Display Device Side Reinforcement via Integrated Auxiliary Layers

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Solution Overview

Problem

Conventional display devices with separate auxiliary layers attached via individual film-attach processes often result in stepped shapes on side surfaces, leading to lower durability and mechanical strength due to processing errors and size mismatches, which are exacerbated by impact resistance tests like Charpy impact tests.

Innovation Solution

The integration of a display panel with simultaneously processed first and second auxiliary layers, along with a side-reinforcing member that encloses and clamps cut surfaces, compensating for tapers and volume losses, and featuring a thickness that changes with the cut surface shape, filled with a liquid or solid reinforcing agent, and potentially including fine particles for hygroscopic or water-repellent properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate auxiliary layers are attached via individual film-attach processes, then the display panel can have functional layers for optical properties, but stepped shapes occur on side surfaces leading to lower durability and mechanical strength

Engineering Contradiction:

ImprovedurabilityVSAvoidstepped shapes on side surfaces

Core Design Contradiction:

ReliabilityVSShape

Solution Approach 1:

The patent combines multiple auxiliary layers (polarizing layer, protective layer, touch sensor layer) into a single integrated auxiliary layer structure that is attached to the display panel as one unit. This merging eliminates the stepped shapes that occur when separate layers are attached individually, as the integrated layer maintains uniform thickness and proper alignment across all functional layers, thereby improving durability and mechanical strength.

Inventive Principle:

Principle #5Merging (Combining)

2Strength

If separate auxiliary layers are attached individually, then processing flexibility is maintained, but processing errors and size mismatches occur reducing mechanical strength

Engineering Contradiction:

Improvemechanical strengthVSAvoidprocessing errors and size mismatches

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent merges multiple auxiliary layers into a single integrated structure that is processed and attached as one unit. This approach eliminates processing errors and size mismatches that occur during separate attachment processes, ensuring precise alignment and uniform dimensions across all functional layers, thereby enhancing mechanical strength.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent performs preliminary integration of multiple auxiliary layers into a single structured layer before attachment to the display panel. This preliminary action ensures that all layers are pre-aligned and pre-positioned with precise dimensions, preventing processing errors and size mismatches that would otherwise occur during separate attachment processes.

Inventive Principle:

Principle #10Preliminary action

3Shape

If conventional cutting processes are used for separate layers, then individual layer processing is simple, but tapers and volume losses occur on cut surfaces

Engineering Contradiction:

Improvecut surface qualityVSAvoidvolume loss

Core Design Contradiction:

ShapeVSLoss of substance

Solution Approach 1:

The patent combines multiple auxiliary layers into a single integrated structure before cutting. This merging allows for unified cutting processing that eliminates tapers and volume losses on cut surfaces, as the integrated structure maintains consistent dimensions and proper alignment throughout the cutting process, preventing material loss and shape deformation.

Inventive Principle:

Principle #5Merging (Combining)

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 enhances the side strength and durability of the display device by minimizing stepped shapes and reinforcing mechanical strength, particularly on side surfaces, while reducing module thickness and preventing moisture permeation.

Implementation Method 1

a side-reinforcing member enclosing cut surfaces of the display panel, the first auxiliary layer, and the second auxiliary layer... an insulator that encloses and clamps the cut surfaces

Methodology Applied

Scientific EffectMechanical Fastening: Mechanical Fastener

Implementation Method 2

The side-reinforcing member may include fine particles having hygroscopicity or water-repellent properties

Methodology Applied

Scientific EffectHygroscopicity: Hydrophile

Implementation Method 3

The side-reinforcing member may include fine particles having hygroscopicity or water-repellent properties

Methodology Applied

Scientific EffectWater-repellent properties: Hydrophobe

Data Source

PatentUS11413843B2Display device and method of manufacturing the same

Publication Date: 2022.08.16 SAMSUNG DISPLAY CO LTD

AI summary

Provided herein may be a display device and a method of manufacturing the same. The display device may include a display panel including a first surface, and a second surface opposite the first surface, a first auxiliary layer on the first surface of the display panel, and including at least one layer, a second auxiliary layer on the second surface of the display panel, and including at least one layer, and a side-reinforcing member enclosing cut surfaces of the display panel, the first auxiliary layer, and the second auxiliary layer.