementation Method 1

The filler material can include a potting material that is positioned in the bend region in contact with the curved surface

Methodology Applied

Scientific EffectViscoelasticity: Viscoelasticity

Implementation Method 2

the filler material defines a tortuous leak path between an ambient environment and the internal volume

Methodology Applied

Scientific EffectPhysical barrier:

Implementation Method 3

a conformal coating at least partially covering the display layer and at least a portion of the contact component

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS20220061166A1Mobile display encapsulation to improve robustness and water resistance

Publication Date: 2022.02.24 APPLE INC

AI summary

An electronic device including a housing defining an aperture, a display component positioned in the aperture, and a filler material at least partially surrounding a periphery of the display component. The filler material can contact the display component and a portion of the housing defining the aperture.